Additive Manufacturing High Density Materials with Locally Controllable Deformation Properties

Depleted uranium’s (DU) success as a kinetic energy penetrator (KEP) comes largely from its uniquely powerful shear properties. Non-toxic high-density alternative materials are needed to replace DU, but current state of the art solutions with tungsten (W) lack the ability to match DU’s shear properties. A proprietary design process, with specialized laser-based additive manufacturing (AM), is disclosed, that has been shown to allow the engineer to locally control the material microstructure. This will be used to impart DU-like ballistic shear properties within alternative high-density materials, including W. The high TRL status of the design and AM processes selected for this effort enable an expedited, lower risk development pathway to replace DU KEPs with non-toxic W KEPs that retain >90% of DU shear properties. Additionally, the proposed approach provides reliable manufacturing scalability and potential for customization of performance at any 20-120mm ordinance caliber. The innovations enclosed also have immediate commercial opportunity by solving unique needs within various aerospace, industrial, and defense market niches.