Innovative Refractory Metal Processing for Warhead Applications

Enhanced ballistic performance and lethality of warheads are materials limited. High density materials with high flow strength, strain to failure ductility, texture, and lethal energy release are desirable. The refractory materials meet many of these requirements, but not all of these attributes in a single elemental composition. It would be highly desirable to produce a layered composite of Zr and Ta, but conventional routes to produce the desired layers result in an abrupt interface between Ta and Zr, which would be prone to delamination during firing. In a Phase I program, MER demonstrated the capability to produce layered composites of Zr/Ta/Zr with a functionally graded interface and excellent bonding between the two metals. The process used was plasma transferred arc solid free form fabrication. In the Phase II program, the process conditions for producing this composite will be optimized versus ballistic performance and manufacturability.