Process for making metallic/intermetallic composite laminate materian and materials so produced especially for use in lightweight armor

A composite laminate material consisting of

• a plurality of metal layers selected from the group consisting of titanium, nickel, vanadium, and iron and alloys and combinations of titanium, nickel, vanadium, and iron;
• interleaved with
• a plurality of intermetallic regions, coextensive with the metal layers, selected from the group consisting of
• said tatanium, nickel, vanadium, and iron and alloys and combinations of titanium, nickel, vandium, and iron;
• reacted in situ with
• aluminum or alloys of aluminum;
• wherein the intermetallic regions exist as boundaries between the metal layers, and vice versa;
• wherein reaction of the (i) aluminum or alloys of aluminum with (ii) the titanium, nickel, vanadium, and iron and alloys and combinations of titanium, nickel, vanadium, and iron forms the hard intermetallic material in situ within the composite laminate material.

A composite laminate material consisting of

• a plurality of metal layers of one or more tough first metals or metal alloys;
• interleaved with
• a plurality of regions, coextensive with the metal layers, of hard intermetallic material consisting of the one or more first metals and metal alloys reacted in situ with one or more second metals or second metal alloys;
• wherein the tough metal layers are separated by the regions of hard intermetallic material, and vice versa;
• and
• wherein the composite laminate material has a density between 3 and 4.5 grams per cubic centimeter.

A composite laminate material consisting of

• a plurality of metal layers of one or more tough first metals or metal alloys;
• interleaved with
• a plurality of regions, coextensive with the metal layers, of hard intermetallic material consisting of the one or more first metals and metal alloys reacted in situ with one or more second metals or second metal alloys;
• wherein the tough metal layers are separated by the hard intermetallic regions, and vice versa;
• and
• wherein the composite laminate material has a density less than 6 grams per cubic centimeter.

A composite laminate material consisting of

• a plurality of metal layers of one or more tough first metals or metal alloys;
• interleaved with
• a plurality of regions, coextensive with the metal layers, of hard intermetallic material consisting of the one or more first metals and metal alloys reacted in situ with one or more second metals or second metal alloys;
• wherein the tough metal layers are separated by the hard intermetallic regions;
• wherein the metal layers are greater than 10 in number and larger than 100 cm2 in area.

Armor comprising:

• at least 10 metal layers, at least 100 cm2 in area, of at least one tough first metal or metal alloy;
• separated by and interleaved with
• at least 9 hard intermetallic regions, coextensive with the metal layers and thus at least 100 cm2 in area, of (i) the at least one tough first metal or metal alloy reacted in situ with (ii) at least one second metal or metal alloy;
• in a laminate composite having the tough metal layers separated by the hard intermetallic regions that are formed in situ;
• wherein reaction of the at least one second metal or metal alloy with the at least one first metal or metal alloy forms the hard intermetallic material in situ within the laminate composite.

Armor comprising:

• at least 10 metal layers, at least 100 cm2 in area, selected from the group consisting of titanium, nickel, vanadium, and iron and alloys and combinations of titanium, nickel, vanadium, and iron;
• interleaved with
• at least nine intermetallic regions, coextensive with the metal layers and thus at least 100 cm2 in area, selected from the group consisting of
• said titanium, nickel, vanadium, and iron and alloys and combinations of titanium, nickel, vanadium, and iron;
• reacted in situ with
• aluminum or alloys of aluminum;
• wherein said intermetallic regions exist as boundaries between the metal layers, and vice versa;
• wherein reaction in situ of the (i) titanium, nickel, vanadium, and iron and alloys and combinations of titanium, nickel, vanadium, and iron with the (ii) aluminum or alloys of aluminum forms the intermetallic regions.