Quasi-static and impact perforation of polymer-metal bi-layer plates by a blunt indenter

Abstract

The use of polymer layers to alter the impact response of metallic plates has emerged recently as an effective and economical means to enhance perforation resistance. However, the function of the polymer in such laminate systems remains unclear. In this investigation we aim to identify, through systematic experiments, the influence of a polymer layer on the perforation mechanisms and energy absorption of laminated plates. In particular, we consider the combination of a polymer with a thin metallic plate in a bi-layer configuration, subjected to either quasi-static or impact loading by a blunt indenter. Bi-layers are investigated which comprise an aluminium alloy layer (6082-T6) and a polyethylene layer (LDPE, HDPE and UHMWPE). It is found that the energy required to perforate the bi-layer plate can significantly exceed that of the bare metallic substrate (showing the potential for polymer coatings as an effective retro-fit solution) when the polymer is on the impacted face. Furthermore, bi-layer configurations are also shown to outperform the equivalent mass of monolithic metal if the correct thickness ratio of polymer and metal is selected. The effectiveness of a polymer layer in enhancing perforation energy is connected to its large ductility, allowing extensive deformation of the polymer under the indenter, which in turn suppresses plugging and diffuses plastic deformation in the metal layer. In this way the energy absorbed by the metal layer can be maximised. The thickness of the polymer layer is found to be a crucial parameter in maximising the effectiveness of the bi-layer target. An optimum polymer thickness is observed which maximises energy absorption per unit mass of bi-layer target (for a fixed substrate thickness). The synergy between metal and polymer layers also depends on the polymer type and the rate of loading. A polymer with high strain hardening performs best under impact conditions. However, under quasi-static loading, the bi-layer performance is less sensitive to the yield strength and strain hardening of the polymer.