Ceramic Materials For Light-weight Ceramic Polymer Armor .

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KMWCeramic Materials forlight-weight CeramicPolymer Armor SystemsKMW

www.garant-protection.comLIGHT-WEIGHT CERAMIC ARMORThe world has changed. Military and Security forces worldwide have been forced to adapt to newdomestic and international terror threats and to theincreased tempo of combat deployments in hostileterritory.Vehicles designed for a traditional land conflict areoften lightly or inadequately protected from asymmetric threats such as Improvised Explosive Devices(IED’s) and Explosively Formed Projectiles (EFP’s)which are encountered with alarming frequency bytroops on operations.National sensitivities to casualties and straineddefence budgets force engineers to continuallyadapt existing vehicle platforms to these constantlychanging threats. The challenge to offer the highestlevel of protection with the lowest possible weightis a constant battle of material science, integration technologies and physics. These systems mustprotect from a range of threats such as direct gunfire, shaped charges, fragmentation and land mines.Once soldiers deploy from their protected vehiclesthey also require lightweight body protection thatallows them to operate freely at elevated temperatures and altitudes carrying a full battle load.Military vehicles have traditionally been manufactured from high strength armor plate steel. Modernceramic composites have largely replaced steel asthe non-structural armor in combat vehicles.Its major advantage lies in its significantly lowerareal weight which allows weight savings of morethan 50 per cent over conventional metallic solutions.The most important ceramic materials today forballistic protection are: Alumina (Al2O3) Silicon carbide (SiC)Owing to its excellent price-efficiency ratio, aluminais the preeminent ceramic armor material for vehicular applications. Only when an extremelylow weight is required (e.g. for personal protection or for helicopters) silicon carbide materials maybe used.Beside these qualities, other ceramic materials havealso been considered and were examined intensively for the purpose of ballistic protection. Silicon nitride (SN)Titanium boride (TiB2)Aluminium nitride (AlN)SIALON (Silicon aluminium oxynitride)Fibre-reinforced ceramic (e.g. C-SiC)Ceramic-metal composite materials (CMC)However, and in spite of high ballistic performance,these materials have not been established for technical and economic reasons.

2 3CERAMIC POLYMER ARMOR SYSTEMSSplinter foilCeramicGlueBackingSplinter FoilCeramicMicronized ProjectileBackingIn general, the construction of light-weight composite system is based on four main components: Spall foilCeramicComposite substrateAdhesiveIn a composite armor system, the ceramic is normally placed on the strike face, preferably perpendicular to the expected threat. Polymer fibrescomposed of polyaramide, polyethylene or polypropylene form the composite backing. The stiffening and structural enhancement of the individualpolymer layers is achieved by impregnation andsubsequent curing of the adhesive. Proper selection of adhesives, such as rubber, polyurethane orepoxies, results in the desired shore hardness, andthereby the required mechanical properties whichcan be tailored to the threat requirements.This chemical bond between ceramic and composite substrate and/or between the individual polymerlayers is of key significance for the performance ofthe entire system. In addition, spall protection isapplied on the front side of the ceramic – glass fibrelaminates are preferably used for this purpose.Each component within the composite system hasa specific function. The hard ceramic layer reducesthe speed of the projectile and micronises the projectile. The resulting low mass and the significantlyreduced speed of these residual fragments, is completely absorbed by the elastic/plastic deformationin the composite substrate.CeramTec-ETEC does not supply complete armorsystems. Our expertise is in the manufacture ofhigh-performance ceramic armor materials – cut,drilled and machined to customer specifications,and ready to assemble into protective moduleswithout further work. We do not produce armorsystems for sale.

CARBIDE ARMOR MATERIALSALOTEC 96 SB20 μmALOTEC 98 SBALOTEC 96 SBDensityρ20 μmALOTEC 98 SBSICADUR FC20 μmALOTEC 99 SBSICADUR FCg/cm3 3.753.803.873.1 2 2 2.5610 5Residual PorosityP% 2Medium Grain SizeDμmVickers HardnessHV(5)GPa 12.513.51526Young‘s ModulusEGPa 310335365410Bending Strength 4-Point σBMPa 250260280400Fracture ToughnessKIcMPam1/23.53.63.2Sound VelocityvLm/s10000 10200 10300 1200053.5Alumina MaterialsAlumina with an Al2O3 content of 96 to 99 masspercentages is still the most important ceramicmaterial in vehicular ballistic protection. It ischaracterized by good processability and economic volume production and possesses veryhigh mechanical properties.ALOTEC 96 SBThe basis is Bayer alumina with a low alkali content.The Al2O3 content is 96 mass percent. Glass forming silicates are used as sintering additives whichcause a lowering of the sintering temperature andregulate the grain growth.ALOTEC 98 SBHigher rigidity and hardness values are achievedthrough the reduction of the glass phase. Themicrostructure is similar to that of ALOTEC 96 SB.The proportion of corundum is slightly higher.ALOTEC 99 SBHere, sinter-reactive Bayer alumina is used forproduction. Induced by the lack of glass-formingsubstances, consolidation is achieved not by liquidphase sintering but by solid-state sintering. Un-controlled grain growth is avoided by addingaround 400 ppm of magnesium oxide. The highproportion of corundum enhances the mechanicalproperties, thus enabling an increase in ballisticefficiency.Silicon Carbide MaterialsAside from alumina materials which are widelyin use today, silicon carbide will be used wheresignificant weight reduction or increased mechanical properties are required.SICADUR FC (SSiC)SSiC is produced by solid-state-sintering. The sinteradditives, boron carbide and carbon, lie at 1 mass %.The material is nearly nonporous; its hardness liesin the range of 25 GPa, though the fracture toughness is slightly lower than that of LPSSiC.

4 5CERAMIC PRODUCTION TECHNOLOGYRaw MaterialsIncoming RawMaterials InspectionMaterialpreparationRelease of theWorking MassMoldingVisual Inspectionof Green DensityGreen MachiningSinteringThe ceramic production process is fundamentallydifferent from other conventional technologiessuch as metals, glass and polymers. After the rawmaterial synthesis and formulation the materialis pressed into the desired shape and thickness.CeramTec-ETEC presses armour tiles with multipleuniaxial high tonnage presses. The pressed greenbodies are then stacked for the sintering process ortransferred to the mechanical finishing area.Ceramic materials require sintering in high temperature kilns where the ceramic microstructureis formed by consolidation of the original powder.The characteristic properties of the ceramic are created by the sintering process at temperatures of1600 C for alumina, and more than 1900 C forcarbide materials. This process is associated witha distinct reduction in the dimensions of the preshaped component. The loss in general dimensionsis about 15 to 20 per cent and the volume loss isabout 50 per cent.The finishing of materials and/or components bymeans of remelting, post curing, reshaping – as isusual in the case of metals – is not possible in thecase of ceramics.Mechanical finishing of the ceramic componentsis expensive since only diamond cutting tools areused for this purpose. The production of speciallyshaped components (e.g. edge plates) takes placeprior to the sintering process in the so-called greenstage, by sawing, cutting, milling and drilling.ComponentsFinal StatisticalCheck Release ofthe Production LotsPackagingShipmentVisual InspectionEach process step influences the properties of thefinal ceramic component. Errors that have occurredduring a previous process step cannot be rectifiedthrough subsequent processes. A stringent QualityAssurance process is rigidly followed throughout allphases of production.Ceramic technology permits the production of alarge variety of different components. In commercial production, pressing tools for the most diverseshapes and dimensions are used.Consistent product quality is guaranteed bycooperation with highly respected and experiencedraw material producers, by the use of modernproduction technologies and by a mature QualityAssurance System (according to DIN ISO 9001.2008standard).As an additional service to its customers,CeramTec-ETEC offers ceramic CAD engineering ofthe tile matrix layout for armor panels. Furthermore,preassembling of the armor panels has proved tobe a major labor saving exercise for many of ourcustomers. These pre-assembled panels can bedirectly inserted into the production process for thecomposite assembly.

CERAMIC MATERIALSAnalytical Model for DwellKinetic Energy vs. Time for Dwelling AP Projectiles Ekin by Dwell Ekin by Erosion Ekin by Dwell and ErosionAP Projectile100Ceramic80BackingStopped bullet in cracked ceramic6040Kinetic Energy (%)Partiallydamaged20051015202530Time (µs)Cracked ceramic caused by fragment firePenetration mechanismThe mechanism of reducing the kinetic energy ofan armor piercing penetrator can be explainedthrough analysis of flash X-ray data.When the projectile impacts the surface of theceramic, its kinetic energy is greatly reducedwithout penetrating the ceramic. This is causedby the dwell effect. In that phase the projectileexperiences a highly ductile deformation. Afterapprox. 15 to 20 μs, the projectile actually penetrates the ceramic body, and in the process thekinetic energy of the projectile is reduced furtherby erosion. The shattered fragments of the projectile completely penetrate the ceramic after approx.30 μs. The residual energy of these fragmentsamounts to only about 15 % which can be fullyabsorbed by the backing.This means:ΔEK due to dwell is to approximately 35 per centΔEK by erosion is approximately 50 per centΔEK by backing is approximately 15 per cent(The ΔEK values due to dwell are materialspecific).Selection of MaterialsThe mechanical properties of the ceramic materialsare the single greatest consideration for highballistic efficiency. Ceramics used in armor systemsmust demonstrate a defined microstructure withhigh grain size stability combined with high homogeneity. In spite of significant scientific investigations, it has not yet been possible to establish anexact relationship between ceramic propertiesand ballistic efficiency. However, it is indisputablethat high hardness and high sonic velocityare necessary for ballistic efficiency. High modulusof elasticity and high relative density arethe prerequisites for high sonic velocity. It is notyet understood what part mechanical strength(pressure, bend and shear resistance) and fracture resistance play in the overall performance ofthe ceramic as compared to other properties in aballistic event.The same is valid for the fluidity of ceramic athigh compressive loads. This implies that extensiveballistic testing by the system designer is mandatory to determine the correct ceramic material inconjunction with the most appropriate backing orsubstrate. A comparison of different protectionmaterials and/or of different material qualities ispossible by means of the DOP (depth of penetration)* test for the determination of ballistic mass efficiency. The DOP* test is merely a tool to aid in theselection of ceramic in ceramic-polymer compositesystems; rather, tests with the complete compositesystem must be conducted for final determination.

6 7Mass required to defeat a given threat109.88Al2O3-96Al2O3-99SiCTotal cost to defeat a given threat1Al2O3-96Ceramic MaterialsThe aim of every system development must be tofind the lowest weight and most cost-effective solution for a specified threat. Smaller structural shapeslike cylinders and hexagons may be used for countering direct gun fire – especially for high multihit threats. On the other hand, larger componentsare advantageous for protection against fragmentsand IEDs. The thickness of the ceramic componentsdepends on the specified threat level and can vary,but is normally between 4 and 25 mm.Weight reduction strategies: A reduction of the ceramic thicknessA revised composite backing system to accountfor a modified ceramic thicknessReplacement of the composite backing systemwith a lighter or higher performance materialThe use of ceramic materials with high ballisticefficiency and low material density1.7Al2O3-99The first two strategies result in only minor weightreduction – if the composite is of the same familywith similar density. Complete replacement of thebacking material can provide significant advantages, for instance by the use of functionally gradedmaterials.Since the ceramic component is the major player insystem weight, the selection of a different materialquality is often the only solution. If, for instance,Al2O3 is replaced by SiC, a reduction of systemweight is possible. However, this is associated witha corresponding and significant increase in cost.7SiC

PERLUCOR. SHAPING UP THE VISION.PERLUCOR is a system component and cannot beused alone, i.e. without a system. Therefore it ismandatory to integrate the ceramics into a complete transparent protection system similar toopaque composite panels.Larger areas can be assembled with multi tile layouts. The edges of the individual ceramic tiles arereworked by means of a special procedure to minimize the gaps to the greatest possible extent. Furthermore, the multi tile array increases the ballisticprotection performance against multi hit threats.PolycarbonatePERLUCORGlass100 mm210 kg/m2GlassCeramic inforced bullet proof glass for STL3(Hybrid system)PolycarbonateConventional bullet proof glass for STL350 mm120 kg/m2Although the multi-hit specifications currently applying for the transparent parts of vehicles are muchsimpler, with PERLUCOR it is possible to achieve avirtually identic performance as in the opaque areas.The ceramics have an optical quality (transparency)of 80%. The standard tile size is 90 x 90 mm, andfurther custom-sized dimensions can be made fromthis basic format. The tile thickness can be individually produced to a precision within a tenth of millimetre, and is usually between 2 and 9 mm.Temperature resistancy 1200 CTransparency IT 80%Spot frequency 7%Thermal conductivity 10 W/mKDensity 3,57 g/cm3Hardness 14 GPaBending strength150 MPaDimensions90 x  90 mmThickness2 – 9 mm

8 9BODY PROTECTIONConventional soft armor protection vests provideprotection from smaller calibers such as hand gunsand submachine guns; however they have inadequate protection against larger rounds fired by military rifles. According to the type of construction thevests can be upgraded by inserting rigid polyaramidfiber plates as protection against hand guns, orby ceramic composites plates against rifle fire. Therequirements of the upper protection levels can bemet by using ceramic-composite inserts, e.g. DIN52290 level 4 and 5, NIJ Standard level III and IV,European Standard level B5, B6 and B7. www.garant-protection.comToday, ceramic plates are used as inserts for armorvests. CeramTec-ETEC supplies inserts based on single curved ceramic tiles with radii between 200 and400 mm. They consist of small standard tiles e.g.50 x 50 mm, providing an improved multi-hit protection. For special applications it is also possible toproduce customized layouts and sizes.

CERAMICS FOR VEHICLE YAKTencatePiranhaRenault/IBDVABASV (M 1117)KMWFennekKMWBoxerKMWPuma

10 11CERAMICS FOR SPECIAL PURPOSESKMWKMWFaunKMWMungoTankerPolice carToyotaContainerNH 90ScanfibreKMWAMPVTencateT45NH Industries

CeramTec-ETEC Lohmar GermanyModern production facilityCeramic Experience WorldwideCeramTec-ETEC is an integral part of CeramTecGroup since November 2008, and is one of the mostimportant suppliers of solutions for industrial wearand corrosion protection and for armor components worldwide.CeramTec-ETEC employs a highly skilled team ofceramic material specialists and experienced technicians, in a production plant equipped with thelatest equipment including full CAD engineering,advanced quality assurance equipment and hightech production machinery.More than 25 years of experience in the field ofceramic production, modern plants and equipmentand a world-wide distribution network enableCeramTec-ETEC to produce a variety of differentcomponents with high dimensional accuracy.In this way, it is possible to guarantee the production of high-quality products to extremely tighttolerances with en serial scale. By means of a highlysophisticated quality assurance system – certifiedaccording to ISO 9001 – it is possible to ensure theproduction and supply of products with a continuously high quality, thus enabling CeramTec-ETECto comply with the high standards required byour customers.Made in GermanyCeramTec-ETEC GmbHAn der Burg Sülz 1753797 LohmarGermanyPhone: 49 2205 9200  - 0Fax: 49 2205 9200 xes and parameters for ceramic substances: In order to profile ceramic substances certain parameters are indicated. The crystalline nature of these substances, statistical fluctuations in the composition of thesubstances and in the factors that impact on the production processes indicate that the figures quoted are typically mean values and hence the substance parameters quoted in this brochure are only standard,recommended or guide values that might differ given dissimilar dimensions and production processes.B0AE www.wedkom.de www.okapidesign.com Printed in GermanyAWARDSCERAMTEC-ETEC

transferred to the mechanical finishing area. Ceramic materials require sintering in high tem-perature kilns where the ceramic microstructure is formed by consolidation of the original powder. The characteristic properties of the ceramic are cre-ated by the sintering process at temperatures of 1600 C for alumina, and more than 1900 C for

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