A temporary joint project workspace was set up in a corner of the engineering deck.
It was quickly overwhelmed by data slates, various metal samples, and disassembled components of CMC powered armor, resembling a cutting-edge development laboratory far more than a ship's maintenance bay.
Osiris first provided a series of alloy formulas codenamed the "WS-7 Series."
Just as he had stated, these formulas primarily utilized base metals such as iron, titanium, aluminum, and vanadium, without relying on any scarce elements.
The core of the technology lay in a unique proportioning of trace elements coupled with a multi-stage heat treatment process.
"The key resides in precise cooling control during the third-stage annealing, alongside the targeted accumulation of trace rhenium at the grain boundaries," Osiris explained as he brought up a complex alloy phase diagram. "This process elevates both toughness limits and fatigue strength simultaneously, without noticeably increasing material brittleness. The process documentation includes complete temperature curves and furnace atmosphere control parameters."
Swann carefully reviewed the detailed process manual and immediately gathered several core mechanics, allocating a dedicated zone in the ship's refining workshop to begin smelting the first batch of experimental alloy under strict adherence to the protocol.
Discussions on structural reinforcement unfolded concurrently. Osiris's proposal did not alter the overall external profile of the armor, focusing instead on critical load-bearing nodes.
"Failures often initiate at the weakest points or where stress concentration is highest," he highlighted several areas on a 3D model of the CMC powered armor's spine structure. "For example, the lumbar connection bears complex, compound stresses during high-intensity tactical maneuvers. Existing designs rely on baseline material properties and structural geometry to resist them. We can integrate a specially crafted 'WS-7c' buffer pad here."
He showcased a multi-layered composite gasket design: the outer layer featured a modified elastomeric polymer honeycomb structure engineered to absorb mid-to-low-frequency vibrations, while the inner layer was filled with a non-Newtonian fluid material optimized to withstand instantaneous, high-intensity impacts.
The overall thickness was strictly controlled within eight millimeters, sufficient to be embedded into the lining space of existing armor without interfering with external hardpoints.
"How do you lock it in reliably?" Swann pointed out the crux. "Traditional adhesives can fail under severe impacts and extreme thermal cycles. Meanwhile, welding or riveting would compromise the structural integrity of the armor substrate."
"Utilizing a hybrid method of mechanical latches and energy activation," Osiris displayed the microscopic design along the gasket's edges—a series of flexible, barbed clasps. "During installation, align the gasket with pre-fabricated slots inside the armor and press it in to achieve initial mechanical locking. Subsequently, apply a short pulse of a specific frequency using a portable energy source. The pulse activates the reactive material on the gasket's backing, inducing limited molecular-level bonding with the armor's inner wall to form a robust secondary joint. This process is reversible, though requiring specialized equipment for dissociation."
"Clever thinking!" Swann praised. "It doesn't damage the main body, makes replacement easy, and guarantees bond strength. We'll need to pin down the exact parameters for the energy activation..."
The collaboration between the two swiftly entered a state of high efficiency. Drawing from his deep understanding of the entire CMC powered armor pipeline—from production line to battlefield maintenance—Swann continuously raised sharp, practical questions: How could they ensure consistent alloy performance across different production batches?
What was the long-term reliability of the buffer materials under harsh conditions like Tarsonis's high-temperature radiation environments or Braxis's extreme sub-zero cold?
Could the energy activation equipment be integrated into a frontline repair unit's standard toolkit?
What was the exact amortized cost per individual armor suit for every single modification?
Osiris systematically answered each question, providing corresponding test datasets, alternative material options, or process adjustment recommendations.
All of his proposals strictly adhered to several core tenets: compatibility with the existing CMC framework, cost control, and feasibility for mass production alongside field maintenance. This extremely pragmatic demeanor further solidified Swann's technical trust in him.
Their discussions gradually expanded to broader possibilities for system optimization: Could they optimize the cooling circuit design of the power pack to reclaim more waste heat and convert it into auxiliary power—where even a minor efficiency boost would compound into substantial gains during long operations?
Could they introduce new composite energy-absorbing structures inside the helmet lining to better attenuate explosive shockwaves, lowering concussion risks for soldiers? These explorations did not yield immediate, disruptive shifts, but they embodied the engineering ethos of pushing mature equipment performance toward its absolute limits.
During the project's progression, the Hyperion underwent several routine sub-light runs and warp jumps. Yet the rhythm of activity in this workspace remained tightly packed. To Swann, the process offered the pure satisfaction of untangling technical hurdles—a practical path toward extracting greater potential from an already reliable platform.
To Osiris, the process was equally valuable. Through every question Swann posed and every experience-driven piece of feedback, Osiris rapidly absorbed and integrated this universe's practical combat engineering logic. He was observing an industrial design philosophy rooted in standardization, mass manufacturability, and rapid battlefield repair—vastly distinct from the "Archeotech" paradigm of the Warhammer universe.
Raynor or Matt occasionally passed by, often seeing the two standing shoulder to shoulder, scrutinizing floating blueprints while engaging in swift, professional debates over a specific data point; or silently buried in data slates and physical samples, exchanging only brief, intermittent technical jargon. They usually nodded knowingly and moved on without disturbing them.
They could sense that the work underway held potential significance no less vital than planning a successful military campaign.
When the first batch of "WS-7a" alloy test ingots completed all basic mechanical tests, the report was delivered to the workspace.
The data clearly demonstrated that key metrics—such as tensile strength, yield strength, and impact toughness—all met, and in some cases exceeded, the median performance ranges Osiris had initially predicted.
Swann thoroughly reviewed every set of numbers on the report, raising his head with a look of conviction in his eyes. He slapped Osiris forcefully on the arm—his habitual gesture for expressing high approval. "The numbers don't lie," his tone was far more resolute than usual. "We're on the right track. This thing has the potential to be a real game-changer."
Osiris took the report, quickly reading and archiving the critical data. He gave a calm nod: "Initial validation passed. This confirms the feasibility of both the formula and the process route." His tone remained steady, marking confirmation of their current milestone.
The CMC-framework enhanced powered armor project had crossed its first substantial technological hurdle.
In Osiris's evaluation, the "engineering intuition" and problem foresight contributed by Swann—forged in vast practical experience—were worth no less than the new alloy formulas themselves.