Composite Armor Research Articles

Anti-ballistic properties of hybrid UHMWPE fiber-reinforced composite armour

Anti-ballistic properties of hybrid UHMWPE fiber-reinforced composite armour

Numerical Analysis of SiC and UHMWPE Composite Ballistic Plates against 0.5 Caliber BMG Projectile

The aim of this study was to determine the optimal configuration of silicon carbide-ultrahigh molecular weight polyethylene (SiC-UHMWPE) plates to effectively withstand 0.5 caliber Browning Machine Gun (BMG) projectiles. Six composite plates with varying thicknesses were 3D modeled and assessed for ballistic resistance using finite element analysis in Ansys Explicit Dynamics simulation software. These plates were subjected to high-velocity impacts at 930 m/s using 7.62 mm projectiles. The findings revealed that an 11 mm SiC/80 mm UHMWPE plate provided comparable bullet-stopping performance to a standard 8 mm steel 4340/60 mm UHMWPE plate, but with a significantly lower areal density. The primary mode of failure observed in penetrated samples was petaling, consistent with known behaviors of composite armor under high-impact conditions.

Penetration resistance of Al2O3 ceramic-ultra-high molecular weight polyethylene (UHMWPE) composite armor: Experimental and numerical investigations

To enhance the protective performance of ceramic composite armor, ballistic penetration experiments were conducted on Al2O3 ceramic-ultra-high molecular weight polyethylene (UHMWPE) composite armor with different thickness configurations. The damage and failure modes of hard projectiles and ceramic-fiber composite targets were analyzed. The recovered projectiles and ceramic fragments were sieved and weighed at multiple stages, revealing a positive correlation between the degree of fragmentation of the projectiles and ceramics and the overall ballistic resistance of the composite targets. Numerical simulations were performed using the LS-DYNA finite element software, and the simulation results showed high consistency with the experimental results, confirming the validity of the material parameters. The results indicate that the projectile heads primarily exhibited crushing and abrasive fragmentation. Larger projectile fragments mainly resulted from tensile and shear stress-induced failure. The failure modes of the composite targets included the formation of ceramic cones and radial cracks under high-velocity impacts. The UHMWPE laminated plates exhibited interlayer separation caused by tensile waves, permanent plastic deformation of the rear surface bulging, and perforation failure primarily due to shear forces.Through extended numerical simulations, while maintaining the same areal density and configuration of 9 mm Al2O3 ceramic + 12 mm UHMWPE laminated composite armor, the thickness configurations of the Al2O3 ceramic and UHMWPE laminated backplates were varied, and various thicknesses of UHMWPE laminates were simulated as the cover layer for the ceramic panels. The simulation results indicated that the composite armor configuration of 10 mm Al2O3 ceramic + 8 mm UHMWPE composite armor increased energy absorption by 13.48 %. When altering the cover layer thickness, a 4 mm UHMWPE + 9 mm Al2O3 + 8 mm UHMWPE composite armor demonstrated a 27.11 % improvement in energy absorption, showing a relatively significant enhancement.

Biomimetic design and impact simulation of Al2O3/Al composite armor based on armadillo shell

The advancement of lightweight protective armors holds critical importance for enhancing the maneuverability and combat capabilities of helicopters. Leveraging insights from bionics, it provides a new idea for high-performance armor design. In this study, a new type of composite armor was designed by referring to the structural characteristics of hard phase-protection, soft phase-buffering of unitization armadillo shell. Through the numerical study, the anti-ballistic performance of armor with varying thickness ratios of the dense ceramic layer to the interpenetrating layer is obtained, and the influence of different structures of armor on the anti-ballistic performance is analyzed. The results show that compared with the traditional laminated composite armor, the Al2O3/Al biomimetic composite armor not only improves the separation phenomenon caused by wave impedance mismatch, but also greatly improves the speed drop in resisting high-speed and penetrating bullets. When the thickness ratio is 2:1, the armor has higher ballistic protection performance.

Explosive welding of TA2-SiC-AW5083 composite armor

This study investigates the use of explosive welding to encapsulate SiC between TA2 and 5083, aiming to achieve large-area, high-efficiency, and low-cost fabrication of ceramic composite armor. A new weldability window was established, and six configurations of ceramic composite armor were devised. Ten sets of experiments were conducted to explore the influence of explosive welding parameters, ceramic fracture, and different configurations of composite complate on mechanical properties, macro-deformation, welding interface morphology, and energy absorption and conversion. The research revealed that the fracture of ceramic influences the welding quality, the propagation of the blast wave, and the kinetic energy utilization of the flying plate, while the crevices between the ceramic and the groove on the base plate do not influence the welding quality. When the ceramic remains intact, the kinetic energy utilization rate of the flying plate can be calculated using the η = E1(1-A1/A)/Ef, and when the ceramic penetratively fractures, the kinetic energy utilization rate of the plate can be calculated using the η=(E1-E4) (1-A1/A)/Ef. Finally, we recommend adding a suitable interlayer as a buffer between the flying plate and the ceramic, and the static parameters for explosive welding should strictly adhere to the “Lower bound principle."By analyzing the energy conversion and absorption during the explosive welding process, the macro-deformation and mechanical properties of the composites, the interface morphology, and the level and characteristics of the ceramic fracture, the energy source of the ceramic fracture was found, and the effects of ceramic fracture and structural characteristics of composites on gap airflow, kinetic energy utilization of face plate, explosive wave propagation path, and welding quality were analyzed. Finally, we propose that the explosive welding static parameters of ceramic composite armor should strictly adhere to the " The principle of lower explosives limit."

Studies on the Effect of Accelerated Ageing on Structural, Physico-Mechanical and Ballistic Properties of Hybrid Silicone-Ceramics Composites

Abstract The aim of this paper was to study and analyze methods of evaluating the service ability and lifespan of ballistic armors made of a hybrid silicone-ceramic (HSC) composites. Experimental tests with accelerated ageing were conducted on the composite ballistic armors in a laboratory to predict and analyze their durability: changes in ballistic performance, as well as physical, and structural properties occurring due to simulated usage conditions. It was proved that despite the changes which took place at the molecular level in the HSC composite materials, accelerated aging processes do not affect the fragmentation resistance level of ballistic HSC inserts.

Study on ballistic impact performance of bionic fish scale protective armor

Composite bulletproof armor used in modern battlefield environments is mostly composed of ceramic/ultra-high molecular weight polyethylene (UHMWPE). In order to further improve its bulletproof performance, this study draws on the superposition of fish scales. The upper layer of the flexible protective armor consists of composite scale layers stacked on top of each other, and the lower layer consists of UHMWPE plates with grooved structures at the corresponding locations of the scales, where a single composite scale consists of an upper SiC ceramic layer and a lower UHMWPE layer. Finite element simulation is used to analyze the protective performance of the protective armor. The effects of back plate thickness, scale tilt angle, and impact location on the protection performance are investigated. The results show that the 8 mm thick back plate can effectively resist the impact of Type 53 7.62 mm armor-piercing incendiary ammunition, and the protective effect is best when the scale tilt angle is 30°. The maximum depression depth of the backplane is 12.4 mm, and the deformation of the backplane is reduced by 3 mm when the bullet hits the overlapping area of the scale compared with the central area of the target scale, accounting for 32.67% of the total deformation. The research work has guided the development of new bionic flexible protective armor.

Experimental and finite element analysis of ballistic properties of composite armor made of alumina, carbon and UHMWPE

AbstractThe performance of multi‐layer ceramic/composite ballistic armor consisting of Alumina, Carbon fiber, and Ultra High Molecular Weight Polyethylene (UHMWPE) under the impact of 7.62 × 51 M61 caliber armor‐piercing (AP) bullets was examined by experimental and finite element methods. The alumina ceramic thickness used in the experiments is 12 mm. The composite structure thickness used in all samples is 10 mm. Explicit dynamic analyses were also conducted using the Ls‐Dyna to verify the experimental studies. The analysis results were compared with experimental studies and evaluated by considering the damage status of the bullet and armor. According to ballistic test results, partial penetration was observed in all armor produced. The front ceramic layer caused corrosion of the bullet, and a mushrooming effect occurred on it. The carbon fiber layer has dramatically helped as an alternative or support to UHMWPE. Since the results obtained with the carbon fiber ratios used remain within the standards, it will not pose a problem regarding usage. On the contrary, using carbon fiber, which is relatively easier to produce and supply than UHMWPE and more economically suitable, will provide more significant benefits. Experimental and numerical studies have revealed consistent results for all armors.Highlights The effect of a 7.62 × 51 armor‐piercing bullet on ceramic/composite armor was examined. Carbon fiber and UHMWPE hybrid structure was created in different thicknesses. The carbon fiber layer has dramatically helped as an alternative or support to UHMWPE. Using carbon fiber, which is relatively easier to produce and supply than UHMWPE and is more economically suitable. Experimental and numerical studies have revealed consistent results for all armors.

Review of the penetration resistance performance of lightweight ceramic composite armor under high-speed impact

Due to the constant updates in armor materials and structures, as well as the continuously increasing ballistic threats, higher requirements have been put forward for the ballistic performance of lightweight ceramic armor. In this paper, we first studied the types of ballistic threats faced by lightweight armor and determined the range of main materials and various combinations used in common ceramic composite armor, while comparing their performance with other constituent materials. Next, we reviewed the coupling mechanism of the projectile and target during the ballistic penetration process and the energy dissipation mechanism, and discussed the structural parameters that affect the ballistic performance of the ceramic composite armor. Finally, we pointed out the future direction of development for ceramic composite armor, reviewed the coupling mechanism of the projectile and target during the ballistic penetration process and the energy dissipation mechanism, and discussed the structural parameters that affect the ballistic performance of the ceramic composite armor.

Composite armor philosophy (CAP): Holistic design methodology of multi-layered composite protection systems for armored vehicles

A philosophy for the design of novel, lightweight, multi-layered armor, referred to as Composite Armor Philosophy (CAP), which can adapt to the passive protection of light-, medium-, and heavy-armored vehicles, is presented in this study. CAP can serve as a guiding principle to assist designers in comprehending the distinct roles fulfilled by each component. The CAP proposal comprises four functional layers, organized in a suggested hierarchy of materials. Particularly notable is the inclusion of a ceramic-composite principle, representing an advanced and innovative solution in the field of armor design. This paper showcases real-world defense industry applications, offering case studies that demonstrate the effectiveness of this advanced approach. CAP represents a significant milestone in the history of passive protection, marking an evolutionary leap in the field. This philosophical approach provides designers with a powerful toolset with which to enhance the protection capabilities of military vehicles, making them more resilient and better equipped to meet the challenges of modern warfare.

Research on dynamic mechanical properties and damage model of ceramic materials under multi‐axial stress

AbstractDue to their exceptional impact resistance, ceramics are extensively used in various fields. However, unavoidable pores, microcracks, and inherent defects can degrade the performance of ceramic materials. A damage model of SiC ceramics under passive confining pressure was constructed based on the Lemaitre strain equivalence principle and the Weibull distribution function. This paper presented a dynamic damage model for SiC ceramics subjected to passive confinement pressure based on the principles of damage mechanics. Additionally, the split Hopkinson pressure bar device was employed to investigate the compressive strength and damage evolution of SiC ceramics at various shock pressures and confinement degrees. The experimental results indicate that constraints can reduce the damage to ceramics. The metal sleeve increased stiffness when compressing the ceramic material, allowing the specimen to convert from brittle–plastic–brittle. When sufficient constraints can be provided, the peak strain decreases gradually with the increase of the impact air pressure. Experimental data showing good agreement with the proposed model validated and analyzed the established model. Thinner boundary constraints cannot maintain the stability of ceramic structures, thicker boundaries do not significantly improve performance, and thicker boundaries can cause more weak areas. This paper provides guidance for the design of encapsulated ceramic composite armor by quantitatively studying the constraint thickness.

Thermo-Chemo-Mechanical Modeling of Residual Stress in Unidirectional Carbon Fiber-Reinforced Polymers during Manufacture.

The application of carbon fiber-reinforced composite materials in marine engineering is growing steadily. The mechanical properties of unbonded flexible risers using composite tensile armor wire are highly valued. However, the curing process generates a certain amount of internal residual stress. We present a detailed analysis of epoxy resin laminates to assess the impact of thermal, chemical, and mechanical effects on the curing stress and strain. An empirical model that correlates temperature and degree of cure was developed to precisely fit the elastic modulus data of the curing resin. The chemical kinetics of the epoxy resin system was characterized using differential scanning calorimetry (DSC), while the tensile relaxation modulus was determined through a dynamic mechanical analysis. The viscoelastic model was calibrated using the elastic modulus data of the cured resin combining temperature and degree of the curing (thermochemical kinetics) responses. Based on the principle of time-temperature superposition, the displacement factor and relaxation behavior of the material were also accurately captured by employing the same principle of time-temperature superposition. Utilizing the empirical model for degree of cure and modulus, we predicted micro-curing-induced strains in cured composite materials, which were then validated with experimental observations.

Ballistic impact wave and back bulge propagation mechanism and blunt trauma assessment of ceramic/UHMWPE composite body armor

With increasing local conflicts worldwide, studying the impact response of body armor is crucial for enhancing soldier survival rates. However, there is still insufficient understanding of the back bulge expansion patterns, the impact waves transmission features, and blunt injury assessing method of body armor. To investigate these problems deeply, the three-dimensional digital image correlation method and numerical models were employed to reveal the ballistic response mechanism of ceramic/ultra-high-molecular-weight polyethylene (UHMWPE) composite body armor impacted by 7.62 mm rifle bullet. This study built theoretical function for the bulge expansion, revealed the wave transmission mechanism and fractures in both materials and their interaction. Firstly, the experiment revealed that the back-face bulge transverse expansion velocity exhibits a double exponential decrease. Secondly, the contour of back-face bulges consistently demonstrated excellent hyperbolic characteristics at various moments. Thirdly, the average Viscous Criterion (VC) and Blunt Criterion (BC) values were 5.37 and 0.95, corresponding to Abbreviated Injury Scale (AIS) values of 6 and 4. Fourthly, the simulation revealed that the ceramics transverse and radial cracks seems primarily induced by shear stress xy; ceramics conical cracks occurring at the boundaries of equivalent stress seems primarily induced by stress in x and y directions. Fifthly, numerical results revealed that the velocity of compression waves within the laminate increases over time in the impact direction and consistent with ceramic velocity impacted on the laminate. These findings lead to experimental and theoretical advances in the impact response mechanism of composite body armor and provide index for improving the protective performance.

Review of the Development of an Unbonded Flexible Riser: New Material, Types of Layers, and Cross-Sectional Mechanical Properties.

Unbonded flexible risers consist of several helical and cylindrical layers, which can undergo large bending deformation and can be installed in different configurations to adapt to harsh marine environments; thus, they can be applied to transport oil and gas resources from ultra-deep waters (UDW). Due to their special geometric characteristics, they can ensure sufficient axial tensile stiffness while having small bending stiffness, which can undergo large deflection bending deformation. In recent years, the development of unbonded flexible risers has been moving in an intelligent, integrated direction. This paper presents a review of unbonded flexible risers. Firstly, the form and properties of each interlayer of an unbonded flexible riser are introduced, as well as the corresponding performance and configuration characteristics. In recent years, the development of unbonded flexible risers has been evolving, and the development of machine learning on unbonded flexible risers is discussed. Finally, with emphasis on exploring the design characteristics and working principles, three new types of unbonded flexible risers, an integrated production bundle, an unbonded flexible riser with an anti-H2S layer, and an unbonded flexible riser with a composite armor layer, are presented. The research results show that: (1) the analytical methods of cross-sectional properties of unbonded flexible risers are solved based on ideal assumptions, and the computational accuracy needs to be improved. (2) Numerical methods have evolved from equivalent simplified models to models that account for detailed geometric properties. (3) Compared with ordinary steel risers, the unbonded flexible riser is more suitable for deep-sea resource development, and the structure of each layer can be designed according to the requirements of the actual environment.

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.

Microstructural examination and ballistic testing of field-assisted sintering technology produced Ti-TiB2 functionally graded material composite armour plates

High hardness ceramics are potent in their use for armour applications globally, but intrinsically brittle. This can result in fragmentation damage, as well as low multi hit capacity. In this work, alternative 250 mm diameter Ti-6Al-4 V discs were produced using field-assisted sintering technology (FAST) with and without stepped functional grading using low wt.% TiB2 concentrations, respectively, to investigate their microstructure and ballistic performance. The in situ generation of a significant quantity of high strength, ceramic TiB needles was confirmed for the samples, and the plates were ballistically tested to attain V50 values. In addition to a microstructural examination. The ballistic results indicated a superior behavior to the monolithic titanium alloy plates without TiB2 additions.

Exploring the impact resistance of hybrid sandwich composite body armor through experimental analysis

Exploring the impact resistance of hybrid sandwich composite body armor through experimental analysis

Ballistic behaviour of hybride carbon/basalt fiber reinforced epoxy-hBN composite

Ballistic behaviours of hybrid composite armors were investigated through experiments. The effects of hexagonal boron nitride (h-BN) nanopowders and number of layers on ballistic performance were examined. Four types of armors were manufactured by hand lay-up and vacuum bagging technique: 60 layers of fabric (30 layers carbon and 30 layers basalt fabrics) with 0% h-BN (1-A) and 1% h-BN (1-B), also 100 layers of fabric (50 layers carbon and 50 layers basalt fabrics) with 0% h-BN (2-A) and 1% h-BN (2-B) with epoxy resin. Ballistic impact tests were performed on the armors using a 9 mm full metal jacket projectile. The densities of the ballistic plates are 1.53, 1.56, 1.61 and 1.65 respectively. After three shots to each plate, the average hole depths were 5.55 mm on the 1-A coded plate, 4.34 mm on the 1-B armor, 4.68 mm on the 2-A plate, and 4.69 mm on the 2-B armor. All of the armors were able to confront for the velocities between [Formula: see text] m/s successfully. However, the h-BN showed a significant influence on the overall ballistic performance of composite armors. It has been found that the penetration depth decreases with the addition of h-BN. Also SEM-EDS mapping and XRD analysis were used to characterize the hybrid composites.

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

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

Penetration Characteristics of Ceramic/Metal Composite Armor Impacted by Different Projectiles

Penetration Characteristics of Ceramic/Metal Composite Armor Impacted by Different Projectiles