PRESS RELEASE – June 2005 Ultra-lightweight Ballistic Protection

PRESS RELEASE – June 2005
IBCOL Composites GmbH
Hans-Pinsel-Straße 7
85540 Haar (Munich)
Germany
Telephone: + 49 (0) 89 / 46 00 06 - 36
Telefax: + 49 (0) 89 / 46 00 06 – 24
Ultra-lightweight Ballistic Protection Systems
for Aircraft and Helicopters
1
Scope
For helicopters and fixed-wing aircraft every
kilo counts. Additional weight reduces the
payload and action radius. This means weight
saving is a prime prerequisite in developing
armouring for helicopters and aircrafts. With
C/SiC ceramic composite material (C/SiC:
Carbon Fibre reinforced Silicon Carbide) we
can achieve weight savings of 70 %,
compared to traditional steel armouring
plates.
The Special Forces of the German Border
Police equips three different types of
helicopters, e.g. Bell 212, EC 155 and Puma
SA 330 with ultra light ceramic composite
armour to protect them in the air against
projectiles fired from the ground. The ballistic
protection system was developed by IBCOL
Composites GmbH. Early in August the
German Army took delivery of the first
Eurocopter NH 90-helicopter provided with
the new ultra light armour prototype. EC 635
and Super-Puma helicopters will also get the
new armour. Shortly, the system will be made
available for the CH-53 helicopters.
2
Introduction
IBCOL Composites GmbH provides high quality products and
solutions for effective ballistic protection of people, equipment and
material. IBCOL Composites designs, develops and tailors the
ballistic protection systems in close co-operation with the clients,
according to their needs and requirements to provide the best
possible ballistic protection against specific threats like rifle calibre
and machine gun bullets or fragments. IBCOL Composites ballistic
protection systems and solutions have also a proven record of service
in extreme conditions, ranging from arctic cold to tropical heat.
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Geschäftsführung:
Dr. Ulrich Papenburg
Dr. Wolfgang Arnold
AG München HRB Nr.107 473
The ultra-lightweight ballistic protection systems based on C/SiC composite ceramics (C/SiC:
Carbon Fibre reinforced Silicon Carbide) for the Bell 212 helicopter, the EC 155 helicopter and
the Puma SA 330 helicopter of the German Border Police were delivered by IBCOL
Composites GmbH in Munich (Germany), a member of the IBC Group.
In order to protect the helicopters against projectiles fired from the ground, the cabin floor
and the lower parts of the sidewalls are armoured. The seats of the pilot and co-pilot have
add-on ballistic protection. The ballistic elements are fitted onto the fixtures present for
securing additional equipment, cargo and seats and are provided with identical fixtures to
enable easy mounting and removal. This solution also makes sure that the crew can operate
without being hindered by the armouring, while the points of fixture remain normally
available. This user-friendly concept puts high demands on the manufacture of the
armouring, because a whole series of ceramic elements with specially formed recesses
must be produced separately.
The main business areas of IBCOL Composites GmbH is the development, production and
world-wide marketing of C/SiC ultra-lightweight ceramic composite armour protection
systems, C/SiC components and systems as well as the technology of this advanced
ceramic matrix composites material and all analogue business. Important part of the IBCOL
Composites business is the development and manufacturing of ultra-lightweight armour
protection systems, rocket nozzles, missile components, optical ceramic structures and
mirrors as well as ceramic brake disks for airplanes and vehicles.
3
Two-step C/SiC – aramid fibre protection
The helicopters must not only be protected
against bullets fired by hand-held arms but
also against armour-penetrating hard-core
projectiles fired from long-barrel weapons. In
order to meet these requirements, IBCOL
Composites developed a two-step ballistic
protection made of advanced ceramic plates
consisting of silicon carbide composites
(C/SiC: carbon fibre reinforced silicon carbide)
provided with an aramid fibre fabric laminate.
Upon the impact with the extremely hard
ceramic material the projectile and its armourpenetrating core are shattered. The ceramic
material is also crushed at the point of impact,
but the ceramic and projectile fragments that
fly away are absorbed by the ballistic aramid
laminate. The single aramid fabric layers are
rubberised on either side and are cured into a
multiplayer laminate under high pressure. In
this process the material gets the required
flexibility to stop the fragments. The laminate
is also optimally suited as carrier material for
the ceramic armouring.
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To design these advanced ceramic components, carbon fibre has to be moulded with phenol
resin and afterwards is winded, pressed and hardened. The design and the mechanical
handling are followed by a carbonisation and infiltration of the parts with high-performance
ceramics within corresponding vacuum high-temperature furnaces. Finally the components
have to be abraded with diamond tools up to the final measurements.
4
Properties and advantages
•
Low specific areal density at high ballistic protection levels
•
Considerable flexibility in structural design (near-net shape processing)
•
Low wall thickness (< 15 mm)
•
High strength and stiffness
•
No porosity, no creeping and no ageing under stress
•
Very high thermal, chemical, corrosion and abrasion resistance
•
Ultra-lightweight capability (small wall thickness and complex stiffeners)
•
The helicopter crew can operate without being hindered by the armouring
•
Nearly unlimited life time during operation in adverse environments and in a wide
temperature range.
•
Considerable flexibility in structural design
•
Design und manufacturing capability for spherical armour protection systems
•
Quick and feasible fastening systems for fast installation and integration.
In the meantime IBCOL Composites GmbH has become number one in the ultra light weight
helicopter armament market and is establishing other C/SiC markets like rocket nozzles, hot
sections of missiles, automobile and aircraft brakes. Plans are under way for ballistic
protection of CH 53, Bell-UH 1D (HUEY) and Super Puma helicopters.
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5
Close cooperation with customers
Thanks to the intensive cooperation with the customers, it took only one year to get official
authorization and produce the system for the various helicopter types. IBCOL Composites
was entrusted with customer coordination, engineering and construction, and the typespecific authorization procedures for the ballistic elements. The ceramic armouring is also
supplied by the Munich-based company ready for installation. The ballistic material was
intensively investigated in hundreds of firing range tests. The main challenge is to find the
optimal balance between weight, ballistic protection and material costs. Engineers of IBCOL
Composites see to the installation of the elements in the helicopters and tests of samples
together with the customer.
6
Design study ballistic protection kit CH-53 Helicopter [German Armed
Forces]
In order to fully meet the customers’
requirements, IBCOL Composites stays in
close contact to the customer not only in the
design and prototyping phase, but also after
the ballistic protection kit has been put into
service. This enables IBCOL Composites to
continually improve its products and we are
able to pass on this know-how to all our
customers.
In the early stage of the design process
engineers from IBCOL Composites will come
to the customer and collect all necessary
information about the design of the
helicopters that are to be armoured. As these
machines are highly customized the armour
kits have to be adjusted in order to offer the
highest
amount
of
protection
while
guaranteeing the least amount of limitations to
the operator.
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7
Ballistic protection kit EC 155 Helicopter [German Border Police]
The special forces of the German Border
Police approached IBCOL Composites with
the need of a ballistic protection system for
their helicopter fleet. As these helicopters are
already equipped with a substantial amount of
add-on equipment, a solution was needed
that would not handicap the normal field of
operation of these aircraft.
The EC 155 ballistic protection kit can easily
be installed on demand. It offers protection to
the cabin and cockpit floor as well as a side
protection for the cockpit.
The operator has the choice of installing only
cockpit protection for cargo transport missions
into hazardous areas. It is also possible
merely install the floor protection panels.
To be able to offer a high level of protection
the cockpit panels have an emergency exit
sliding door incorporated. This offers a large
protected area without blocking regular
emergency exit passages.
On top of the soul operator specific design
and the delivery of the hardware. IBCOL
Composites offers add-ons to the helicopter
operational manuals.
The delivery of the armour kits is carried
through by highly qualified aerospace
engineers and come together with an
installation training session.
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8
Ballistic protection kit Bell 212 Helicopter [German Border Police]
The ballistic protection kit for the Bell 212
helicopters operated by the German Border
Police as delivered in early summer 2004.
As most helicopter manufactures have not yet
standardizes their equipment interfaces (seat
rails, cargo hooks, stretcher connections etc.)
the design of individual fastening systems is
part of the armour protection package.
Detailed examples of these fastening groups
are shown in section 11.
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9
Ballistic Protection Kit AS330 Puma Helicopter [German Border Police]
The ballistic protection kit for the AS330
Puma helicopters operated by the German
Border Police as delivered in early 2005. With
this the complete fleet of large Helicopters
operated by the German Border Police Force
is armoured with IBCOL Composites Armour
Systems.
As most helicopter manufactures have not yet
standardizes their equipment interfaces (seat
rails, cargo hooks, stretcher connections etc.)
the design of individual fastening systems is
part of the armour protection package.
Detailed examples of these fastening groups
are shown in section 11.
In order to further improve the protection level
IBCOL Composites designed an armoured
seat plate for the AS330 Puma.
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IBCOL Composites GmbH is further responsible for the design, development and
manufacturing of the different ceramic composite ballistic protection kits for the two different
NH-90 helicopters for army and air force, which protect the crew, the passengers and the
rear gunner inside the helicopters against ballistic threats fired from the ground.
10 Ballistic Protection NH-90 [German Armed Forces]
The floor of the NH-90 corridor between
cockpit and cabin is equipped with an armour
plate to protect the 3rd crew member. This
armour protection plate is compatible with all
floor and wall mounted 3rd crew seat brackets
to provide clearance for 3rd crew seat
movement during 90° turning.
The connection of the NH-90 side armour
plates to the floor armour panels are designed
simple and easy and will be able to install and
dismantle the ballistic protection system
quickly. The protection of the sidewalls is
compatible with the interior panelling and the
troop seats. The hard points for the troop
seats and the stretchers and the positions of
the different anchor points are duplicated from
the normal NH90 helicopter floor to the
armour protection plates.
The NH-90 floor armour protection plates are
designed to carry 1500 kg cargo payload and
to be walked on with soldier boots and is
covered with an anti-sliding material.
Additional, the ballistic protection floor plates
are designed to withstand normal operation
without service.
The NH90 ballistic protection of the cabin
doors consists of two pieces, one will be fixed,
but quick to connect and separate and the
other is foldable for quick entrance and
escape the helicopter and also for turning the
pintle machine gun in stowing position. The
foldable protection element is designed to
walk on it. The protection kit allows normal
operation of doors and emergency exits.
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11 Customized fastening systems
IBCOL Composites combines the need of the
operator to have to be able to install all
standard equipment after the armour
protection kit has been put into place with the
need to securely fasten the kit.
IBCOL Composites can fall back on a large
variety of fastening systems that have been
designed within the company. This know-how
allows IBCOL Composites to be able to find
quick and feasible fastening systems that
meet the high standards required in
aerospace engineering.
If the customer wants to have extensive
qualification tests IBCOL Composites is able
to handle these, in combination with the
qualification documentation.
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12 Customised layout of the armour
The safety on board of a helicopter underlies highest priority. A large protected area goes hand in
hand with a side protection within the rotorcraft. This means that exits can and should be protected.
Side protection in the door area can be designed in such a manner that emergency exit doors are
integrated.
In the EC 155 armour designed by IBCOL Composites the pilot emergency exit is a sliding door. After
removing the safety bolt it will easily slide out of the way.
Due to a different Cockpit design the emergency exit in the AS 330 Puma is a door that will open
downwards. In the open position it is slid
backwards and thrown of the helicopter.
Safety equipment that needs to be easily
accessible, e.g. the fire extinguisher, to the crew
can be refitted after the ballistic protection system
is installed. The necessary fittings and designs are
incorporated in the ballistic protection design.
It is also possible to integrate customer specific
features such as cargo hook hatches or load
through lids to the cargo compartment. These can
be designed in such a way that it will only cause a
minimal reduction in ballistic protection and at the
same time greatly improve the functionality of the
system.
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According to the customers need the following three main floor layout options are provided.
•
Option A – in this design all the
armour plates will be fixed to the floor
using the standard seat rails. This
version simple connection methods
and a small system weight. It offers
advantages to customers with little
equipment requirements and short
instalment times.
•
Option B – the floor will be covered
with armoured plates and the
necessary seat rails will be fixed on
top of the armouring. This will
guaranty a higher level of protected
surface. Note that the seats within the
Cabin will be raised more than the
thickness of the armour plates. This
version is ideal for customers with very
high safety levels. Unprotected gaps
(common to all armour systems) are
reduced to a minimum.
•
Option C – in this version all the
fixation elements will be integrated in
to the armour plates leaving a
complete level floor. This fixation
method will offer a higher level of
protected area with regards to option
A. It will also allow quick mounting
times as the cabin floor plates click
into the cabin floor seat rails without
the necessity to tighten further screws.
Note that here the equipment will only
be raised by the thickness of the
armour and everything can be installed
in its usual manner.
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13 Future ballistic protection kits for a variety of helicopters
IBCOL Composites is continuously increasing the number of products on the market to meet
our customers’ demands. We are constantly aiming to improve our products as well as our
market share.
Here is a short insight to our current projects worked on in close relationship to our
customers.
•
Black Hawk Helicopter – this multimission-helicopter operated by many
armed forces all over the world will
soon be protected by an ultra-lightweight ballistic protection system by
IBCOL. Protecting its crew and
passengers
from
AK47
API
ammunition.
•
PZL Sokol – Huzar Helicopter – this
multi-mission-helicopter
flown
by
former east block states forces is to be
protected by an ultra – light - weight
ballistic protection system designed
IBCOL. Aiding new NATO States in the
war against terrorism.
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•
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EC 635 & EC 135 Helicopter – this
light mission helicopter operated by
many armed forces as well as law
enforcing units. Its field of action can
be increased by our light weight
armour without really reducing its
mission radius. The armour will protect
the crew when flying over enemy area.
Like all IBCOL products the high level
of variation adds to the customers
convenience. Shown in the pictures
below the operator can fly with a floor
only protection or with a complete
protection with increased safety for the
pilot and co-pilot.
TIGER Helicopter - For crisis control and other military operations it is necessary to protect
the aircrew of the TIGER helicopter (TIGER HAD-E for Spain), against calibre 7.62 mm X
51 mm AP (P80) and calibre 12.7 mm x 99 API (P1947) ammunition. The additional ballistic
protection system is required by the Spain Government for the 24 TIGER Helicopter HAD-E
and it could be also an option for 40 TIGER Helicopters HAD-F (which supersedes 30 HAP
and 10 HAC), in addition to that a further option could be the retrofit of 80 TIGER Helicopter
UHT.
The additional ballistic protection system of both cockpits shall be an "Add-On Armour"
solution, installed as a removeable kit on the HAD TIGER helicopter. The basic requirement
is light weight design in order to maintain the specified performance of the HAD-E TIGER
helicopter. The additional armour protection system has to be modular and
assembly/disassembly has to be possible in the field. For the armour protection plate at
frame 1 and behind the pilot installation of the equipment is possible only during
maintenance, because of the restricted accessibility.
To enable the "Add-On Armour" solution effectively, fixtures should be permanently
attached to the TIGER helicopter's structure, preferably during helicopter production, and
prior to its final assembly. The vulnerable parts of the TIGER helicopter from ground fire
small arms are the two cockpit floors, the frame 1 and the cockpit side walls.
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•
MD 900 Helicopter– this light mission
helicopter operated is by many lawenforcing units. Its field of action can
be increased by our light weight
armour without really reducing its
mission radius. The armour will protect
the crew when flying over enemy area.
Like all IBCOL Composites products
the high level of variation adds to the
customers convenience.
The projects shown above incorporate protection systems up to 7,62 * 51 mm AP and 12.7 x
99 mm AP projectiles. On demand IBCOL Composites is able to offer ballistic protection
systems to any other threat. It is our goal to protect you from whatever may get into your
way.
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