Sinter Bonded Projectile

Abstract

The invention of the present subject matter relates to a sinter bonded projectile comprising a core component and a copper component which has been sintered in such a manner to form a solid mass over the core. More particularly, the invention of the present subject matter provides a core component to which a copper component is melted at a temperature sufficient that it penetrates into the pores and geometry of the core component under compression due to thermal shrinkage, resulting in a tightly bonded solid mass containing no voids. The invention of the present subject matter also provides a process for manufacturing the projectile.

Claims

1. A sinter bonded projectile comprising a core component and a copper component which has been sintered in such a manner to form a solid mass over the core.

2. A sinter bonded projectile in accordance with claim 1, wherein said core component is selected from the group consisting of tungsten carbide, monel, nickel, tungsten, steel and stainless steel.

3. A sinter bonded projectile in accordance with claim 2, wherein said core component is tungsten carbide.

4. A sinter bonded projectile in accordance with claim 2, wherein said copper component is in the form of copper powder containing no frangibility inducing additives.

5. A sinter bonded projectile in accordance with claim 2, wherein said copper powder contains a copper content in the range of about 98.5% about by weight copper to about 100% by weight copper.

6. A sinter bonded projectile in accordance with claim 2, wherein said copper component is in the form of copper wire.

7. A sinter bonded projectile in accordance with claim 6, wherein said copper wire contains a copper content in the range of about 98.5% about by weight copper to about 100% by weight copper.

8. A sinter bonded projectile in accordance with claim 1, wherein said solid mass is formed by sintering at a temperature sufficient such that the copper component is melted and penetrates into the pores and geometry of the core component under compression due to thermal shrinkage, resulting in a tightly bonded solid mass containing no voids.

9. A singer bonded projectile comprising a core component in the form of tungsten carbide and a copper component which is sintered around and into the core to form a tightly bonded solid mass containing no voids.

10. A single bonded projectile in accordance with claim 9, wherein said copper component is in the form of copper powder.

11. A single bonded projectile in accordance with claim 10, wherein said copper powder contains a copper content in the range of about 98.5% about by weight copper to about 100% by weight copper.

12. A single bonded projectile in accordance with claim 9, wherein said copper component is in the form of copper wire.

13. A single bonded projectile in accordance with claim 11, wherein said copper wire contains a copper content in the range of about 98.5% about by weight copper to about 100% by weight copper.

14. A single bonded projectile in accordance with claim 9, wherein said copper component contains no frangible additives.

15. A single bonded projectile consisting of a core in the form of a tungsten carbide pin and a copper component selected from the group consisting of copper powder and copper wire, said copper component being sintered around and into the core to form a tightly bonded solid mass containing no voids.

16. A single bonded projectile in accordance with claim 15 wherein said copper component contains a copper content in the range of about 98.5% about by weight copper to about 100% by weight copper.

17. A method of manufacturing a sinter bonded projectile comprising the steps of a) centering a core component within a hole formed into carbon block, b) filling said hole with a copper component, c) sintering said carbon block containing the centered core component and said copper component at a temperature sufficient to melt said copper in such a manner that said melted copper penetrates into the pores and geometry of the core, resulting in a tightly bonded solid mass containing no voids, d) cooling said carbon block and removing said tightly bonded solid mass from said carbon block, and e) machining said tightly bonded solid mass into a desired size and shape.

18. A method of manufacturing a sinter bonded projectile in accordance with claim 17, wherein said core component is in the form of a tungsten carbide pin.

19. A method of manufacturing a sinter bonded projectile in accordance with claim 18, wherein said copper component is in the form of a copper powder containing no additives.

20. A method of manufacturing a sinter bonded projectile in accordance with claim 19, wherein said copper powder contains a copper content in the range of about 98.5% about by weight copper to about 100% by weight copper.

21. A method of manufacturing a sinter bonded projectile in accordance with claim 18, wherein said copper component is in the form of copper wire containing no additives.

22. A method of manufacturing a sinter bonded projectile in accordance with claim 21, wherein said copper wire contains a copper content in the range of about 98.5% about by weight copper to about 100% by weight copper.

23. A method of manufacturing a sinter bonded projectile in accordance with claim 17, wherein said carbon block is sintered at a temperature in the range of between about 1300 F. to about 24S0 F.

24. A method of manufacturing a sinter bonded projectile in accordance with claim 23, wherein said carbon block is sintered at a temperature in the range of between about 2000 F. to about 24S0 F.

25. A method of manufacturing a sinter bonded projectile in accordance with claim 17, wherein said copper component is melted and penetrates into the pores and shape of the core under compression due to thermal shrinkage, resulting in a tightly bonded solid mass containing no voids.

26. A method of manufacturing a sinter bonded projectile in accordance with claim 24, wherein said copper component is melted and penetrates into the pores and shape of the core under compression due to thermal shrinkage, resulting in a tightly bonded solid mass containing no voids.

27. A method of manufacturing a sinter bonded projectile in accordance with claim 16, wherein said carbon blocking containing said core component and said copper component is sintered in an atmosphere protective environment.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0015] FIG. 1 shows a top view of the mold of the sinter bonded projectile.

[0016] FIG. 2 shows a magnified view of the sinter bonded projectile.

[0017] FIG. 3 shows a perspective view of the sinter bonded projectile.

DETAILED DESCRIPTION OF THE INVENTION

[0018] In the following description, like reference numbers are used to identify like elements. Furthermore, the drawings are intended to illustrate major features of exemplary embodiments in a diagrammatic manner. The drawings are not intended to depict every feature of every implementation nor relative dimensions of the depicted elements and are not drawn to scale. In the following description, numerous specific details are set forth to clearly describe various specific embodiments disclosed herein. One skilled in the art, however, will understand that the presently claimed invention may be practiced without all the specific details discussed below. In other instances, well known features have not been described so as not to obscure the invention.

[0019] The sinter bonded projectile of the present invention comprises a core component and a copper component which have been sintered in such a manner to form a solid mass over the core. More particularly, the core component can be composed of a variety of materials with specialty type properties to enhance velocity, impact, ductility, hardness, penetration, and accuracy. In a preferred embodiment of the present invention, the core component is tungsten carbide. More preferably, the core component is a tungsten carbide pin. Other materials suitable for use as the core material include, for example, monel, nickel, tungsten, steel and stainless steel. However, will be understood to those skilled in the art that these are examples of other suitable materials and not limited thereto.

[0020] The copper component of the sinter bonded projectile of the present subject matter can be in the form of a copper powder or copper wire. In a preferred embodiment, the copper content is relatively high, for example in the range of at least about 98.5% by weight to about 100% by weight. However, it is contemplated to be within the scope of the present subject matter that the copper component can be in the form of a copper alloy having a copper content lower than 98.5% by weight. More preferably, the copper component does not contain any additives that would enhance frangibility.

[0021] The sinter bonded projectile is formed by sintering and melting copper powder around and in the core to form one solid mass. The temperature of the sintering must be sufficient such that the copper is melted and penetrates into the pores and geometry of the core under compression due to thermal shrinkage. This sintering results in a tightly bonded solid mass containing no voids. The sintering temperature will be dependent in part on the amount of copper in the copper component. Preferably, the sintering temperature is in the range of between about 1300 F. and about 24S0 F. More preferably, the sintering temperature is in the range of between about 2000 F. to about 24S0 F.

[0022] In operation, a hole is drilled into a carbon block, suitable examples of which include a graphite mold or ceramic mold, and the core component is centered within the carbon block. FIG. 1 illustrates a top view of the carbon block. The hole with the centered core component is filled with the copper component. The carbon block is placed in an oven or blast furnace having an atmosphere protective element. The carbon block is then sintered at a temperature sufficient to melt the copper component in such a manner that the melted copper component penetrates into the pores and geometry of the core component. This sintering process results in the formation of a tightly bonded solid mass containing no voids. The carbon block is cooled and the tightly bonded solid mass is removed from the carbon block. The resulting cooled solid mass is placed on a lathe or similar device and machined into the desired shape and size as shown in FIG. 2 and FIG. 3. In this manner, a non-jacketed projectile is formed having a core component and an outer layer having the copper component.

[0023] It will be obvious to those skilled in the art that the desired size and shape of the sinter bonded projectile can be configured by altering the diameter of the hole drilled into the carbon block. It also will be obvious to those skilled in the art that altering the core component pin can change the grain weight and performance.

[0024] While several illustrative embodiments of the invention have been shown and described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternative embodiments are contemplated and can be made without departing from the scope of the invention as defined in the appended claims.