Lightweight Composite Armor An Industry Transformation Opportunity

Lightweight Composite Armor
An Industry Transformation Opportunity
Armored Vehicles – India
November, 2010
© 2010 Owens Corning
About Owens Corning
• Founded in 1938, an industry leader in glass fiber
insulation, roofing and asphalt and glass fiber
reinforcements
• 2009 sales: $4.8 billion
• 16,000
16 000 employees in 26 countries
• FORTUNE 500 company for
56 consecutive years
Owens Corning Building
Materials and Services
Owens Corning
Composite Solutions
•
•
•
•
•
•
Residential Insulation
Commercial & Industrial
Insulation
Manufactured Stone
Veneer
Residential Shingles
Roofing Asphalts
Composite
p
Reinforcements
2
Owens Corning
g Historyy with the Militaryy
• Insulation for Warships (1939) – U.S. Navy Bureau of
Ships specified OC insulation for new ships.
• Structural Aircraft Parts (1942) – OC partnered with U.S.
A.A.F. to develop plastic laminates.
• B
Beta® yarn (1963) – OC develops
d
l
fib
fiber ffor aerospace
applications and use in NASA spacesuits.
• S-Glass® (1959-63) – Developed by OC under contract
with
ith U
U.S.
S N
Navy.
• Piedmont Products, Inc. (1979) – OC manages
reinforcements plant under government contract
• OC Armor (1989) – Product specified for NATO and US
Military personnel carriers and first-aid trucks.
• ShieldStrand® Reinforcements (2007
(2007-2009)
2009)
– MRAP, HMMWV
3
Market Transformation Opportunities
pp
HARD Armor
SOFT Armor
Personnel protection
Body armor inserts
Helmets
Shields
Anti-mine shoes, leg protection, …
Personnel protection
body armor
Gloves
Clothes
Armored vehicles
Light vehicles
Ballistic panels for floor, door, bodywork, roof, interior armor ...
Cash in transit, ambulance,…
Law enforcement, Army : car, 4x4, hummer, van, truck …
Civilian: VIP car, 4x4, limousine, …
Heavy vehicles
Ballistic panels for military vehicles. External & internal armor
Tank, char, wheeled vehicle, tracked vehicle
Armored aerial vehicles
Helicopters : floor, seat (panels), cockpit…
Aircraft : cockpit doors
doors, seat
seat, …
Armored marine vehicles
Submarine
Shipboard : bridge, compartment, …
Fixed structure
Ballistic panels for structural parts
Bank counter, prison, bridge, shelter, vulnerable building (embassy,
airport,…)
4
Mobilityy & Lethalityy drives solution
High
• Helicopter
• Defense Vehicles
• Amphibious Assault
V hi l
Vehicles
M
Mobility
• Fighter Jets
• Tactical Vehicles
• Personal Armor
• Homeland Security
• Bridges / Infrastructure
• Embassies
•
•
•
•
Marine Deckhouses
Marine Hull Components
Coast Guard
Battlefield ISO Shelters
Low
Low
Ballistic Lethality
High
5
History of Composite Vehicles
Functional Requirements
• weight (lighter)
• range of protection
levels
• fire performance
• ballistic and blast
performance
• Electromagnetic
properties
• damage tolerance
• maintainability
• affordability
Monocoque
Technology Gaps:
• structural
performance
Appliqué
• Lightweight Multifunctional
Materials are needed
• Materials-by-design vs trial
and error
Integral
• Multi-scale modeling across all
l
length
th scales
l and
d loading
l di
rates
• Systems Approach for Design
and Optimization
Structure (A) + Armor (B)
6
Industryy Needs
Protection
P f
Performance
D
Drivers
i
Performance
P l d
Payload
• Protection against blast and fragmentation
• Performance improved with vehicle mobility
• Payload capacity increased
• Lighter, faster, more fuel efficient vehicles
• Higher
g
survivability
y at affordable p
price
7
Design Drivers
Ballistic energy absorbing fracture mechanisms may be
combined within same armor systems to meet requirements of
different threats.
This combination is based on:
¾ Weight
W i ht limitation
li it ti
¾ Space constraints
¾ Structural role
¾ Environment (moisture,FST)
¾ Type of projectile(s)
¾ Need for single shot or multi-hit capability
y leads to armor systems
y
which are based on
And usually
multimaterials, multilayer arrangements, each providing a
specific functionality.
8
Maximize energy absorption in composite integral armor
while maintaining structural properties
• Potential mechanisms in composite layer
– Delamination
– Fiber and resin fracture/deformation
– Fabric deformation effects
– Fiber-matrix interphase damage
– Frictional
F i ti
l effects
ff t – interlaminar,
i t l i
fib
fiber-matrix,
ti
etc.
9
Tailoring Composite Performance
Fiber design
Enhancement of
compressive
strength
Interphase &
thermodynamic
effects
Micromechanical
Characterization
•Energy Absorption
Strain Rate
•Strain
•Durability
Effects of sizing &
Resin Compatibility
Optimum Composites
for Desired Properties
• Ballistic
• Structure
• Durability
Grading of
Interlaminar
g
Region
Control of Resin
Permeability
10
Material Choices for Armor Protection
• Shieldstrand® ((High
g Strength
g Glass Fiber))
• Aramid fiber
• UHMWPE fiber
• Ballistic nylon fiber
• Ceramics
• Steel
• Aluminum
• Titanium
11
Effectiveness vs. selected threats
Material
Projectile
j
Velocity
y
Km/s
Ball
0.9
Armor Piercing
0.9
Sabot-light AP
1.1
Tungsten carbide AP
0.9
AP Discarding sabot
1.2
F
Fragment
t simulating
i l ti
05
0.5
Fragment simulating
1.5
Self-forging fragment
2.0
Long rod penetrator
16
1.6
High velocity KE
2+
Shaped charge
7.0
Effectiveness:
<
<
Al
Steel
Aramid
Shield
strand
System
Ceramic
<
12
Benefits of ShieldStrand Armor Solutions
Tangibles - Mitigates Behind Armor Debris from
F
Fragmentation
t ti
and
dO
Overmatch
t h Threats
Th
t off IED,
IED EFP
• Stronger & Lighter
• Thinner
• Durable
• Excellent Processing
g
• Affordable
• Consistent Supply Chain
• Phenolic Fire Resistance
• Ballistic Performance to Specifications for
Composite Armor Systems MIL
MIL-DTL-64154
DTL 64154
• Qualified for Spall Liner, Frag 5, Frag 6 and EFP
13
Benefits of ShieldStrand Armor Solutions
Intangibles – Heritage of Proven Spall Liner Field
P f
Performance
and
d Prototype
P t t
Structural
St
t
l Armor
A
Hull
H ll
Performance for Aluminum and Steel Substitution
• Depot / Field Installation Capable
• Battle Damage and Repair Field Maintenance Capable
• Flat or Curved Plate or Complex Shape Demonstrated
• Installs with Fastener Systems typical to Metals
• Surface ready for CARC or adhesive for Metal and/or
Ceramic Bonding
g / Joining
g
• No Corrosion or galvanic corrosion
• Good Durability to Vehicle Environment
• Complies with FMVSS 302 Flammability
14
ShieldStrand® Enables Lightweight
Composite Armor Affordability
$60.00
UHMWPE
Co
ost ($/lb)
$50.00
$40 00
$40.00
$30.00
$20.00
Aramid/Phenolic
$10 00
$10.00
ShieldStrand® S
$0
2
4
S-2 Glass®
ShieldStrand® Advantex® (E-glass)
RHA Steel
5083 AL
6
8
10
12
Weight required to meet MIL-DTL-64154B (lbs/sf)
15
ShieldStrand® Offers the opportunity for
Hybridization with other materials for Optimum
Solution
Ballistiic Limit V50
0 (ft/s)
7000
6000
5000
4000
3000
0.25"AL5083/ ShieldStrand/ 0.25"RHA
ShieldStrand/ 0.25"RHA
ShieldStrand VE
RHA
ShieldStrand/HB2 50/50AD
ShieldStrand VE/ Spectra3124/EPS/0.14"RHA
0.50"AluminaRE/ShieldStrand/0.14"RHA
0.4"Alumina/ShieldStrand VE/AL Foam
2000
1000
0
0
10
20
30
40
50
2
Areal Density (lb/ft )
Data shown for comparative purposes only and should not be construed
as a guaranty or warranty of performance. Absolute performance will vary
16
by resin system or process
Integrated
g
Structural Armor
ShieldStrand® is making new armor solutions
p
possible
• The strength of ShieldStrand® provides structure
as well as protection, allowing armor to be
integrated into the vehicle structure, reducing
overall vehicle weight
• Shi
ShieldStrand®
ldSt d® can be
b molded
ld d iinto
t llarge complexl
shaped structural parts using proven large scale
composite manufacturing technologies.
• ShieldStrand® has been tested in combination
with a steel or ceramic strike face to provide
protection
t ti when
h armor piercing
i i and
d multi
lti hit
capability is required or an overmatched threat
exists.
17
ShieldStrand® Armor Solutions for Blast
and Multi
Multi-hit
hit Fragmentation Performance
• Offers good performance in blast – structurally
good
d with
ith minimal
i i l global
l b ld
deflection
fl ti
• Local Deflection with Large Fragments
• FR Vinylester ShieldStrand V-hull passed blast
& full scale diesel fuel fire test
• Minimal secondary behind armor effects – V-hull
V hull
vents Blast, Composite stops fragmentation,
while structure absorbs Blast energy and
dissipates shock
shock.
Force vs. Time
8000
7000
6000
5000
Force (lbss)
4000
3000
2000
1000
0
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
-1000
-2000
Time (s)
18
ShieldStrand® Phenolic Plate:
Provides structure as well as protection
Elastic Constants
Longitudinal
g
Modulus
Transverse Modulus
Axial Shear Modulus
Axial Comp Modulus
Poisson's Ratio
Strength Properties
Longitudinal Tension
Longitudinal Compression
Transverse Tension
p
Transverse Compression
Normal Compression
In-Plane Shear
Interlaminar Shear
Longitudinal Flexural
Longitudinal Bearing
D3039, D638
D3039, D638
D3518
D695
D3039
106 PSI
3.5 - 4.6
3.5 - 4.6
0.5 - 0.7
5.2 - 6.7
0.24 - 0.27
Ultimate Strains
Longitudinal
g
Tension
Longitudinal Compression
Transverse Tension
Transverse Compression
In-Plane Shear
D3039, D638
D3410, D695
D3039, D638
D3410, D695
D695
D3518
D2344
D790
D953
103 PSI
60 - 100
20 - 80
60 - 100
20 - 80
100 - 120
17 - 30
1.9 - 4.0
20 - 45
35 - 80
Physical Properties
Fiber Volume
D2734
Resin Weight
D2584
Water Absorption
D570, D792
Longitudinal Flexural, Wet Ret. D790
Thickness (in.)
Ply Thickness (in.)
25 ply
Areal Density (lb/sf)
25 ply
Density (lb/ci)
D792
Hardness (M scale)
D785
Thermal Transition
D4065
Flammability
UL 94
Time to Ignition @50kW/sm (s) E1354
Total Heat Release (MJ/sm)
E1354
MAHRE (kW/sm)
E1354
FIGRA
E1354
D3039, D638
D3410, D695
D3039, D638
D3410, D695
D3518
%
1.5 - 4
0.7 - 2
1.5 - 4
0.7 - 2
2 - 2.5
61 - 66%
16 - 24%
<1.5%
>70%
0.470 - 0.530
0.019 - 0.020
4.6 - 5.4
0.072 - 0.074
>80
210 - 240
V0
500 - 600
25 - 60
20 - 35
0.10 - 0.20
Data shown for comparative purposes only and should not be construed
as a guaranty or warranty of performance. Absolute performance will vary
19
by resin system or process
Shieldstrand® Solution Case Histories
MRAP
HMMWV
Spall Liner
JLTV
FCS
MRAP EFP Kit
Integrated
Structural
Cab
Composite
V-hull
Frag 5 Door Kit
spall liners
exterior armor modules
Compression Molded Phenolic
v-hull
structural components
Infusion Molded FR Epoxy Vinylester
20
Shieldstrand® Solutions for Armor
Protection
otect o
Shieldstrand® Fibers delivers
optimum strength and stiffness
Ultimate energy absorption controlled by strain to failure of the fibres. Once
fibres have ruptured the armour collapses and no further energy is absorbed.
ShieldStrand®
S Plus
Metal
S-2 Glass
Aramid
UHMW
Polyethylene
(Steel & Al)
Assumes equal ballistic threat for all materials
Weight
+
-
+
++
+++
++
+++
+
-
--
Structural Capability
+
++
+
-
--
Part thickness
+
++
+
-
--
++
-
++
+
-
Fire, Smoke and
Toxicity
+
++
+
+
-
Temperature
Resistance
+
++
+
+
-
Cost
(thin is +)
Resistance to acid
and chemical attack
A balanced solution ½ weight of Steel and 1/3 cost21
of UHMWPE
21