Composite Armour Systems Research Articles

Numerical Modeling on Ballistic Impact Analysis of the Segmented Sandwich Composite Armor System

This research delves into the design, modeling, and finite element impact analysis of the segmented sandwich composite armor system subjected to impact loading, considering different parameters such as materials to be used, armor height, and armor design configuration. Initial studies were performed to select the ideal model that will provide the best impact resistance at the least weight and with minimal fabrication requirements. Material type, thickness, and overall model configuration were defined during the initial model development period. Once the final design was defined, finite element analysis was performed using 2017 ABAQUS software to observe the performance of the model and to validate the efficiency of the chosen armor. Based on the results from the material selection and thickness validation, the optimal design with the best impact resistance was noted as 1.2 mm thick rectangular segmented silicon carbide tiles, serving as the top layer that covers the three-level gradient core composed of a titanium metal honeycomb frame filled with silicon carbide inserts, and finally a 2 mm thick glass epoxy composite layer made from four laminas in a 0/45/90/-45-degree configuration serving as the last layer of the armor.

Ballistic performance evaluation of 3-dimensional orthogonal composite soft armor systems

Ballistic performance evaluation of 3-dimensional orthogonal composite soft armor systems

A Numerical Study on the Ballistic Trauma of B4C ceramic backed UHMWPE Composite Armor System

A Numerical Study on the Ballistic Trauma of B4C ceramic backed UHMWPE Composite Armor System

Experimental investigation on the ballistic performance of B4C/Aramid/UHMWPE composite armors against API projectile under different temperatures

In the design of lightweight composite armor, it is crucial to consider the challenging conditions of extreme environments encountered during service. This study proposes to investigate the effect of temperature on the ballistic performance of a B4C/aramid III/UHMWPE composite armor system against 12.7 mm armor-piercing incendiary (API) projectiles with an impact velocity of ∼500 m/s. A series of ballistic experiments were conducted under low temperature (-40 ℃), high temperature (+70 ℃), and room temperature (+20 ℃) respectively considering two shooting distances of 100 m (long-range shooting) and 30 m (close-range shooting). The structural failure modes and associated mechanisms were identified and analyzed in detail from both macroscopic and microscopic scales. The experimental results indicate that the designed composite armor is believed to perform better than the existing design schemes in resisting the 12.7 mm half-speed API projectile on the basis of similar or less areal density. The ballistic performance of the composite armor system is significantly enhanced at low temperatures and weakened at high temperatures in terms of structural damage levels and backplate bulge deformation. The decrease in shooting distance transformed the panel failure mode essentially from non-penetration to penetration under room and high temperatures, whereas the specimens under low temperatures could prevent penetration. Both the ceramic and composite laminate materials are affected by temperature and show different microscopic damage modes, indicating the damage mechanism changes at the microscopic level. These findings provide valuable insight into the design of lightweight composite armor systems to adapt to extreme service environments.

Ballistic performance of optimised light weight composite armour

This research paper presents a comprehensive investigation into the response of a 3D finite element model when subjected to 7.62 AP projectiles. The study utilises Hetherington's armour composite equation and incorporates the Johnson-Holmquist material model to analyse the strength and failure criteria of the ceramic and Kevlar/epoxy components, respectively. The results highlight the remarkable resilience of the composite armour, demonstrating its ability to withstand projectile velocities up to 1500 m/s. However, as the ballistic velocity limit increases, the armour experiences significant damage, including projectile erosion and panel delamination. Through numerical simulations and advanced modelling techniques, the paper thoroughly explores the failure modes and energy absorption characteristics of composite armour systems under projectile impact. It investigates key parameters such as velocity, acceleration, kinetic energy, internal energy, pressure distribution, displacement, and damage progression. The analysis reveals a progressive decrease in kinetic energy as the projectile interacts with the armour, underscoring the crucial role of energy absorption in preventing projectile penetration. Moreover, the impact velocity influences the distribution of internal energy within the composite armour, with higher velocities leading to greater energy absorption up to a threshold limit. The study also determines the ballistic limit velocity (V50) using the velocity history approach and validates the findings with existing literature. Overall, the research provides valuable insights into the limitations of composite armour and offers important recommendations for designing and improving materials to achieve superior ballistic protection. It emphasises the significance of reaching the maximum ballistic limit while maintaining a lightweight armour structure by optimising the total armour thickness. This study contributes to the advancement of armour technology and enhances our understanding of the behaviour of composite materials under high-velocity impacts. It offers valuable guidance for the development of more robust armour systems suitable for various defence and protection applications.

Ballistic design and testing of a composite armour reinforced by CNTs suitable for armoured vehicles

This paper is investigating the use of composite armour reinforced by nanomaterials, for the protection of light armoured (LAV) and medium armoured military vehicles (MAV), and the interaction between the composite materials and high-performance ballistic projectiles. Four armour materials, consisted of front hybrid fibre reinforced polymer cover layer, ceramic strike-face, fibre reinforced polymer intermediate layer and the metal matrix composite reinforced backplate, were manufactured and assembled by adhesive technology. The proposed laminated protection system is suitable for armoured ground vehicles; however, it could be used as armour on ground, air and naval platforms. The design of the protection system, including material selection and thickness, was elaborated depending on the performance requirements of Level 4 ＋ STANAG 4569 military standard (projectile 14.5 mm × 114 mm API B32) and especially on a design philosophy which is analysed with the specifications. The backplate of this new composite is a hybrid material of Metal Matrix Composite (MMC) reinforced with carbon nanotubes (CNTs), manufactured with the use of powder metallurgy technique. The composite backplate material was morphologically, mechanically and chemically analysed. Results show that all plates are presenting high mechanical properties and ballistic characteristics, compared to commonly used armour plates. Real military ballistic tests according to AEP - STANAG 4569 were carried out for the total composite armour systems. After the ballistic tests, AA2024-CNT3 showed the best protection results, compared with the other plates (AA2024-CNT1 and AA2024-CNT2), with the projectile being unable to fully penetrate the composite plate.

Analysis of the influence of different constraints on the ballistic performance of B4C/C/UHMWPE composite armor

A lightweight composite armor system composed of boron carbide (B4C) ceramic panels, carbon-fiber interlayer, and ultra-high molecular weight polyethylene (UHMWPE) backplate has been widely used. This study aims to explore the effect of different constraint conditions on the ballistic resistance of lightweight composite armor. Thus, ballistic experiments of 12.7 mm armor-piercing incendiary (API) projectiles impacting armor targets under different constraint conditions are designed, and numerical simulations are performed to simulate the structural impact response of composite armor. A satisfied consistency is revealed by comparing the numerical results and the ballistic experimental results. Besides, the numerical simulation method is used to research the influence of the distance between the impact point and the constraint conditions on the ballistic performance of the composite armor. The results demonstrate that the ballistic performance of the composite armor is better if the impact point is farther from the constraint conditions as this can enhance the flexibility of composite armor. In conclusion, the flexibility of the constraint conditions is positively correlated with the ballistic performance of B4C/C/UHMWPE composite armor. This conclusion provides a guideline for the design and application of composite armor.

Ballistic evaluation of steel/UHMWPE composite armor system against hardened steel core projectiles

Thin high hardness steel sheets can be an alternative to expensive ceramic armor systems designed to defeat hardened core projectiles. A thin high hardness steel sheet backed with UHMWPE fiber-reinforced composite was ballistically tested against a 7.62 × 39 mm hardened steel core projectile in a single-stage gas gun. Thin steel sheets of 530 BHN hardness were adhesively bonded with UHMWPE fiber-reinforced composite to fabricate armor plates. Armor plates were able to defeat the projectile showing considerable potential. Tensile strength of steel sheet and UHMWPE-fiber reinforced ply was also determined. A detailed numerical simulation of the impact event was also performed to understand the phenomenon of defeat and penetration in greater detail. The numerical model was calibrated from the recovered projectile's core after the ballistic test.

Investigations of the ballistic response of hybrid composite laminated structures

Classic lightweight composite armour systems are usually made of ceramics, metals and fabric laminates separately or combination of two materials to resist a ballistic impact by 7.62 mm projectile. To enhance the ballistic impact resistance, this paper proposes hybrid laminated structures, which are developed through combinations of ceramics, Dyneema, Kevlar and compressed wood. There were twenty-five hybrid ballistic panels manufactured first, which were then subjected to field ballistic tests with 7.62 mm (×39 mm) bullets in a velocity range from 806.0 to 887.5 m/s. Here, five of twenty-five panels successfully stopped 7.62 mm projectile. The results of the ballistic performance, energy absorption, back face signature and failure mode of each type of the composite panels were obtained and examined. The mechanisms of ballistic resistance associated with different hybrid panels designed are investigated and discussed. In addition, analytical models are developed to predict ballistic perforation performance of single material layers and the related hybrid composite structures. The theoretical predictions of residual velocities are compared with the corresponding experimental measurements in a good agreement. These results provide the first-hand data to support further concept design of the hybrid ballistic panels and to validate computer models for optimizing lightweight composite armour.

Numerical simulation study of ballistic performance of Al2O3/aramid-carbon hybrid FRP laminate composite structures subject to impact loading

Aramid-carbon hybrid fiber reinforced polymer (FRP) laminates have been widely used in the design of the ceramic/FRP laminate composite armor systems for their outstanding mechanical properties. In order to figure out the influence of the stacking sequence of the aramid-carbon hybrid FRP laminate on the ballistic performance of the ceramic/FRP laminate composite structures, a finite element model (FEM) which is used to simulate the condition of the 7.62 M61 AP against the Al2O3/aramid-carbon hybrid FRP laminate composite structure is carried out in ABAQUS/Explicit software, and the JH-2 constitutive model and 3D-Hashin failure criteria which is programmed by a user subroutine VUMAT are utilized to describe the mechanical behavior of Al2O3 and FRP laminate in this FEM. The accuracy of this FEM is checked by a verification FEM and the method of establishing this FEM is proved to be reasonable. The simulation results reveals that when the carbon fiber is stacked at the top of the aramid-carbon hybrid FRP laminate, the ballistic performance and the integrity of the geometry structure of the ceramic/FRP laminate composite structure is the best when the proportion of the carbon fiber in the hybrid FRP laminate is a constant, which provides an innovative way to enhance the ballistic performance of the ceramic/FRP laminate composite armor system.

A metal/UHMWPE/SiC multi-layered composite armor against ballistic impact of flat-nosed projectile

A novel multi-layered composite armor system is proposed for ballistic protection in the present study. The composite armor is composed of a ductile metal front, followed by a ceramic/UHMWPE laminate composite as the intermediate layer, and a ductile metal back layer. The ballistic performance of the composite armor against flat-nosed projectile was investigated experimentally and numerically. Experimental results show that the proposed composite armor exhibited several failure modes, including ductile hole enlargement of metallic face sheets, fragmentations and cracks of the ceramic layer, delamination, fiber fracture and bulge deformation of UHMWPE laminates. Three-dimensional numerical model was established to analyze the evolution of the whole ballistic response, and to discuss the effect of the ceramic layer placement and the mass allocation between the ceramic layer and UHMWPE laminate layer on the ballistic performance. Simulation results reveal the evident reduction in residual velocity that results from the optimal placement of the ceramic layer. Good balance among the contributions of the target components can be achieved to maximize the total energy absorption of composite armor by optimizing the ceramic placement strategy. The projectile residual velocity and the total energy absorption are insensitive to the mass ratio of ceramic layer to UHMWPE laminate layer within a certain range. Under the condition of a higher mass ratio, the specific energy absorption of UHMWPE layer can be significantly improved due to the full development of its bulging deformation. Consequently, it would benefit the energy absorption capability of the composite armor.

Impact simulation and ballistic analysis of B4C composite armour based on target plate tests

Lightweight composite armour systems composed of a B4C ceramic panel and composite back panel have excellent bulletproof performance and are used to resist attacks from armour-piercing incendiary projectiles. Numerical simulations can be used to simulate the process of projectiles impacting armour; thus, this method is widely used in armour ballistic performance analyses. To verify the accuracy of the B4C material model, a finite element method based on two-dimensional smoothed particle hydrodynamics is used to simulate the penetration process of steel projectiles into B4C/Al composite armour. To verify the accuracy of the ultra-high molecular weight polyethylene (UHMW-PE) model, a three-dimensional Lagrange method was used to simulate the penetration of a fragment simulating projectile into the UHMW-PE. The influence of geometric strain in the erosion algorithm on the ballistic performance of the UHMW-PE was investigated, and the erosion geometric strain suitable for the UHMW-PE was identified. The impact of a 12.7 mm armour-piercing incendiary projectile on the B4C/UHMW-PE and B4C/C/UHMW-PE armours was then simulated and tested experimentally. The results showed that the B4C/UHMW-PE armour was penetrated by the projectile, while the B4C/C/UHMW-PE armour was not penetrated. The ballistic performance of the B4C composite armour, damage state of the B4C ceramic, and bulge deformation of the UHMW-PE were accurately obtained in the simulations. A comparison with the experimental results showed that the proposed method could accurately simulate the penetration process of the B4C/UHMW-PE armour, reveal the penetration mechanism of composite armour, reduce the number of projectile tests, and provide a basis and technical means for the design and optimisation of lightweight composite armour.

Numerical Simulation Study on Influence of Structural Interspace on Anti-penetration Performance of GFRP and Steel Composite Armor System

In this study we investigated the influence of the structural interspace on the ballistic performance of GFRP and steel composite armor system, using finite element analysis by ANSYS/LS-DYNA to simulate, found out the failure modes of steel plates and GFRP plates, and analysed the anti-penetration mechanisms of the composite armor systems. The results indicated that impact by high velocity projectiles, the failure modes of GFRP plates change greatly by setting structural interspace, but less influence on the failure modes of steel plates. Impact by high velocity projectiles, structural interspace has little effect on the anti-penetration performance of steel-GFRP armor structure. Enough interspace can improve the antipenetration performance of GFRP-steel armor structure, but the anti-penetration performance changes little with the increase of the interspace.

Development and validation of a numerical model for the simulation of high-velocity impacts on advanced composite armor systems

The anti-ballistic properties of a new advanced composite armor system have been investigated with the aim to minimize the armor system total weight per unit area. The innovative protection, made of a silicon carbide ceramic outer layer and an inner composite back-packing layer formed by ultra-high molecular weight polyethylene (UHMWPE) fibers, namely $$\hbox {Dyneema}^\circledR $$ Hard Ballistic 26, was realized and then tested performing dedicated ballistic impact tests. In order to investigate its permanent deformation, ceramic cracking, dimension of the rupture, and extension of the impact damage, nondestructive and destructive tests were conducted on the tested panels. The experimental results were used to develop and validate a transient nonlinear dynamic simulation model of the high-velocity impact of a 7.62 AP bullet on the tested armor system. After an accurate setting of the parameters involved in the description of the material constitutive models and of the involved physical phenomena, a complex numerical model was developed in the $$\hbox {ANSYS-Autodyn}^\circledR $$ environment using both mesh and meshless approaches at the same time. The comparison reveals a good agreement between experimental and computational results in terms of ballistic properties, deformations, fragmentation, and fracture of the ballistic armor system. Hence, a new numerical model for the design and the optimization of the ballistic efficiency of composite armor systems was developed and can be now used in current practice.

Mesoscale ballistic damage mechanisms of a single-layer woven glass/epoxy composite

Understanding damage mechanics across multiple length scales is necessary for design of enhanced protection by composite armor systems. In this work, we investigated the perforation mechanics of a single layer, woven composite target transversely impacted below and above the ballistic limit by a rigid projectile sized on the order of a tow width. To visualize mesoscale damage mechanisms of woven composites, a thin translucent composite target was used providing access to both impact and back-face surfaces. High-speed video, high-speed digital image correlation, high-resolution photography, and X-ray computed tomography were used to gather data. Impact and residual velocity data, ballistic limit velocity, and projectile impact location relative to the weaving architecture were quantified. It was found that impact on a tow-tow crossover requires more energy to perforate than impact on a matrix-rich interstitial site or on adjacent, parallel tows. Dynamic deflection and the transverse deformation cone wave-front velocity of the thin composite were measured. Meso-mechanical damage in thin, woven composites was characterized for impact velocities below and above the ballistic limit. Four mesoscale damage modes were identified: transverse tow cracks, tow-tow delamination, 45° matrix cracks, and punch-shear. These damage modes were observed both on the surface and inside the composites. The data presented here are useful for mesoscale modeling of woven composites, and this work provides new insight into meso‑mechanical modes of damage in thin composite structures under dynamic impact.

Enhancement of interfacial adhesion based on nanostructured alumina/aluminum laminates

Adhesive methods can enhance the dynamic impact resistance of composite armor systems. We employed nanostructured interfacial adhesion to improve the bonding strength of alumina/aluminum laminates. ZnO nanowires and anodized aluminum oxide nanoholes were fabricated on alumina and aluminum surfaces, respectively, to increase the surface area and roughness of adhered surfaces. These substrates were bonded to form an alumina/aluminum laminated armor. Effects of nanostructured interfacial adhesion were evaluated by performing drop-weight impact tests. Permanent deformations of the aluminum back plate bonded with nanostructured interfacial adhesion were smaller than in laminates without such adhesion. In addition, nanohole-structured bonding was more effective than nanowire-structured bonding.

Investigation on the ballistic behavior of mosaic SiC/UHMWPE composite armor systems

Abstract Experimental study on the ballistic behavior of mosaic Silicon Carbide (SiC) ceramics bonding with Ultra-High Molecular Weight Polyethylene (UHMWPE) plate is presented against 7.62 mm×51 mm Armor Piercing (AP) projectile. The effect of SiC ceramics on the ballistic performance of mosaic SiC/UHMWPE composite armors is systematically investigated, and the bulletproof process of the composite armor combining the hard/brittle SiC and soft/flexible UHMWPE is clarified in detail. The test results show that the ballistic performance of composite armors is significant influenced by the geometry of mosaic SiC ceramics and the impact zone of front layer, different impact zones are defined for the cylindrical mosaic SiC/UHMWPE composite armor. The residual velocities of AP projectile are varied from 648 m/s to 0 m/s for the cylindrical, hexagonal and square mosaic SiC ceramics, when the launch speeds of bullets are 780 m/s with a standard deviation of 10 m/s. The bulge lengths of UHMWPE plate are also changed from 16.5 mm to 43.2 mm for different structures of mosaic SiC ceramic front layer. The bulletproof property can be significantly enhanced by prolonging the interaction time between bullet and target. The conclusions of this paper are practically useful for designing the hard/flexible composite armor systems.

Hybride Composite Armour Systems with Advanced Ceramics and Ultra-High Molecular Weight Polyethylene (UHMWPE) Fibres

Hybride Composite Armour Systems with Advanced Ceramics and Ultra-High Molecular Weight Polyethylene (UHMWPE) Fibres

Comparison of numerical and experimental study of armour system based on alumina and silicon carbide ceramics

Abstract The main goal of this numerical and experimental study of composite armour systems was to investigate their ballistic behaviour. Numerical simulations were employed to determine the initial dimensions of panel layers before the actual ballistic test. In order to achieve this aim, multivariate computations with different thicknesses of panel layers were conducted. Numerical calculations were performed with the finite element method in the LS-DYNA software, which is a commonly used tool for solving problems associated with shock wave propagation, blasts and impacts. An axisymmetric model was built in order to ensure sufficient discretization. Results of a simulation study allowed thicknesses of layers ensuring assumed level of protection to be determined. According to the simulation results two armour configurations with different ceramics have been fabricated. The composite armour systems consisted of the front layer made of Al2O3 or SiC ceramic and high strength steel as the backing material. The ballistic performance of the proposed protective structures were tested with the use of 7.62 mm Armour Piercing (AP) projectile. A comparison of impact resistance of two defence systems with different ceramic has been carried out. Application of silicon carbide ceramic improved ballistic performance, as evidenced by smaller deformations of the second layer. In addition, one of armour systems was complemented with an intermediate ceramic-elastomer layer. A ceramic-elastomer component was obtained using pressure infiltration of gradient porous ceramic by elastomer. Upon ballistic impact, the ceramic body dissipated kinetic energy of the projectile. The residual energy was absorbed by the intermediate composite layer. It was found, that application of composite plates as a support of a ceramic body provided a decrease of the bullet penetration depth

Ballistic performance of composite metal foams

The application of advance materials to manufacture hard armor systems has led to high performance ballistic protection. Due to its light-weight and high impact energy absorption capabilities, composite metal foams have shown good potential for applications as ballistic armor. A high-performance light-weight composite armor system has been manufactured using boron carbide ceramics as the strike face, composite metal foam processed by powder metallurgy technique as a bullet kinetic energy absorber interlayer, and aluminum 7075 or Kevlar™ panels as backplates with a total armor thickness less than 25mm. The ballistic tolerance of this novel composite armor system has been evaluated against the 7.62×51mm M80 and 7.62×63mm M2 armor piercing projectiles according to U.S. National Institute of Justice (NIJ) standard 0101.06. The results showed that composite metal foams absorbed approximately 60–70% of the total kinetic energy of the projectile effectively and stopped both types of projectiles with less depth of penetration and backplate deformation than that specified in the NIJ 0101.06 standard guidelines. Finite element analysis was performed using Abaqus/Explicit to study the failure mechanisms and energy absorption of the armor system. The results showed close agreement between experimental and analytical results.