The present research aims at engineering design of military helmet shells with continuous 3D woven fabric reinforcements for improved protection at a lighter weight and a reduced cost. The research was carried out using both the experimental and numerical methods. The results proved that the designed 3D woven wadded through-the-thickness angle interlock (TTAI) fabrics can be successfully moulded as continuous reinforcements for the doubly curved military helmet shells; therefore, costs in pattern cutting in the current composite helmet making process are eliminated. An improved ballistic performance was also demonstrated in the continuously reinforced composite structures. The wadding yarns added into the conventional TTAI fabrics enhanced the mechanical properties along the warp direction significantly. Improved composite in-plane isotropy was achieved by using the wadded TTAI fabrics as reinforcements. The locking angle method was modified based on the deformation behaviour of TTAI fabrics and was used to predict and evaluate the mouldability of both conventional and wadded TTAI structures. Mouldability factor, defined from the locking angle, assists the design and selection of continuous reinforcements that are of the appropriate mouldability. The mouldability limit of a PASGT (Personnel Armour System for Ground Troops) helmet shell was determined as 25.54. Thus, TTAI fabrics with mouldability factor no larger than this value are capable of continuously reinforcing the doubly curved shape. Ballistic tests and post-mortem examinations through ultrasonic C-scan and X-ray computed tomography (CT) demonstrated the advantages of the continuously reinforced composite in energy absorption. Up to 19.3% more of the kinetic energy was absorbed by the continuously reinforced panel through generating a delamination volume that was twice as large as that of the discontinuously reinforced one, and the delamination damages were distributed over a wider area. Under the same level of fabric mouldability and composite areal density, the panels reinforced with fewer plies of heavier fabrics performed better. The wadded TTAI reinforced composite panel demonstrated the optimal ballistic resistance by showing a 25.5% thickness increase and 55.3% penetration through the thickness. The 3D wadded fabric and 2D plain weave fabric continuously reinforced flat panels presented an equivalent ballistic performance. Meanwhile, further numerical analyses were conducted based on the digitally obtained geometry of a PASGT helmet. Although the ballistic limits varied from location to location, an equivalent ballistic limit of the helmet shell was noticed for the PASGT shell when compared to its flat counterparts. The military helmet shells reinforced by 3D wadded TTAI fabrics continuously offer improved ballistic performance. This is attributed to the preserved reinforcement continuity and the enhanced through-the-thickness properties. The research provides a novel reinforcing strategy for the construction of future composite military helmet shells.

Soft body armour is usually constructed by layering numerous layers of the same fabric. Such a construction, however, may not be the most efficient in providing the required protection due to different ballistic resistant efficiency of each layer. This research aims to optimise the construction of the panels for soft body armour by hybridisation in order to achieve the improvement of ballistic performance and reductions in weight. Twaron woven fabrics with different weave structures and Dyneema uni-directional (UD) laminates were used as components for the hybrid design of panels. Two complementary research approaches were employed in this study, namely the empirical method and the Finite Element (FE) analysis. The first part of this research systematically revealed the different ballistic characteristics of each layer in different positions of an armour panel and the way of energy absorption in the panel. The fabric layers in the front, middle and back of the panel exhibited different extent of transverse deformation and stress distribution. The energy absorption increases from front layer and reaches to the maximum value in the last perforated layer and then decreases gradually in the following back layers. Such pattern of energy absorption was not affected by either the striking velocity or the total number of layers in the panel, but the position, in the thickness, of the peak value in energy absorption was shifted more towards the back of the panel when the striking velocity increases. Such findings contribute to the understanding of different ballistic responses in different positions of an armour panel under ballistic impact. The second part of this research put forward a new hybrid design concept. According to above theoretical understandings of different ballistic characteristics in different positions of an armour panel, the fabric layers in the panel were discretely divided into three groups. In addition to the performance of different components for the panel and the influences of the laying sequence, a procedure for constructing hybrid armour panels has been established. The first group was composed of the first few layers on the striking face. The heavyweight fabrics as heat resistant layers were used in this group to resist the heat generated on the striking face. The second group contained some middle layers close to the last perforated layers. The lightweight fabric was combined in this group due to the higher energy absorption capacity. All back layers were classified into the third group. Dyneema UD laminates were placed in this group to constrain the large transverse deflection of the lightweight fabric and to minimize BFS of the panel. Two hybrid panels were designed and evaluated. In the perforation ballistic tests, the hybrid panel was more likely to stop the projectile compared to Twaron woven panels with the same areal density. In the non-perforation ballistic tests, the hybrid panel exhibited significantly lower BFS and achieved the reductions in weight. Such hybrid design makes best use of different available materials to achieve the improvement of ballistic performance and lightweight of a panel. It has a practical significance for the soft armour panel design.

No description available.

Armoured vehicles in current military service are requiring ever more protection to enable them to carry out their mission in a safe, effective manner. This requirement is driving vehicle weight up to such an extent that the logistics of vehicle transport is becoming increasingly difficult. Composite materials are an important material group whose high specific properties can enable structures to be manufactured for a far lower weight than might otherwise be possible. Composite materials in an armoured vehicle will require structural performance as well as ballistic performance. The mechanical and ballistic performance of tl-kk armour and structural composites has been investigated against dcformable and armour-piercing ammunitions, over a range of impact velocities. Testing has indicated that heavy/coarse reinforcement weaves perform well against deformable ammunition and light/fine weaves well against armour piercing ammunition. The effect of individual mechanical properties on ballistic performance has been investigated as has the damage morphology of impacted materials. High tensile strength combined with low fracture toughness has been identified as an important requirement. Failure mechanisms have been identified from sections of ballistic impacts and through the use of mechanical test data the energy absorbed by each mechanism has been calculated. An energy audit has been carried out of all materials tested and a modelling procedure developed based on mechanical characteristics, damage morphology and failure mechanisms. This model has been tested against literature results and found to give very satisfactory performance.

Armoured vehicles in current military service are requiring ever more protection to enable them to carry out their mission in a safe, effective manner. This requirement is driving vehicle weight up to such an extent that the logistics of vehicle transport is becoming increasingly difficult. Composite materials are an important material group whose high specific properties can enable structures to be manufactured for a far lower weight than might otherwise be possible. Composite materials in an armoured vehicle will require structural performance as well as ballistic performance. The mechanical and ballistic performance of tl-kk armour and structural composites has been investigated against dcformable and armour-piercing ammunitions, over a range of impact velocities. Testing has indicated that heavy/coarse reinforcement weaves perform well against deformable ammunition and light/fine weaves well against armour piercing ammunition. The effect of individual mechanical properties on ballistic performance has been investigated as has the damage morphology of impacted materials. High tensile strength combined with low fracture toughness has been identified as an important requirement. Failure mechanisms have been identified from sections of ballistic impacts and through the use of mechanical test data the energy absorbed by each mechanism has been calculated. An energy audit has been carried out of all materials tested and a modelling procedure developed based on mechanical characteristics, damage morphology and failure mechanisms. This model has been tested against literature results and found to give very satisfactory performance.

This Thesis covers work conducted to understand the mechanisms underpinning the operation of the electrothermal-chemical gun. The initial formation of plasma from electrically exploding wires, through to the development of plasma venting from the capillary and interacting with a densely packed energetic propellant bed is included. The prime purpose of the work has been the development and validation of computer codes designed for the predictive modelling of the elect rothe rmal-ch em ical (ETC) gun. Two main discussions in this Thesis are: a proposed electrically insulating vapour barrier located around condensed exploding conductors and the deposition of metallic vapour resulting in a high energy flux to the surface of propellant, leading to propellant ignition. The vapour barrier hypothesis is important in a number of fields where the passage of current through condensed material or through plasma is significant. The importance may arise from the need to disrupt the fragments by applying strong magnetic fields (as in the disruption of metallic shaped charge jets); in the requirement to generate a metallic vapour efficiently from electrically exploding wires (as per ETC ignition systems); or in the necessity to re-use the condensed material after a discharge (as with lightning divertor strips). The ignition by metallic vapour deposition hypothesis relies on the transfer of latent heat during condensation. It is important for the efficient transfer of energy from an exploded wire (or other such metallic vapour generating device) to the surface of energetic material. This flux is obtained far more efficiently through condensation than from radiative energy transfer, because the energy required to evaporate copper is far less than that required to heat it to temperatures at which significant radiative flux would be emitted

This Thesis covers work conducted to understand the mechanisms underpinning the operation of the electrothermal-chemical gun. The initial formation of plasma from electrically exploding wires, through to the development of plasma venting from the capillary and interacting with a densely packed energetic propellant bed is included. The prime purpose of the work has been the development and validation of computer codes designed for the predictive modelling of the elect rothe rmal-ch em ical (ETC) gun. Two main discussions in this Thesis are: a proposed electrically insulating vapour barrier located around condensed exploding conductors and the deposition of metallic vapour resulting in a high energy flux to the surface of propellant, leading to propellant ignition. The vapour barrier hypothesis is important in a number of fields where the passage of current through condensed material or through plasma is significant. The importance may arise from the need to disrupt the fragments by applying strong magnetic fields (as in the disruption of metallic shaped charge jets); in the requirement to generate a metallic vapour efficiently from electrically exploding wires (as per ETC ignition systems); or in the necessity to re-use the condensed material after a discharge (as with lightning divertor strips). The ignition by metallic vapour deposition hypothesis relies on the transfer of latent heat during condensation. It is important for the efficient transfer of energy from an exploded wire (or other such metallic vapour generating device) to the surface of energetic material. This flux is obtained far more efficiently through condensation than from radiative energy transfer, because the energy required to evaporate copper is far less than that required to heat it to temperatures at which significant radiative flux would be emitted

The effect of the chemical composition, austenitisation temperature and tempering temperature and time on the mechanical properties and on the ballistic performance of martensitic steel armour plates was studied. It was established in this study that the mechanical properties and the ballistic performance of martensitic steels can be optimised by controlling the chemical composition and the heat treatment parameters. However, it was observed that for a given chemical composition of the steel the heat treatment parameters to be applied to advanced ballistic performance armour plates were different from those required for higher mechanical properties. Such a contradiction rendered the relationship between mechanical properties and ballistic performance questionable. Systematic analysis of the microstructure and the fracture mechanism of some martensitic armour plate steels was carried out to explain the improved ballistic performance of steels whose mechanical properties were below that specificied for military and security applications. It was inferred from phase analysis and its quantification by X-ray diffraction, characterisation of the martensite using scanning electron microscopy, transmission electron microscopy and atomic force microscopy that the retained austenite located in the plate interfaces and on grain boundaries of the martensite was the main constituent resisting localised yielding during ballistic impact on thin steel plates. A part of the kinetic energy is transformed into adiabatic heat where a reaustenitisation of the plate martensite and the formation of new lath martensite was observed. Another part is used to elastically and plastically deform the ballistic impact affected region around the incidence point. Dislocation pile-ups at twinned plate interfaces suggest that the twin interfaces act as barriers to dislocation movement upon high velocity impact loading. The diameter of the affected regions, that determines the volume of the material deforming plastically upon impact, was found to vary as a function of the volume fraction of retained austenite in the martensitic steel. Upon impact, retained austenite transforms to martensite by Transformation Induced Plasticity, the “ TRIP ” effect. High volume fractions of retained austenite in the martensitic steel were found to yield low values of the ratio yield strength to ultimate tensile strength (YS/UTS) and a high resistance against localised yielding and, therefore, against ballistic perforation. A Ballistic Parameter was proposed for the prediction of ballistic performance using the volume fraction of retained austenite and the thickness of the armour plate as variables. Based on the martensite structure and the results of the ballistic testing of 13 armour plate steels a design methodology comprising new specifications was proposed for the manufacture of armour plates whose thicknesses may be thinner than 6mm. / Dissertation (MSc (Metallurgical Engineering))--University of Pretoria, 2007. / Materials Science and Metallurgical Engineering / unrestricted

<p>Additive manufacturing of gun propellants is an emerging and promising field which addresses the limitations of conventional manufacturing techniques. Gun propellants are manufactured using wetted extrusion, which uses volatile solvents and dies of limited and constant geometries. On the other hand, additive techniques are faced with the challenges of maintaining the gun propellant’s energetic content as well as its structural integrity during high pressure combustion. The work presented in this thesis demonstrates the feasibility of producing functioning gun propellant grains using vibration-assisted 3D printing, a novel method which has been shown to extrude extremely viscous materials such as clays and propellant pastes. At first, the technique is compared to screw-driven additive methods which have been used in printing gun propellant pastes with slightly lower energetic content. In chapter two, diethylene glycol dinitrate (DEGDN), a highly energetic plasticizer, was investigated due to its potential to replace nitroglycerin in double base propellants with high nitroglycerin content. A novel isoconversional method was applied to analyze its decomposition kinetics. The ignition and lifetime values of diethylene glycol dinitrate were obtained using the new isoconversional method, in order to assess the safety of using the plasticizer in a modified double base propellant. In chapter three, a modified double base propellant (M8D) containing DEGDN was additively manufactured using VAP. The printed strands had little to no porosity, and their density was nearly equal to the theoretical maximum density of the mixture. The strands were burned at high pressures in a Crawford bomb and the burning was visualized using high speed cameras. The burning rate equation as a function of the M8D propellant as a function of pressure was obtained. Overall, this work shows that VAP is capable of printing highly energetic gun propellants with low solvent content, low porosity, with high printing speeds, and which have consistent burning characteristics at high pressures. </p>

<p dir="ltr">Additive manufacturing (AM) of gun propellants is an emerging and promising field which addresses the limitations of conventional manufacturing techniques. Overall, this thesis is a body of work which serves to bridge the gap between fundamental research and application of additively manufactured gun propellants.</p>