Abstract: An armor blast shield for use on the bottom of a vehicle to protect occupants of the vehicle from improvised explosive devices. A preferred embodiment is configured in a V-shaped configuration formed by at least two planar blast resistant panels and an I-beam having channels with inclined walls which receive the panels at an obtuse angle. The panels are adhesively adhered to the I-beam channel walls and at least one bolt is secured through the I-beam and a panel to provide superior blast resistant performance as compared to welded panels.

Abstract: An armor bolt, that is, a bolt in which the bolt head is fabricated from an armor plate and then attached, such as by welding, to a threaded stud or shaft to form the threaded portion of the armor bolt. A preferred embodiment of the invention employs a hex-shaped bolt head cut with a laser or water jet cutter from armor steel plate meeting Mil-A-12560 or Mil-A-46100. The diameter of the bolt head is determined by the hole size in the armor to be attached to the vehicle and the diameter of the threaded stud or shaft. The thickness or height of the bolt head is dictated by the ballistic threat it needs to stop. The threaded shaft in a preferred embodiment is resistance welded to be perpendicular to the head at the center of one face of the hex head.

Abstract: A method to attach a V-shaped or parabolic-shaped blast shield or other blast shields, to the bottom of a vehicle space frame that serves the purpose of redirecting the blast forces away from the crew compartment of the vehicle. Inner beams that run the length or width of the blast shield, align with the space frame running in the same direction. The beams are attached with bolts going through the top of each beam and into a threaded boss welded in the space frame. To attach the sides of the blast shield to the space frame, a rail adapter bracket mounts to the bottom of the space frame that has threaded bosses welded into the space frame. Slotted holes for forward and back and side-to-side adjustment on an adapter bracket are employed to help attach the blast shield to the space frame.

Abstract: An armor blast shield for use on the bottom of a vehicle to protect occupants of the vehicle from improvised explosive devices. A preferred embodiment is configured in a V-shaped configuration formed by at least two planar blast resistant panels and an I-beam having channels with inclined walls which receive the panels at an obtuse angle. The panels are adhesively adhered to the I-beam channel walls and at least one bolt is secured through the I-beam and a panel to provide superior blast resistant performance as compared to welded panels.

Abstract: The adjustable louvered armor window system invention comprises angled louvers made of the lightweight opaque armor. For the front window a viewing window of ballistic glass can be installed, the rear or sides could be solid armor. The louvers have overlaps to provide for gap protection. When no threat is present, the louvers are in the full open position. Once a threat is detected, then the louvers are closed. The movement of the louvers can be accomplished by a push/pull cable, hydraulic pressure, air pressure or other means. The system in the fully open position allows for a complete unobstructed viewing area. In the semi-deployed or partial down position, the system provides partial ballistic coverage for the occupant, and still allows for some occupant vision capability. In the fully deployed, or fully closed position, the system provides full ballistic coverage for the occupant, with a small viewing area or port, which is made of ballistic grade transparent armor.

Abstract: The adjustable louvered armor window system invention comprises angled louvers made of the lightweight opaque armor. For the front window a viewing window of ballistic glass can be installed, the rear or sides could be solid armor. The louvers have overlaps to provide for gap protection. When no threat is present, the louvers are in the full open position. Once a threat is detected, then the louvers are closed. The movement of the louvers can be accomplished by a push/pull cable, hydraulic pressure, air pressure or other means. The system in the fully open position allows for a complete unobstructed viewing area. In the semi-deployed or partial down position, the system provides partial ballistic coverage for the occupant, and still allows for some occupant vision capability. In the fully deployed, or fully closed position, the system provides full ballistic coverage for the occupant, with a small viewing area or port, which is made of ballistic grade transparent armor.

Abstract: Method and arrangement for spray forming an article. The method includes spraying a plurality of metal streams upon a low-heat resistant model and thereby forming a spray formed article. Each of the plurality of metal streams is composed of moltenized droplets, and as between the plurality of metal streams, each is composed of different constituent elements. In the spray form process, conditions of the metal streams are controlled, particularly around the time that the droplets land, to prevent adverse affects such as melting or burning the master model. The spray conditions are controlled in such a manner that the individual metal droplets forming the metal streams remain substantially segregate. The segregated state is maintained through out solidification so that the resulting spray formed article is composed at least partially of psuedo-alloy.

Abstract: A method and arrangement for implementing post-heat treatment after spray forming is ended to achieve stress control in the manufacture of a spray formed metallic tool involves providing a spray-formed metallic tool by applying a spray-forming material on a mold substrate and causing substantially homogenous metallic phase transformations of the spray forming material within the spray-formed metallic tool to a substantially homogenous distribution of commingled metallic phases consisting, for example, of predetermined proportions of at least a bainite phase and a martinsite phase.

Abstract: The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.

Abstract: The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.

Abstract: The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.

Abstract: One method of the present invention relates to a method for enhancing adhesion of spraying metal to a ceramic model. The method is comprised of providing the ceramic model having a spray surface, and modifying at least a portion of the spray surface if the ceramic model to enhance adhesion of spray metal to the spray surface.

Abstract: One method of the present invention relates to a method for enhancing adhesion of sprayed metal to a ceramic model. The method is comprised of providing the ceramic model having a spray surface, and modifying at least a portion of the spray surface of the ceramic model to enhance adhesion of spray metal to the spray surface.

Abstract: One method of the present invention includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle and lowering the temperature of the slurry to freeze the slurry and form a freeze-cast substrate while controlling temperature gradients within the mold unit to minimize distortion in the freeze-cast substrate. Another method includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle, placing insulation material around at least a portion of the casting receptacle to minimize distortion in the freeze-cast substrate by controlling temperature gradients within the mold unit, and lowering the temperature of the slurry to freeze the slurry to form a freeze-cast substrate.

Abstract: One method of the present invention relates to a method for spray forming metal deposits. The method is comprised of providing a ceramic substrate having a spraying pattern for receiving sprayed metal particles, spraying metal particles onto the spraying pattern to form a metal deposit on the spraying pattern for at least a first spray period, controlling the spraying step during the first spray period so that the temperature of the deposited metal particles increases at an average rate of less than or equal to about 15° per minute. The first spray period can be defined as lasting until the temperature of the deposited metal particles is at or about a steady state temperature. The steady state temperature is preferably in the range of about 330° C. to about 370° C.

Abstract: One method of the present invention relates to a method for spray forming metal deposits. The method is comprised of providing a ceramic substrate having a spraying pattern for receiving sprayed metal particles, spraying metal particles onto the spraying pattern to form a metal deposit on the spraying pattern for at least a first spray period, controlling the spraying step during the first spray period so that the temperature of the deposited metal particles increases at an average rate of less than or equal to about 15° per minute. The first spray period can be defined as lasting until the temperature of the deposited metal particles is at or about a steady state temperature. The steady state temperature is preferably in the range of about 330° C. to about 370° C.

Abstract: The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.

Abstract: One method of the present invention includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle and lowering the temperature of the slurry to freeze the slurry and form a freeze-cast substrate while controlling temperature gradients within the mold unit to minimize distortion in the freeze-cast substrate. Another method includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle, placing insulation material around at least a portion of the casting receptacle to minimize distortion in the freeze-cast substrate by controlling temperature gradients within the mold unit, and lowering the temperature of the slurry to freeze the slurry to form a freeze-cast substrate.

Abstract: Method and apparatus incorporating an infrared sensor, in the form of a two-wavelength imaging pyrometer into a metallic spray form process for providing real-time measurement of the surface temperature distribution of a steel billet thereby formed. The steel billets may be advantageously used as tools in metal forming processes, injection molding, die casting tooling and other processes that require hard tooling, such as in the automotive industry. The steel billet is formed based on a goal of uniform surface temperature distribution thereby minimizing thermal stresses induced within the steel article thereby produced.

Abstract: Spray form cell including a two-wavelength imaging pyrometer adapted to provide real-time measurement of the surface temperature distribution of a metal billet thereby formed. The steel billets may be advantageously used as tools in metal forming processes, injection molding, die casting tooling and other processes that require hard tooling, such as in the automotive industry. The steel billet is formed based on a goal of uniform surface temperature distribution thereby minimizing thermal stresses induced within the steel article thereby produced.