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 Owens Corning

Materials and Services Composite Solutions
• Residential Insulation • Composite
p
• Commercial & Industrial Reinforcements
Insulation
• Manufactured Stone
Veneer
• Residential Shingles
• Roofing Asphalts
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.
Beta® yarn (1963) – OC develops
• B 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 NNavy.
• 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
Personnel protection
Body armor inserts
Helmets body armor
Shields Gloves
Anti-mine shoes, leg protection, … 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

• Fighter Jets • Helicopter

• Tactical Vehicles • Defense Vehicles
• Personal Armor • Amphibious Assault
V hi l
Vehicles
Mobility
M

• Marine Deckhouses
• Homeland Security • Marine Hull Components
• Bridges / Infrastructure • Coast Guard
• Embassies • Battlefield ISO Shelters

Low

Low High
Ballistic Lethality

5
 History of Composite Vehicles
Functional Requirements
• weight (lighter) • structural
performance
• range of protection
levels • fire performance
• ballistic and blast • Electromagnetic
performance properties
• damage tolerance • maintainability
• affordability
Monocoque

Technology Gaps: 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 Structure (A) + Armor (B)
and Optimization 6
Industryy Needs

Protection Performance

P f
Performance D
Drivers
i 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
And usuallyy leads to armor systems
y which are based on
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
Interphase & Enhancement of
thermodynamic compressive
effects strength

Micromechanical
Characterization Optimum Composites
•Energy Absorption for Desired Properties
Strain Rate
•Strain • Ballistic
•Durability • Structure
• Durability

Grading of Control of Resin

Effects of sizing & Interlaminar Permeability
Resin Compatibility g
Region

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 System
Projectile
j Velocity
y Al Steel Aramid Shield Ceramic
Km/s
strand
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: < < <

12
Benefits of ShieldStrand Armor Solutions

Tangibles - Mitigates Behind Armor Debris from

F
Fragmentation
t ti anddO
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 MILMIL-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 andd 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

$50.00 UHMWPE

$40 00
$40.00
ost ($/lb)

$30.00
Co

$20.00
Aramid/Phenolic
S-2 Glass®
$10 00
$10.00 ShieldStrand® S
ShieldStrand® Advantex® (E-glass)
5083 AL RHA Steel
$-
0 2 4 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

7000

6000
0 (ft/s)

5000
Ballistiic Limit V50

4000

3000
0.25"AL5083/ ShieldStrand/ 0.25"RHA
2000 ShieldStrand/ 0.25"RHA
ShieldStrand VE
RHA
ShieldStrand/HB2 50/50AD
1000 ShieldStrand VE/ Spectra3124/EPS/0.14"RHA
0.50"AluminaRE/ShieldStrand/0.14"RHA
0.4"Alumina/ShieldStrand VE/AL Foam
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
by resin system or process 16
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 complex-
l
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
goodd with
ith minimal
i i l global
l b lddeflection
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
Force vs. Time
dissipates shock
shock.
8000

7000

6000

5000

4000
Force (lbss)

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 106 PSI Ultimate Strains %
Longitudinal
g Modulus D3039, D638 3.5 - 4.6 Longitudinal
g Tension D3039, D638 1.5 - 4
Transverse Modulus D3039, D638 3.5 - 4.6 Longitudinal Compression D3410, D695 0.7 - 2
Axial Shear Modulus D3518 0.5 - 0.7 Transverse Tension D3039, D638 1.5 - 4
Axial Comp Modulus D695 5.2 - 6.7 Transverse Compression D3410, D695 0.7 - 2
Poisson's Ratio D3039 0.24 - 0.27 In-Plane Shear D3518 2 - 2.5

Strength Properties 103 PSI Physical Properties

Longitudinal Tension D3039, D638 60 - 100 Fiber Volume D2734 61 - 66%
Longitudinal Compression D3410, D695 20 - 80 Resin Weight D2584 16 - 24%
Transverse Tension D3039, D638 60 - 100 Water Absorption D570, D792 <1.5%
p
Transverse Compression D3410, D695 20 - 80 Longitudinal Flexural, Wet Ret. D790 >70%
Normal Compression D695 100 - 120 Thickness (in.) 0.470 - 0.530
In-Plane Shear D3518 17 - 30 Ply Thickness (in.) 25 ply 0.019 - 0.020
Interlaminar Shear D2344 1.9 - 4.0 Areal Density (lb/sf) 25 ply 4.6 - 5.4
Longitudinal Flexural D790 20 - 45 Density (lb/ci) D792 0.072 - 0.074
Longitudinal Bearing D953 35 - 80 Hardness (M scale) D785 >80
Thermal Transition D4065 210 - 240
Flammability UL 94 V0
Time to Ignition @50kW/sm (s) E1354 500 - 600
Total Heat Release (MJ/sm) E1354 25 - 60
MAHRE (kW/sm) E1354 20 - 35
FIGRA E1354 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
by resin system or process 19
 Shieldstrand® Solution Case Histories

MRAP JLTV
FCS

Integrated
HMMWV MRAP EFP Kit Structural
Spall Liner
Cab

Composite
V-hull
Frag 5 Door Kit

spall liners exterior armor modules v-hull structural components

Compression Molded Phenolic 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® Metal S-2 Glass Aramid UHMW
S Plus (Steel & Al) Polyethylene

Assumes equal ballistic threat for all materials

Weight + - + ++ +++

Cost ++ +++ + - --

Structural Capability + ++ + - --

Part thickness + ++ + - --
(thin is +)
Resistance to acid ++ - ++ + -
and chemical attack
Fire, Smoke and + ++ + + -
Toxicity
Temperature + ++ + + -
Resistance

A balanced solution ½ weight of Steel and 1/3 cost21

of UHMWPE
21