Typically 20–40 films of a tough first
metal, normally 0.1–1.0 mm thick films of
titanium,
nickel,
vanadium, and / or steel (iron) and alloys thereof, interleaved with a like number of films of a second
metal, normally 0.1–1.0 mm thick films of aluminum or alloys thereof, are pressed together in a stack at less than 6 MPa and normally at various pressures 2–4 MPa while being gradually heated in the presence of atmospheric gases to 600–800° C. over a period of, typically, 10+ hours until the second
metal is completely compounded; forming thus a metallic-
intermetallic laminate
composite material having (i) tough first-metal
layers separated by (ii) hard, Vickers microhardness of 400 kg / mm2+,
intermetallic regions consisting of an
intermetallic compound of the first and the second metals. The resulting
composite material is inexpensive, lightweight with a density of typically 3 to 4.5 grams / cubic
centimeter, and very hard and very tough to serve as, among other applications, lightweight armor. Upon
projectile impact (i) the hard intermetallic,
ceramic-like,
layers are confined by the tough metal
layers while (ii)
cracking and fracturing is blunted and channeled in directions orthogonal to the axis of
impact.