Phase gradient nanocomposite window fabrication and method of fabricating durable optical windows

Abstract

An optical window is provided and includes a core layer, a cladding layer and an electromagnetic interference (EMI) layer interposed between the core and cladding layers.

Claims

1. An optical window, comprising: multiple anti-reflection coatings; an outermost window layer interleaved between an outermost one of the multiple anti-reflection coatings and an outer-intermediate ones of the multiple anti-reflection coatings; an innermost window layer interleaved between an innermost one of the multiple anti-reflection coatings and an inner-intermediate ones of the multiple anti-reflection coatings; and an electromagnetic interference (EMI) treatment layer interleaved between the outer-intermediate and inner-intermediate anti-reflection coatings, wherein an additional anti-reflective coating is interposed between the innermost and inner-intermediate ones of the multiple anti-reflection coatings and the additional anti-reflective coating is displaced from the inner-intermediate one of the multiple anti-reflection coatings to define a thermal management space.

2. The optical window according to claim 1, wherein the multiple anti-reflection coatings, the outermost and innermost window layers and the EMI treatment layer have a curved shape.

3. The optical window according to claim 1, wherein the outermost window layer comprises nanocomposite optical ceramic material and the innermost window layer comprises a single phase material.

4. The optical window according to claim 3, wherein the nanocomposite optical ceramic has distribution gradients of nanocomposite formulations defined in terms of a first axis and a second axis perpendicular to the first axis.

5. The optical window according to claim 1, wherein a material of the outermost window layer is harder than a material of the innermost window layer.

6. The optical window according to claim 1, wherein the EMI treatment layer comprises an electrically conductive film.

7. The optical window according to claim 1, wherein one or more of the multiple anti-reflection coatings respectively comprise a deposited geometric optic coating.

8. The optical window according to claim 1, further comprising an adhesive layer adjacent to the EMI treatment layer, the adhesive comprising at least one or more of polyethylene, polystyrene, polypropylene, optical glass, paraffin, a thiol and a urethane.

9. An optical window, comprising: multiple anti-reflection coatings; an outermost window layer interleaved between an outermost one of the multiple anti-reflection coatings and an outer-intermediate ones of the multiple anti-reflection coatings; an innermost window layer interleaved between an innermost one of the multiple anti-reflection coatings and an inner-intermediate ones of the multiple anti-reflection coatings; and an electromagnetic interference (EMI) treatment layer interleaved between the outer-intermediate and inner-intermediate anti-reflection coatings, wherein the outermost window layer comprises nanocomposite optical ceramic material and has first and second distribution gradients of nanocomposite formulations defined in terms of a first axis and a second axis perpendicular to the first axis, respectively.

10. The optical window according to claim 9, wherein the multiple anti-reflection coatings, the outermost and innermost window layers and the EMI treatment layer have a curved shape.

11. The optical window according to claim 9, wherein the innermost window layer comprises a single phase material.

12. The optical window according to claim 9, wherein the first axis is a central longitudinal axis of the optical window and the second axis is perpendicular to the central longitudinal axis of the optical window.

13. The optical window according to claim 9, wherein a material of the outermost window layer is harder than a material of the innermost window layer.

14. The optical window according to claim 9, wherein the EMI treatment layer comprises an electrically conductive film.

15. The optical window according to claim 9, wherein one or more of the multiple anti-reflection coatings respectively comprise a deposited geometric optic coating.

16. The optical window according to claim 9, further comprising an adhesive layer adjacent to the EMI treatment layer, the adhesive comprising at least one or more of polyethylene, polystyrene, polypropylene, optical glass, paraffin, a thiol and a urethane.

17. An optical window, comprising: an outermost window layer interleaved between an outermost anti-reflection coating and an outer-intermediate anti-reflection coatings; an innermost window layer interleaved between an innermost anti-reflection coating and an inner-intermediate anti-reflection coatings; and an electromagnetic interference (EMI) treatment layer interleaved between the outer-intermediate and inner-intermediate anti-reflection coatings, wherein: the outermost window layer comprises nanocomposite optical ceramic material and has first and second distribution gradients of nanocomposite formulations defined in terms of a first axis and a second axis perpendicular to the first axis, respectively, and an additional anti-reflective coating is interposed between the innermost and inner-intermediate anti-reflection coatings and is displaced from the inner-intermediate anti-reflection coating to define a thermal management space.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts:

(2) FIG. 1 is a side view of a unitary radome layer in accordance with embodiments;

(3) FIG. 2 is a side view of a unitary radome layer in accordance with further embodiments;

(4) FIG. 3 is a perspective view of a unitary radome layer in accordance with alternative embodiments;

(5) FIG. 4 is a perspective view of a unitary radome layer in accordance with alternative embodiments;

(6) FIG. 5 is a flow diagram illustrating a unitary radome layer assembly method in accordance with embodiments;

(7) FIG. 6 is a schematic illustration of a centrifuge used to generate a distribution gradient in a unitary radome layer prior to curing or sintering in accordance with embodiments;

(8) FIG. 7 is a schematic illustration of a centrifuge used to generate a distribution gradient in a unitary radome layer prior to curing or sintering in accordance with further embodiments;

(9) FIG. 8 shows a side view of an optical window in accordance with embodiments;

(10) FIG. 9 shows a side view of a simplified version of the optical window in accordance with further embodiments;

(11) FIG. 10 shows an EMI treatment layer of the optical windows of FIGS. 8 and 9 in accordance with alternative embodiments;

(12) FIG. 11 shows an EMI treatment layer of the optical windows of FIGS. 8 and 9 in accordance with alternative embodiments;

(13) FIG. 12 shows a side view of an optical window with a thermal management space in accordance with embodiments;

(14) FIG. 13 is a flow diagram illustrating a method of assembling an optical window in accordance with embodiments;

(15) FIG. 14 is a schematic illustration of a fixture for providing an optical window with a cladding layer in accordance with embodiments; and

(16) FIG. 15 is a schematic illustration of a method of sandwiching an EMI treatment layer between core and cladding layers of an optical window in accordance with embodiments.

DETAILED DESCRIPTION

(17) As will be discussed below, potentially quite large and curved optical widows with excellent long-wave and mid-wave broadband transparency and high mechanical durability are provided. The windows are made of very durable nanocomposite materials with high optical transparency and are formed based upon the fact that optical transparency is required of the entire bulk of the window while durability is only required at the surface of the material that is exposed to environmental effects. A centrifuge is used to increase the density of the hardening agent near the outer surface of the windows to increase mechanical strength where it is most needed while reducing or eliminating the hardening agent in other areas of the window bulk. By maintaining less total volume of hardener, the optical transparency of the window as a whole is relatively improved. Meanwhile, by increasing the density of the hardener at the surface of the window, mechanical durability is improved. The resulting optical and mechanical performance of the phase gradient nanocomposite window will exceed that of the current technology and even allow new hardening agents to be introduced without strongly or adversely affecting optical transparency. The use of centrifugal force generated by the centrifuge allows less optically absorbing material to be used in the nanocomposite formulation while actually increasing the mechanical strength of the window and its durability against rain, sand and other impacts. Ultrasonic agitation may be added as a method for performing dry powder centrifugal sedimentation.

(18) With reference to FIG. 1, a unitary radome layer assembly 10 is provided and includes a first nanocomposite formulation 11 and a second nanocomposite formulation 12. The second nano-composite formulation 12 has a hardener and a higher effective density than the first nanocomposite formulation 11. The first nano-composite formulation 11 may be but need not be more optically transparent than the second composite nano-formulation 12 due at least in part to the lack of the hardener in the first nano-composite formulation. The first and second nanocomposite formulations 11 and 12 are provided together in a unitary radome layer 13 with each having a respective distribution gradient defined relative to an axis or to multiple axes of the unitary radome layer 13.

(19) In accordance with embodiments and, as shown in FIG. 1, the unitary radome layer 13 may be provided with a nose cone or ogive shape 14 that has a pointed nose cone or ogive tip 140 and curved sidewalls 141 extending in the aft direction from the pointed nose cone or ogive tip 140. In these and other cases, the respective distribution gradients of the first and second nano-composite formulations 11 and 12 are defined relative to a lateral axis A1 of the unitary radome layer 13 which is oriented transversely or perpendicularly with respect to a central longitudinal axis A2 of the unitary radome layer 13. That is, the lateral axis A1 may effectively define a first, front or forward portion 15 of the unitary radome layer 13 as being any part of the unitary radome layer 13 that is proximate to the nose cone or ogive tip 140 and a second, rear or aft portion 16 of the unitary radome layer 13 as being any part of the unitary radome layer 13 that is remote from the nose cone or ogive tip 140.

(20) To the extent that the second nanocomposite formulation 12 has the hardener and a higher effective density than the first nano-composite formulation 11, the unitary radome layer 13 can be formed and cured (e.g., sintered) such that the distribution gradient of the second nano-composite formulation 12 is characterized in that most of the second nano-composite formulation 12 is located in the forward portion 15 and such that the distribution gradient of the first nano-composite formulation 11 is characterized such that most of the first nano-composite formulation 11 is located in the aft portion 16. These characterizations of the respective gradients have the following results.

(21) With the first and second nano-composite formulations 11 and 12 generally being located in the aft and forward portions 16 and 15, respectively, homogeneity within the forward and aft portions 15 and 16 is increased and a tendency of the unitary radome layer 13 to scatter or absorb electro-magnetic (EM) radiation is correspondingly reduced as compared to what would otherwise occur if the first and second nano-composite formulations 11 and 12 were distributed evenly throughout the unitary radome layer 13.

(22) In addition, with the second nano-composite formulation 12 with the hardener being relatively harder than the first nano-composite formulation 11 and being generally or mostly located in the forward portion 15 where the unitary radome layer 13 is most likely to experience impacts with foreign objects and where optical transmission of signals through the unitary radome layer 13 is generally less important, an overall strength and durability of the unitary radome layer 13 is enhanced without sacrificing useful optical transparency. Meanwhile, with the first nano-composite formulation 11 being relatively more optically transparent than the second nano-composite formulation 12 and being generally or mostly located in the aft portion 16 where optical transmission of signals through the unitary radome layer 13 is most important and where impacts are generally less common, an overall optical transparency of the unitary radome layer 13 is enhanced without sacrificing strength or durability.

(23) With reference to FIG. 2 and in accordance with further embodiments, the unitary radome layer 13 may be provided with the nose cone or ogive shape 14 as in FIG. 1 but with the respective distribution gradients of the first and second nano-composite formulations 11 and 12 defined relative to multiple axes of the unitary radome layer 13. In these or other cases, the multiple axes may include for example the lateral axis A1 and the central longitudinal axis A2. That is, while the lateral axis A1 may effectively define the forward and aft portions 15 and 16 of the unitary radome layer 13, the central longitudinal axis A2 may define outer portions 17 of the unitary radome layer 13 as being those parts of the unitary radome layer 13 that are proximate to outer surfaces of the nose cone or ogive tip 140 and the sidewalls 141 and inner portions 18 of the unitary radome layer 13 as being those parts of the unitary radome layer 13 that are proximate to interior surfaces of the nose cone or ogive tip 140 and the sidewalls 141.

(24) In the embodiments of FIG. 2, the unitary radome layer 13 can be formed and cured (e.g., sintered) such that the distribution gradient of the second nano-composite formulation 12 is characterized in that most of the second nano-composite formulation 12 is located along the outer portions 17 in the forward portion 15 and such that the distribution gradient of the first nano-composite formulation 11 is characterized such that most of the first nano-composite formulation 11 is located along the inner portions 18 in the aft portion 16.

(25) In accordance with still further embodiments, the first nanocomposite formulation 11 may include yttrium oxide (Y.sub.2O.sub.3) particles of relatively small or first sizes (e.g., as measured in terms of mean or average individual particle diameters) S1 and the second nanocomposite formulation 12 may include magnesium oxide (MgO) particles of relatively large or second sizes (e.g., as measured again in terms of mean or average individual particle diameters) S2 where the second sizes S2 are generally larger than the first sizes S1. Thus, in the case of the embodiments of FIG. 1, the respective distribution gradients are characterized with an increased distribution of the Y.sub.2O.sub.3 particles of the first sizes S1 remote from the nose cone or ogive tip 140 in the aft portion 16 and an increased distribution of the MgO particles of the second sizes S2 proximate to the nose cone or ogive tip 140 in the forward portion 15. In the case of the embodiments of FIG. 2, the respective distribution gradients are characterized with an increased distribution of the Y.sub.2O.sub.3 particles of the first sizes S1 remote from the nose cone or ogive tip 140 and along the inner portions 18 in the aft portion 16 and an increased distribution of the MgO particles of the second sizes S2 proximate to the nose cone or ogive tip 140 and along the outer portions 17 in the forward portion 15.

(26) With reference to FIGS. 3 and 4 and in accordance with embodiments, the unitary radome layer 13 may have at least one of a rounded (e.g., spherical, hemi-spherical, etc.) shape 301 (see FIG. 3) and a flattened shape 401 (see FIG. 4). In either or other cases, the unitary radome layer 13 may include the first and second nano-composite formulations 11 and 12, as noted above, with the respective distribution gradients. Thus, in exemplary cases, the unitary radome layer 13 with the rounded shape 301 of FIG. 3 may have an increased distribution of the first nano-composite formulation 11 toward the interior surface of the curvature and an increased distribution of the second nano-composite formulation 12 toward the exterior surface of the curvature. Similarly, the unitary radome layer 13 with the flattened shape 401 of FIG. 4 may have an increased distribution of the first nano-composite formulation 11 toward one side thereof and an increased distribution of the second nano-composite formulation 12 toward the other side thereof.

(27) With reference to FIG. 5, a unitary radome layer assembly method is provided. The method initially includes designing a unitary radome layer with first and second portions (such as the unitary radome layer 13 with the nose cone or ogive shape 14 and the first, front or forward portions 15 and the second, rear or aft portions 16 of FIGS. 1 and 2, the unitary radome layer 13 with the rounded shape 301 of FIG. 3 or the unitary radome layer 13 with the flattened shape 401 of FIG. 4) such that the first portions are more durable than the second portions and such that the second portions are more optically transparent than the first portions (block 501). The method further includes providing first and second nanocomposite formulations together in a unitary radome layer mold (such as a mold with a nose cone or ogive shape as in FIGS. 1 and 2) where the second nanocomposite formulation has a hardener and a higher effective density than the first nanocomposite formulation (block 502). The method then includes an operation of generating respective distribution gradients for the first and second nanocomposite formulations prior to curing (e.g., sintering) (block 503).

(28) In accordance with further embodiments and as shown in FIG. 5, the method may also include controlling undesirable separation parameters of the first and second nanocomposite formulations (block 504) and an addition of materials to at least one of the first and second nanocomposite formulations to adjust at least one of respective effective densities and respective sedimentation rates thereof (block 505). The controlling of the undesirable separation parameters of block 504 may include, for example, an ultrasonic assist process executed with respect to the first and/or the second nano-composite formulations.

(29) The first and second formulations may be suspended in fluid or provided as dry powders. In the latter case, it is to be understood that the dry powders may not be easily separated using centrifugal force. Here, an ultrasonic agitator can be attached to the centrifuge to ultrasonically assist separation and dispersion processes. The ultrasonic agitation disrupts attractive van der Walls forces between the particles of the first and second formulations to allow them to more easily migrate or glide through the volume. Also, since the hardener of the second nano-composite formulation can tend to lower the effective density of the second nano-composite formulation, a third phase or material that may be optically benign can be added to the second nano-composite formulation to increase the effective density of the second nano-composite formulation beyond that of the first nano-composite formulation.

(30) In accordance with embodiments, the generating of the respective distribution gradients of block 503 may include defining the respective distribution gradients relative to a unitary radome layer axis, such as the lateral axis A1 of FIGS. 1 and 2, or to multiple unitary radome layer axes, such as the lateral axis A1 and the central longitudinal axis A2 of FIGS. 1 and 2 (block 5031). In addition, the generating of the respective distribution gradients of block 503 may further include placing the unitary radome layer mold with the first and second nanocomposite formulations in a centrifuge (block 5032) and activating the centrifuge to rotate the unitary radome layer mold with the first and second nanocomposite formulations about the unitary radome layer axis or about the multiple unitary radome layer axes (block 5033).

(31) With reference to FIG. 6, the generating of the respective distribution gradients of block 503 is illustrated for the case of the unitary radome layer 13 having the nose cone or ogive shape 14 and the respective distribution gradients being defined relative to the lateral axis A1. In this case, the unitary radome layer 13 is coupled to a centrifuge 601 prior to curing of the curable material and the centrifuge 601 is activated to rotate the unitary radome layer 13 about the lateral axis A1. Such rotation produces centrifugal forces that are applied to the first and second nano-composite formulations 11 and 12 that result in the generation of an artificial gravitational field. Within this artificial gravitational field, the first and second nano-composite formulations 11 and 12 segregate from one another due to the second nano-composite formulation 12 having the higher effective density such that the second nano-composite formulation 12 pools at the forward portion 15 and the first nano-composite formulation 11 pools at the aft portion 16.

(32) With reference to FIG. 7, in an event the centrifuge 601 of FIG. 6 were modified to rotate the unitary radome layer 13 about the central longitudinal axis A2 or in an event the unitary radome layer 13 were placed into a new centrifuge, rotation of the unitary radome layer 13 about the central longitudinal axis A2 prior to curing can lead to a further pooling of the second nano-composite formulation 12 along the outer portions 17 in the forward portion 15 and a further pooling of the first nano-composite formulation 11 along the inner portions 18 in the aft portion 16.

(33) It is to be understood that the invention described herein can be employed jointly with EMI protection as explained below with reference to FIGS. 8-15.

(34) As will be discussed below, a durable optical window is provided for use in LWIR applications for example. A standard optical window with a core layer formed of zinc sulfide (ZnS) is augmented with a nanocomposite optical ceramic (NCOC) cladding layer. Both the core and the cladding may be formed using NCOC powder-process sintering/HIPing processes. The cladding is generally only thick enough to meet strength/impact goals while the bulk of the window is formed of the highly transparent ZnS. In addition, an electromagnetic interference (EMI) treatment layer is interposed between the two core and cladding layers to provide EMI protection. The EMI treatment layer may be a deposited films or a microtextured (moth eye) grid on one or more surfaces. The durable optical window may also include anti-reflection and adhesive layers.

(35) With reference to FIG. 8, an optical window 810 is provided and includes multiple anti-reflection coatings between which additional layers are interleaved. In detail, the optical window 810 includes an outermost anti-reflection coating 811, an outer-intermediate anti-reflection coating 812, a cladding or outermost window layer (hereinafter referred to as an outermost window layer) 813 that is interleaved between the outermost anti-reflection coating 811 and the outer-intermediate anti-reflection coating 812, an innermost anti-reflection coating 814, an inner-intermediate anti-reflection coating 815, a core or innermost window layer (hereinafter referred to as an innermost window layer) 816 that is interleaved between the innermost anti-reflection coating 814 and the inner-intermediate anti-reflection coating 815 and an EMI treatment layer 817.

(36) The EMI treatment layer 817 is located or interleaved between the outer-intermediate anti-reflection coating 812 and the inner-intermediate anti-reflection coating 815. The EMI treatment layer 817 serves to provide for EMI protection for the optical window 810. In its position interleaved between the innermost anti-reflection coating 814 and the inner-intermediate anti-reflection coating 815, the EMI treatment layer 817 is protected from external and/or environmental conditions for which exterior EMI layers are not normally suitable.

(37) The optical window 810 may further include an adhesive layer 818. Such an adhesive layer 818 may be disposed adjacent to the EMI treatment layer 817 and may include at least one or more of polyethylene, polystyrene, polypropylene, low melting temperature glasses, a thiol and a urethane.

(38) As shown in FIG. 8, the optical window 810 and the various components and layers thereof may have a curved shape 8101. More particularly, the optical window 810 and the various components and layers thereof may have a nose-cone shape for provision at a forward end of an aircraft or a missile.

(39) In accordance with embodiments, the outermost window layer 813 may include nanocomposite optical ceramic (NCOC) material and, in some cases, may include multiple NCOC materials and possibly hardening materials with one or more gradients defined therein. Meanwhile, the innermost window layer 816 may include a single phase material, such as quartz or zinc sulfide (ZnS). In any case, the outermost window layer 813 may be harder or substantially harder than the innermost window layer 816 (e.g., the outermost window layer 813 may be up to 5 or more times harder than the innermost window layer 816). The innermost window layer 816 may be thicker or substantially thicker than the outermost window layer 813.

(40) With reference to FIG. 9, which includes some but not all the features of FIG. 8 for purposes of clarity, a thickness of the optical window 810 may be variable at various locations where the optical window 810 and the various components and layers thereof have a curved or nose-cone shape. For example, in the case of the optical window 810 having the nose-cone shape, the optical window 810 may have a maximum thickness T1 along a central longitudinal axis A thereof a lesser thickness T2 at terminal side edges thereof and a decreasing thickness with increasing radial distance from the central longitudinal axis A. In addition, as shown in FIG. 9, the innermost window layer 816 may be thicker than the outermost window layer 813 along the central longitudinal axis A and at the terminal side edges. Moreover, while the outermost window layer 813 and the innermost window layer 816 both may exhibit decreasing thicknesses with increasing radial distance from the central longitudinal axis, the degree of the decrease may be more pronounced in the innermost window layer 816.

(41) With continued reference to FIG. 8 and with additional reference to FIGS. 10 and 11, certain features of the EMI treatment layer 817 will now be described. As shown in FIG. 8, the EMI treatment layer 817 is interposed between the outermost surface 8150 of the inner-intermediate anti-reflection coating 815 and either an innermost surface 8120 of the outer-intermediate anti-reflection coating 812 or an innermost surface (not shown) of the adhesive layer 818. The EMI treatment layer 817 may be substantially thinner than the outermost window layer 813 and, in some cases, the innermost window layer 816 as well. The EMI treatment layer 817 may exhibit greater losses as compared to either the outermost window layer 813 or the innermost window layer 816 but, since a thickness of the EMI treatment layer 817 is relatively small, such losses can be limited. In any case, the EMI treatment layer 817 may include or be formed as at least one of a conductive grid 8170 (see FIG. 10) and a conductive film 8171 (see FIG. 11).

(42) In the case of the EMI treatment layer 817 being provided as a conductive grid 8170 as in FIG. 10, the outermost surface 8150 of the inner-intermediate anti-reflection coating 815 may be micro-textured (e.g., as at least one of a deposited geometric optic coating pattern and a micro-textured physical optic coating pattern) to form grooves in which the material of the EMI treatment layer 817 can sit. For example, the conductive grid 8170 can be formed with a moth-eye pattern 820 where the outermost surface 8150 (see FIG. 8) includes an array of raised hexagonal protrusions 8201 that are separated from one another by inter-protrusion grooves 8202. During processing of the optical window 810, materials of the EMI treatment layer 817 are disposed or deposited within these inter-protrusion grooves 8202 and subsequently cured therein to form the EMI treatment layer 817.

(43) With reference to FIG. 12 and in accordance with further embodiments, an additional anti-reflective coating 8501 may be interposed between the innermost anti-reflection coating 814 and the inner-intermediate anti-reflection coating 815. This additional anti-reflection coating 8501 may also be displaced from the inner-intermediate anti-reflection coating 815 to define a thermal management space 8502 therebetween. In operational conditions, this thermal management space 8502 may be supplied with coolant, such as air flow or fluid, or a heating element, such as an electrically resistive element, to maintain an appropriate operating temperature of the optical window 810.

(44) With reference to FIG. 13, a method of assembling an optical window, such as the optical window 810 with the curved shape as described herein, is provided. As shown in FIG. 13, the method includes pre-processing core layer material (block 1301), disposing electromagnetic interference (EMI) treatment layer material onto the core layer material (block 1302), providing cladding layer material to sandwich the EMI treatment layer material between the cladding layer material and the core layer material (block 1303) and post-processing at least the core layer material and the cladding layer material (block 1304). As noted above, the cladding layer material may include a nanocomposite optical ceramic (NCOC) and, in some cases, may include multiple NCOC materials and possibly hardening materials with one or more gradients defined therein, and the core layer material may include a single phase material such as zinc sulfide (ZnS).

(45) In accordance with embodiments, the pre-processing of the core layer material and the cladding layer material of block 1301 and 1303 may include at least one or more of sintering and hot isostatic pressurizing (HIPing). Similarly, the post-processing of at least the core layer material and the cladding layer material of block 1304 may include at least one or more of sintering and HIPing.

(46) With reference to FIG. 14 and in accordance with embodiments, the providing of the cladding layer material of block 1303 may include placing pre-processed core layer material and EMI treatment layer material in a fixture 1401 that is formed to set a cladding layer thickness and subsequently depositing the cladding layer material into the space 1402 in the fixture 1401 between the pre-processed core layer material and the EMI treatment layer material.

(47) With reference to FIG. 15 and in accordance with alternative embodiments, the providing of the cladding layer material of block 1303 may include pre-processing both the core layer material and the cladding layer material, sandwiching the EMI treatment layer material between the core and cladding layer materials and at least one or more of sintering and HIPing the various layers together.

(48) It is to be understood that the invention described herein can be employed jointly with a phase gradient nanocomposite layer.

(49) While the preferred embodiments to the invention have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.