Injection Molding an Additive Layer Manufacturing of Boron Carbide for Ballistic Testing
Abstract
ABSTRACT: INJECTION MOLDING (IM) AND ADDITIVE LAYER MANUFACTURING (ALM) OF BORON CARBIDE FOR BALLISTIC TESTING PROJECT GOAL: In the proposed project Purdue will use established methods of injection molding and 3D printing of B4C greenbodies with subsequent pressureless sintering to produce plates for NRL/NSWC-Carderock to ballistically test. The proposed work is divided into two year-long efforts. In Year 1, we will fabricate 40 mm diameter plates of B4C, varying the sintering aids (Y2O3, and Al), thickness (7, 10, and 12 mm), sintering temperatures (2100o and 2200oC), for depth of penetration (DOP) testing. We anticipate that the primary forming process will be injection molding; however, we will choose the most promising processing conditions to prepare samples via ALM. Furthermore, we will also prepare 40 mm dia alumina samples with both an equiaxed and aligned platelet microstructures for DOP testing. If we are successful in Year 1 efforts, we anticipate fabricating larger 100 mm dia samples for Year 2. In this work, we would work closely with the NSWC-Carderock to choose those forming and sintering conditions that were most successful as determined from DOP testing. To prepare these plates, it would be necessary to acquire a furnace with a much larger hot zone than is available at Purdue. The estimated cost is $150k. Specific Tasks for Year 1 are: Task 1: Purdue will utilize the known methods developed for B4C processing and densification to produce boron carbide plates of 40 mm dia for DOP testing. Plates of alumina with unaligned and aligned microstructures will also be provided. Task 2: From the testing at NSWC-Carderock, formulations will be down-selected to the most promising sintering aid and further examined for improved processing. Tasks 1 and 2 will occur in parallel. Task 3: Based on Task 2 results, ALM direct ink writing of B4C with subsequent burnout and sintering will be performed and samples sent to NSWC-Carderock for testing. Specific Tasks for Year 2 are: Task 1: Purdue will develop the tooling, injection molding and sintering sequence to make 100 mm dia billets of B4C. A larger furnace will be purchased if Year 2 is selected by NSWCCarderock. Task 2: Purdue will prepare 100 mm dia billets of B4C for ballistic testing at NSWC-Carderock using the best combination of sintering aids, sintering times and temperatures, etc., and determined from Year 1 efforts. Task 3: From the testing at NSWC-Carderock, formulations will be down-selected to the most promising sintering aid and further examined for improved processing. Tasks 2 and 3 will occur in parallel.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Jan 04, 2017
- Source ID
- N000141712155
Entities
People
- Jeffrey P Youngblood
Organizations
- Office of Naval Research
- United States Navy
- University of Virginia