Abstract: A composite knife made from layers of Metal Matrix Composite (MMC) is disclosed. It includes a middle layer of fibrous preform including a hard insert placed longitudinally at its periphery. The hard insert, after sharpening, represents the cutting blade portion of the composite knife. The composite knife further includes a carrier which forms the load bearing member of the cutting blade, as well as forming the integral handle of the composite knife. The carrier portion of the composite knife includes at least one top and at least one bottom layers of fibrous preform, sandwiching the middle layer that contains the cutting edge portion of the knife. A metallic material is infiltrated within the fibrous preforms and extends throughout the composite blade structure forming the MMC knife, the metallic material bonding the middle layer within the carrier, and bonding the top and bottom surface of the hard insert within the carrier.

Abstract: A method of producing a Metal Matrix Composite (MMC) with uniform surface layers is disclosed. First, a low volume fraction compressible discontinuous ceramic fiber paper is set on the base of a mold cavity. Next, an array of reinforcement preform(s) (1×1, 2×2, 4×4, 2×8, etc) are set in the mold on top of the ceramic fiber paper. A top layer of ceramic fiber paper is next placed on the array of reinforcement preforms and the mold cover seals the mold. The reinforcement porous preform(s) are held to the center of the mold cavity when the sealed mold compresses the top and bottom layers of ceramic fiber paper. The ceramic fiber paper exerts an equal and opposite force on the reinforcement preform(s) within the closed mold centering the preform(s) within the mold cavity. The mold cavity is next infiltrated under pressure with molten metal allowing for metal to penetrate into any open porosity of the ceramic fiber paper, reinforcement preform(s), and areas within the mold cavity that contain open spaces.

Abstract: A Method of Producing a hybrid tile metal matrix composite armor is disclosed. First, dense ceramic plates are placed within the mold cavity and may rest on spacer(s) that separate the bottom surface of the ceramic plates from the base of the mold cavity to create a space therebetween. The plates are further positioned within the mold cavity to create a controlled space between any adjacent plates. A second set of spacers may be placed on the plates top surface to create a space between the mold cavity cover and the ceramic plates top surface. A plurality of ceramic plates and spacers may also be stacked into multiple layers according to the shape of the mold cavity and desired ballistic resistance. The mold cavity is next infiltrated with liquid metal under pressure forming a hybrid metal matrix composite structure with an encapsulating aluminum rich skin.

Abstract: The armor tile system embodying the principles of the present invention comprises one or more hybrid tiles which can be connected together to cover a protected structure. Various arrays of material layers may be utilized (1×1, 2×2, 4×4, 2×8, etc) within a hybrid tile system and multiple hybrid tiles may be mounted on the area to be protected. Each hybrid tile comprises one or more material layers stacked within a single metal matrix casting. Each material layer within a hybrid tile includes at least one reinforcement insert arranged along a common surface. The reinforcement inserts comprise material types suitable for containment, structural support, and projectile deflection and destruction. The armor tile system of the present invention is created utilizing a molten metal infiltration process.