Novel Reactive Structural Materials

Materials and Manufacturing Systems, Inc. (MATSYS) proposes to develop novel reactive structural materials for the enhancement of munitions lethality. This effort will combine our unique expertise in instrumented-Hot Isostatic Pressing (HIP) with new approaches in intermetallic design to develop a new generation of cost-efficient, high strength and reactive composites. The proposed material system will have a blend of three elemental powders, consisting of two highly reactive materials interspersed with a reactive “binder” material. The existence of three different powders will allow for tailoring of the mechanical and reactive properties of the composite by varying the volume fraction of each element, and its particle size. The feasibility of this approach was successfully demonstrated in the Phase I project by the consolidation of a powder blend to full density below the reaction temperature. The fully dense compact was reactive and had good mechanical properties. MATSYS proposes to develop the tools for design with this new class of material, design and optimize powder blend formulations for DoD applications, and demonstrate the approach by fabrication of components for sub-scale prototype weapon effects and lethality tests. A successful field demonstration will greatly enhance the insertion of this new class of materials into new military applications.