Abstract: The Composite Ceramic Structure embodying the principles of the present invention includes a structural composite laminar sheet having top and bottom layers that are equivalent in number and have an identical positioning in the laminar sheet relative to the middle layer. These identically positioned top and bottom layers are further symmetric in both geometry and material composition to alleviate warping during expansion or contraction due to temperature change. At least one top and at least one bottom layers form a metal matrix composite (m) and at least one middle layer (dense ceramic), impervious to metal infiltration, remains a dense ceramic (c). The material combinations allow for the middle layer to have an in-plane residual compressive stress.

Abstract: Helically stranded thermoplastic polymer composite cable (10) includes a single wire (2) defining a center longitudinal axis, a first multiplicity of thermoplastic polymer composite wire (4) helically stranded around the single wire (2), and a second multiplicity of polymer composite wire (6) helically stranded around the first multiplicity of thermoplastic polymer composite wire (4). The helically stranded thermoplastic polymer composite cable (10) may be used as intermediate articles that are later incorporated into final articles, such as electrical power transmission cables, including underwater tethers and underwater umbilicals. Methods of making and using the helically stranded thermoplastic polymer composite cables are also described.

Abstract: A lightweight armor system according to the present invention includes one or more material layers having a fraction of void volume and at least one of those material layers having holes of various sizes and designs integrated therein. The material layers are infiltrated with liquid metal which solidifies within the materials open porosity to bind the layers together to create a coherent integral structure. The holes may be in the form of tubes which are impervious to metal infiltration and reduce the weight of the armor system while contributing to projectile deflection. A process for producing a lightweight armor system is disclosed which comprises the steps of 1.) forming holes in a preform containment layer 2.) positioning sealed tubes in the formed holes so that the tubes run through the thickness of the preform 3.) positioning at least one preform w/ sealed tubes within a mold chamber of a closed mold and 4.) infiltrating the mold with a liquid metal.

Abstract: Article comprising a monolithic ceramic layer and a polymeric composite layer and method of making is described. The article may be useful, for example, as armor.

Abstract: Mold components comprising soluble cores, metal matrix composite articles, and methods of making metal matrix composite articles.

Abstract: In one embodiment, the invention comprises a polymer matrix pushrod comprising a composite rod having an annular collar affixed over each end portion of the composite rod and an endcap affixed at each end. The composite rod comprises a thermosetting polymer matrix and reinforcing fibers within the polymer matrix.

Abstract: Lightweight, strong, engine valves that incorporate a valve stem made from a refractory monofilament-reinforced, titanium-based metal matrix composite. Advantageously, the composite of the present invention is sufficiently strong so that valve stems incorporating the composite can be hollow for providing significant weight reduction while meeting valve stem strength and stiffness specifications. The valve includes a valve stem comprising a first end, a second end, and EL longitudinal axis extending from the first end to the second end. The valve stem comprises a composite incorporating a titanium-based metal binder matrix and an axially aligned cluster of continuous, refractory monofilaments incorporated in the binder matrix. A valve head is provided at one end of the valve stem, and a valve tip is provided at the other end. The invention also relates to a method of making such valves. The invention further relates to a composite assembly from which such valves may be machined.