In context: Every substance we know is cuttable, even diamonds, until now. Engineers have developed a material they call “Proteus” and claim it is the first uncut material ever made. The compound is made of porous aluminum and ceramic, making it lighter than steel and yet will hold up to any grinder.
Researchers from Durham University in England and the Fraunhofer Institute in Germany claim that Proteus resists cutting by turning cutting tools against themselves and blunting them. The material consists of an aluminum matrix (aluminum foam) embedded with ceramic spheres. It is 15 percent less dense than steel, making it ideal for applications such as light armor.
As the cutting tool bites down on the aluminum, it experiences extreme vibrations when it hits the ceramic balls. This resonance causes the tool to bounce, “blunting” its edge. Also, when the ceramic is hit, fine dust particles fill the matrix. The interatomic forces between the grains increase proportionally to the amount of energy applied, making the material even harder the faster the tool rotates.
Computed tomography of the test sample (masthead) after making the cut attempts.
“The force and energy of the disc or the drill turn on itself, and it weakens and destroys by its own attack,” said Durham’s assistant professor of applied mechanics, Stefan Szyniszewski. “Essentially cutting our material is like cutting a jelly filled with nuggets. If you go through the jelly, you hit the nuggets and the material will vibrate in such a way as to destroy the cutting disc or bit.”
Proteus is effective against angle grinders, drills and other conventional cutting tools. It is even effective against high pressure water jet cutters. In this case, the material works differently in that the rounded surfaces of the spheres disperse the water, weakening the jet.
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The researchers see possible applications in the security and protection sectors. Armored vehicles may be stronger and lighter, or locks may be invulnerable to cutting tools. Ironically, it could also be used to make protective gear for those who use cutting tools.
Proteus is currently pending patent, and the team is looking for manufacturing partners to market the material. If you are interested in technical details, they have published their research in Scientific Reports.
