Additive Manufacturing of Long Rod Penetrator Sabots using Carbon Nanotube Metal Matrix Composites

Additive Manufacturing has the potential to dramatically reduce the weight and cost of long rod penetrator sabots if the right material systems can be utilized in manufacturing. While short fiber polymer composites offer significant weight and cost savings, they are limited in their maximum mechanical performance and cannot meet the specific stiffness and specific strength objectives of this program. Recently,SHEPRA and its development partner the University of Dayton demonstrated a carbon nanotube metal matrix composites produced by Selective Laser Melting (SLM) that demonstrated a 16% increase in elastic modulus and 22% increase in yield strength at 2% carbon nanotube volume loading.These results are consistent with academic literature that shows a 50% increase in modulus and 100% increase in strength at 5% carbon nanotube volume loading in aluminum. These results will meet the requirements of this program.SHEPRA will leverage prior experience to deliver to the Army a carbon nanotubealuminum metal matrix composite for use in Additive Manufacturing of long rod penetrator sabots that utilizes commercial off the shelf materials and AM manufacturing systems. In addition a supply chain has been established that integrates a DOD prime OEM to ensure successful technology transition and commercialization.