Army Research Laboratory 

Aberdeen Proving Ground, MD 21005-5069 

ARL-TR-2319 September 2000 

Cost-Effective Manufacturing 

of Damage-Tolerant Integral Armor 

Bruce K. Fink 

Weapons and Materials Research Directorate, ARL 

John W. Gillespie, Jr. 

University of Delaware 
Abstract 

The U.S. krny Research Laboratory (ARL) and the University of Delaware (UD) have 

developed an enabling technology to produce a polymer matrix composite-based integral armor 

with improved multihit ballistic capability, Current applications for integral armor composites 

include the Composite Armored Vehicle (CAV) technology demonstrator and Crusader 

self-propelled howitzer platforms. Present integral armor manufacturing processes involve 

adhesive bonding of a compbsite structure with ballistic armor tiles, spa11 shield, and nuisance 

cover. ARL, UD, and the CAV/Crusader composite structure contractor, United Defense 

Limited Partnership (UDLP), assessed through-thickness stitching to improve the multihit 

capability and reduce manufacturing costs. The patent-pending co-injection resin-transfer 

molding (CIRTM) process was used to produce a stitched, co-injected integral armor panel that 

demonstrated improved multihit capability. The spa11 shield was fabricated with a phenolic resin 

for fire, smoke, and toxicity protection, while the remainder of the integral armor (structural 

composite resin encapsulating the tiles and the nuisance cover) was fabricated with an epoxy 

resin for structural performance. Through-thickness stitching and CIRTM were used to enhance 

the damage tolerance and to reduce the cost of the armor. 
Acknowledgments 

This manuscript was prepared in collaboration with the Composite Materials Research 

Collaborative Program sponsored by the U.S. Army Research Laboratory (ARL) under 

Cooperative Agreement D&%01-96-2-0048 and participation in the U.S. Army Research Office 

(ARO)-sponsored Tuskegee Research Consortium, “Intelligent Resin Transfer Molding for 

Integral Armor Applications.” The authors acknowledge the contributions of Torrey Pike, 

Mike McArthur and George Thomas of United Defense Limited Partnership (UDLP) for 

fabrication assistance and ballistic testing; Karl Bernetich, Scott Jones, Emanuele Gillio, 

Sunil Naik, Keith Poppiti, and Jeremy Garey at the University of Delaware (UD) for cost, 

manufacturing, testing, and data reduction of the composite specimens; and Mac Puckett of the 

Dow Chemical Company for providing materials and technical support for the vinyl-ester resin 

systems. 

. . . 

111 
h'TENTIONALLY ~FT&ANK. 

iV 
Table of Contents 

Acknowledgments . . . 

. . . . . . . . . . . . . . . ..~*.........*.*....*..........~**.*... ..*.*........*........*.*e* . . .. . . ...*.... 111 

List of Figures . ..~.............~~......*****.*....................~.....~.~....~.*.............................~~... vii 

List of Tables .*.*.........*.***..*..*..........*........*.................~...~.~ *.*...*..........*..*...*. .. . . . . . . . ix 

1. Background *...*.........................*...**.....**...... . ..~..........~............~.......~..............~~.~~. 1 

2. Demonstration of Processing Innovations . . . ..**.............*..*.........*...................*.... 2 

3. Composite Armor Testing . . . . . . . . ..*................**....*..*.*.... .*....*......*.**.*.*..*..~**...*.****. 7 

3.1 Test Matrix ...................................................................................................... 7 

3.2 Ballistic Testing ............................................................................................... 8 

3.3 Extent of Damage ............................................................................................ 9 

3.4 Results ............................................................................................................. 9 

3.4.1 VSO Testing and Data Normalization ........................................................... 9 

3.4.2 7-psf Target Data ....................................................................................... 12 

3.4.3 20-p@ Target Data ..................................................................................... 17 

4. Conclusions *...*............~..........**...***..*.*......,.~~*....~............~.~..~~.*.**..............~..~....... 21 

5. References .. . . . ..*.....*.........~~.~~..~..~..........~.~~~...........*.*.*~. . . . . ..~~~~~.......~...~....*.**~. *....*.. 23 

Distribution List . . . . . . . ..**.............................~...~..*.*.*..*...~~........~~...~............*.*..~~.~..~~ 25 

Report Documentation Page .. . . . . . . . . . . . . . . . . ..*~..~~..............**...*.**..........~..........~..*.....* 45 

V 
~N'TTONALLY LEFT BLANK. 

vi 
List of Figures 

l Figure 

1. 

2. 

3. 

4. 

5. 

6. 

7. 

8. 

9. 

10. 

11. 

12. 

13. 

14. 

15. 

16. 

17. 

18. 

Schematic Comparing Traditional Sequential Manufacturing to the CIRTM 

Process .................................................................................................................. 

Ballistically Tested Panel Manufactured Using Traditional Multistep Process ........ 

Schematic of Through-Thickness Stitching and Co-Injection of Integral &nor ..... 

Co-Injected, Stitched Integral Armor Target Exhibiting Six-Shot Multihit 

Performance Without Separation of the Ballistic Liner Fabricated With 

Stitching and Co-Injection ..................................................................................... 

Activity-Based Cost Analysis Showing the Cost Savings of CIRTM.. .................... 

Plot of 20-mm Vinyl-Ester Panel Delamination Data Showing Normalization 

Procedure .............................................................................................................. 

Cross Section of a 7-psf Target After Ballistic Impact.. .......................................... 

Ultrasonic Scan Plots for the 7-psf Panel Shown in Figure 7 .................................. 

Front Surface of a 7-psf Panel After Ballistic Impact. ............................................ 

Averaged Gate Delamination Data for 7-psf Panels Normalized to 1,550 fps.. ....... 

Average and Maximum Delamination Data for 7-psf Panels .................................. 

AVlYMAX Delamination Data for 7-psf Panels ..................................................... 

AVE/MAX2 Delamination Data for 7-psf Panels .................................................... 

Front Surface of a Stitched Vinyl-Ester 20-psf Panel Prior to Ballistic Impact ....... 

Averaged Gate Delamination Data for 20-psf Panels Normalized to 2,700 fps ....... 

Average and Maximum Delamination Data for 20-psf Panels ................................ 

AVE/MAX Delamination Data for 20-psf Panels ................................................... 

AVE/MAX’ Delamination Data for 20-psf Panels .................................................. 

Page 

6 

6 

11 

11 

12 

13 

14 

15 

16 

17 

18 

19 

19 

20 

20 

vii 
. . . Vlll 
List of Tables 

Table & 

1. Testing Matrix for Panels Without Alumina Tiles .................................................. 7 

2. Testing Matrix for Panels With Alumina Tiles ....................................................... 8 

3. SC-4 Panels, Nonstitched, .50-cal. FSP.. ................................................................ 10 

4. CYCOM Panels, Nonstitched, .50-Cal. FSP........................................................... 10 

5. Delamination Data for the 7-psf Targets ................................................................ 13 

6. Delamination Data for the 20-psf Ballistic Panels .................................................. 18 

ix 
INTENTIONALLYLEFT BLANK. 

X 
f 

1. Background 

Composite materials are playing a key role in the development of lightweight integral armor 

for military vehicles. Current and developing Army applications have identified the need for 

lightweight structural materials in order to enhance deployability and mobility of land combat 

forces. Several research and development programs have demonstrated the effectiveness of 

composite materials for combat ground vehicles to meet these needs. Recent advances include 

the development of composite/ceramic integral armor systems that provide significant 

improvement over monocoque composite structures with applique armor. To optimize the 

weight and performance of the vehicle, integral armor was developed as part of the Composite 

Armored Vehicle (CAV) Program with United Defense Limited Partnership (UDLP) [l]. The 

integral armor system exploits the structural contribution of the armor tiles to the structural 

design of the vehicle and allows the composite structure to perform a role in the ballistic 

protection of the vehicle to minimize area1 density. 

The integral armor designed by UDLP for the CAV upper hull and ramp structures is based 

on hybrid composite technology (i.e., combinations of polymeric, metallic, and ceramic 

materials) to meet multifunctional requirements such as structural; ballistic; signature 

management; electromagnetic interference (EMI) shielding; and fue, smoke, and toxicity (FST) 

protection. Such hybrid systems are designed for optimal utilization of not only the unique 

characteristics of each component material but also the synergistic effects of the entire 

system [2]. 

The manufacture of composite armor components generally involves multiple manufacturing 

steps to produce each composite layer. The individual layers are then adhesively bonded 

together in separate operations, resulting in an integral armor structure. These labor-intensive 

operations increase costs, pollution, part-to-part variability, and part-to-part dimensional 

tolerances and introduce defects at interfaces. Opportunities to enhance multihitidamage 

tolerance are limited by a multistep fabrication process. 
2. Demonstration of Processing Innovations 

Co-injection resin-transfer molding (CIRTM) is a patent-pending process developed by the 

US. Army Research Laboratory (ARL) and the University of Delaware (UD) as a cost-effective, 

pollution-reducing, performance-enhancing alternative to multistep vacuum-assisted 

resin-transfer molding (VARTM) for multifunctional composite structures [3]. A distinct 

advantage of the CIRTM process is the ability to include all of the composite armor elements in 

a single-preform assembly, including various fiberglass fabrics, an elastomer layer, and ceramic 

alumina tile [4-61. At dissimilar material interfaces, a separation layer must be used. For 

integral armor applications, separation layers consisting of polysulfone film and epoxy-film 

adhesives were used. These CIRTM-compatible resin barriers have been shown to produce 

diffusion-enhanced adhesion (DEA) bonds with outstanding properties [7-lo]. A 

high-permeability distribution media is placed on either side of the preform to enable rapid resin 

flow in lateral directions prior to through-thickness preform infiltration. Since no adhesives are 

used in secondary bonding operations and the entire process is performed within a closed, 

controlled system, volatile organic compound (VOC) hazardous air pollutant (HAP) emissions 

are drastically reduced. 

The CIRTM process introduces four distinct advantages for fabricating multiresin composite 

parts. First, Newton et al. [l l] reported significant pollution-prevention benefits to the 

application of CIRTM in production of composites. Second, CIRTM reduces costs by allowing 

single-step manufacture of parts by reducing cycle time and secondary operations. Third, the coinjection process results in a tougher interface between layers when compared with 

manufacturing the layers separately and then postbonding them together. Reduction of 

manufacturing steps is shown in Figure 1. Finally, and perhaps most important for realizing the 

potential of integral armor, the co-injection process enables through-thickness reinforcement of 

multiresin systems, which provides optimal load transfer between structural, fne-protective, and 

shock-wave-management layers of the composite armor. 

2 
material waste 

material waste 

Figure 1. Schematic Comparing Traditional Sequential Manufacturing to the CIRTM 

Process. 

To demonstrate the feasibility of the co-injection process to enable through-thickness 

reinforcement and improved ballistic performance in a manufacturing environment, several 

23 x Z-ft targets were fabricated for ballistic evaluation. The baseline targets were fabricated by 

UDLP, using a conventional multistep manufacturing process where the nuisance cover, tiles, 

and fiberglass composite structure were placed in a dry mold and VARTM was used to wet the 

part out with an epoxy resin (Applied Poleramic SC-15). After wet-out and cure, the part was 

demolded and the ballistic liner was placed on the previously cured laminate and a second 

VARTM manufacturing operation was used to wet-out the ballistic liner with a phenolic resin 

(Applied Poleramic SPH-4). Adhesion between the two resins (epoxy and phenolic) was 

minimal, resulting in poor multihit performance. After a single shot, there was extensive damage 

between the epoxy composite interface with the phenolic composite ballistic liner. The second 

shot resulted in complete separation of the ballistic liner from the epoxy composite (Figure 2). 

To improve multihit performance, through-thickness stitching was employed to join the 

composite backing plate with the ballistic liner. The ClRTM manufacturing process was used to 
Figure 2. Ballistically Tested Panel Manufactured Using Traditional Multistep Process. 

Photo Courtesy of UDLP. 

fabricate the part in a single step, while maintaining separate and discrete layers with the two 

resin systems. A schematic of the co-injected, stitched integral armor target is shown in 

Figure 3. 

for FST performance 

stitching 

thread 

re hard material 

tailored interface 

for enhanced adhesion 

suchasepoxyor 

nuisance 

cover 

Figure 3. Schematic of Through-Thickness Stitching and Co-Injection of Integral Armor. 

4 
The co-injected, stitched integral armor target resulted is’ a composite with a stitched, 

co-cured interface between the separate resin layers that provides superior performance and 

reduced cost compared to traditional multistep fabrication approaches. For this target 

configuration, a UDLP-proprietary barrier was used as a means of controlling the flow of the two 

resins. Co-injecting the phenolic fite-protective layer with the epoxy structural layer in a single 

composite part improved the multihit performance of the targets. 

Ballistic testing showed multihit performance of up to six shots into a single target without 

separation of the spall liner from the epoxy composite (Figure 4). The stitching and toughened 

interlayer bonding clearly improved the damage tolerance of the panels apparent through the 

significant reduction in lateral delamination. Previously reported results show that interlaminar 

shear strength provided by CIRTM is enhanced relative to the weakest resin in the specimen [5]. 

In all CIRTM-manufactured specimens, failure occurred within the phenolic composite layer. 

For the Mode I fracture toughness testing, failure of the co-injected samples was observed to be 

cohesive; conversely, the failure of the secondary-bonded multistep manufactured panels was 

adhesive failure between the epoxy adhesive and the phenolic composite. During Mode I crack 

propagation, multiple delamination planes formed in the phenolic laminate, which is a reflection 

of the higher toughness offered by the CIRTM interphase. Results of both interlaminar shear and 

Mode I fracture toughness for CIRTM were comparable to or exceeded the phenolic baseline. 

The multihit performance of the stitched co-injected integral armor targets showed substantial 

improvement when compared to targets fabricated with the sequential manufacturing process. 

Another advantage of the co-injection process is a lower cost manufacturing process, 

Figure 5 compares the cost of the co-injection process with a sequential two-step manufacturing 

process for an integral armor structure. The activity-based cost analysis was performed on the 

ramp section of the CAV in a simulated manufacturing model. Manufacturing models 

incorporating co-injection and sequential injection processes have indicated that co-injection will 

result in approximately a 15% cost savings over the sequential injection process. These savings 

are mostly due to the decreased material handling time and decreased cycle time for production. 

Materials savings (e.g., bagging materials, waste resin, etc.) are also a component. Not included 

5 
Figure 4. Co-Injected, Stitched Integral Armor Target Exhibiting Six-Shot Multihit 

Performance Without Separation of the Ballistic Liner Fabricated With 

Stitching and Co-Injection, Photo Courtesy of UDLP. 

,= $20,000 

5 

g $15,000 

0 

5 

ij $10,000 

I- 

% 

c $5,000 

g 

e 

0 

1 m EauiPment m Materials Labor 1 

Low Medium High 

Production Volume (Units/Year) 

Figure 5. Activity-Based Cost Analysis Showing the Cost Savings of CIRTM. 

&I the model are environmental cost savings issues. More detail on environmental cost savings 

for this process are covered elsewhere [ll]. Greater annual production volume may &so be 

achieved from co-injection, given an equal capital investment in manufacturing equipment [121. 

6 
3. Composite Armor Testing 

3.1 Test Matrix. Previous work studied the ballistic properties of polyester- [13] and 

epoxy-based [ 14, 151 composite panels. A goal of this study was to provide ballistic properties 

of more cost-effective and VARTMCIRTM process-friendly vinyl-ester resin systems. To test 

the equivalency of a VARTM-compatible vinyl-ester resin system (Dow Derakane 41 l-C-50) 

with a VARTM-compatible toughened epoxy (Applied Poleramic SC-4) and a polyester prepreg 

baseline system (CYCOM 4102), a series of SZ-glass composite panels was fabricated, with 

area1 densities of 7 psf and 20 psf. A 24 oz/yd2, 5 x 5 plain weave, SZglass fabric was used in 

the 20-psf armor systems, while an 18 ozlyd2, 2 x 2 twill weave S2-glass fabric was used in the 

7-psf armor systems. The effect of through-thicknesstitching was assessed for ballistic damage 

confinement for. the VARTM-produced panels. Additionally, the ZO-psf panels were tested with 

0.7~in-thick AD90 alumina ballistic tiles bonded to the outer surface. Tables 1 and 2 summarize 

the test matrix for the 7- and 20-psf panels, respectively. 

Table 1. Testing Matrix for Panels Without Alumina Tiles 

Material Stitching Area1 Vsa Against .50&l. FSP Projectile 

Density SO-ml. FSP Velocity for Testing 

(PSO VP> m> 

VARTM Vinyl Ester No 

VARTM Vinyl Ester Yes 

VARTM Epoxy Resin No 

VARTM Epoxy Resin Yes 

Note: FSP - fragment-simulating projectile. 

7.2 1,780 1,550 

7.0 - 1,550 

7.0 1,750 1,550 

7.0 - 1,550 

The stitched composite targets were fabricated using the following procedure. First, the 

fabric was laid-up dry. The dry preform was stitched using a chain-stitching machine with a 

m-T-87128, 3-cord, soft, Kevlar thread (2,000 denier). The dry preform was stitched in both 

the X and Y directions, with stitch rows on l-in centers. The stitch spacing within the stitch row 

was approximately five threads per inch. The stitch spacing along the stitch row varied slightly, 

7 
Table 2. Testing Matrix for Panels With Alumina Tiles 

Material Stitching Area1 20-mm FSP Projectile 

Density Velocity for Testing 

(PSO (fps) 

Polyester Prepreg No 20 2,700 

VARTM Vinyl Ester No 20 2,700 

VARTM Vinyl Ester Yes 20 2,700 

VARTM Epoxy Resin NO 20 2,700 

VARTM Epoxy Resin Yes 20 2,700 

due to the weight of the preform and the inability to accurately index the preform by hand. An 

estimate of through-thickness reinforcement is 3-4% volume fraction. It should be noted that 

two threads pass completely through a single needle hole in a chain stitch pattern, effectively 

doubling the thread denier. 

3.2 Ballistic Testing. Four-shot V50 testing was used to determine a velocity at which the 

projectile would likely penetrate the 7-psf targets using a SO-&. fragment-simulating projectile 

(FSP). Targets were fabricated using the CYCOM prepreg material and using the SC-4 resin to 

perform the VSO testing. From the 4-shot Vso results, a reduced velocity was chosen to test the 

remainder of the targets. By performing a &hot Va, comparing the results and reducing the 

velocity, it was confidently assumed that the energy level imparted to the targets would cause 

sufficient damage to the laminate without completely penetrating the target. This allowed for 

comparison of the ballistically impacted panels based on the extent of damage given relatively 

equivalent input energies. A velocity of 1,550 fps was chosen for the constant velocity testing of 

the remaining targets. This allowed for subsequent structural testing at a constant velocity and 

correlation with residual strength models. Testing was done in accordance with NIJ Standard 

0101.03. Due to the light powder charge in the projectile case, velocity varied somewhat on the 

constant velocity testing with the .50-cal. projectile but still permitted an accurate relative level 

of comparison between the various targets. Velocity was determined using light screens and a 

chronograph. 

c 

8 
The composite backing plates for the 20-psf alumina-composite armor targets were 

fabricated in a similar fashion as the 7-psf targets, and a single alumina hex tile was bonded to 

the face using an epoxy-paste adhesive. A 0.4mm to 0.6~mm glass bead was used as a spacer to 

maintain a constant thickness within the bondline. This combination provides a line-of-sight 

(LOS) area1 density of 20 psf to the projectile. For the ceramic-faced composite armor targets, a 

20-mm fsp at 2,700 fps was selected for the projectile and velocity given an estimated 

lower-bound 3,000-fps V 50. The velocity was chosen to impart a significant level of damage to 

the projectile with little or no penetration of the projectile into the composite backing plate. 

3.3 Extent of Damage. The damaged targets were nondestructively tested to determine the 

extent of delamination resulting from the projectile impact. All of the targets were ultrasonically 

scanned using four gates to record delamination profiles through the thickness of the panel. 

Gate 1 is located nearest the impact surface of the composite backing plate, Gate 4 near the back 

surface, and Gates 2 and 3 equally spaced through the thickness. A ~-MHZ focused transducer 

was used to ultrasonically scan targets. After the panels were scanned, the images were imported 

into image processing software to determine a percentage of damage within the panel. Percent 

delamination was determined through edge enhancement of the image and highlighting the 

damage region. A calculation could then be done, which compared the highlighted damaged 

portion to the whole image, providing a percent delamination. 

3.4 Results. 

3.4.1 V&I Testing and Data Nornm&ation. Tables 3 and 4 show the results of the V~O 

testing for the SC-4 and polyester 7-psf targets. It is understood that this limited number of shots 

does not provide an accurate VSO ballistic limit for these material systems. It does, however, 

provide a good indication of what reduced velocity across all the panels should be used for a 

“constant velocity” to assess the effects of material variations such as through-thickness stitching 

and resin system Based on these 4-shot VSO results, a velocity of 1,550 fps was chosen as the 

impact velocity for the remainder of the 7-psf targets. 

9 
Table 3. SC-4 Panels, Nonstitched, SO-Cal. FSP 

Panel No. 

SC-43 

SC-42 

SC-44 

SC-41 

Areal Density 

(Pm 

7.0 

6.9 

6.9 

6.9 

Velocity 

IfWS) .A r 

1,749 

1,536 

1,685 

1,729 

Comments 

Complete 

Incomplete 

Incomplete 

Incomplete 

Table 4. CYCOM Panels, Nonstitched, SO-Cal. FSP 

Panel No. 

CYCC)M-1 

Areal Density 

7-f-l 

Velocity 

1 730 

Comments 

---.- - 

CYCOM-2 

rVrnhA-2 

7.0 ’ - - 

7n 

II 

Y L “v+.A-J , 

CYCOM4 1 ;:tl 

-,r-# 

1,776 

1.808 

Partial, Hit Witness 

Complete I 

J 1,663 Incomplete 

n: 1,770 fns I 

While it is desirable to test at a common impact velocity, it is not possible to accurately 

obtain equivalent velocities using charged projectiles. Figure 6 shows the maximum extent of 

delamination data vs. penetrator velocity for the 20-mm vinyl-ester stitched and unstitched 

panels as an example of the method of normalization of extent of damage measurements against 

a common impact velocity. Here, the desired impact velocity was 2,700 fps and the average 

maximum delamination was 30% of the planar area of the target. Normally, one might 

normalize data above and below 2,700 fps back to 2,700 fps by following the heavy solid line 

back to zero. However, since the expected relationship between damage and velocity (below 

V,,-J) generally looks more like the curved dashed line, it is more reasonable to attempt to 

normalize damage data along an expected slope within the region of the neighboring data. Since 

the V50 for these targets was determined to be around 3,000 fps and a maximum circular 

delamination zone of 72% is assumed at VSO, a line was constructed from this point back through 

the data. This line was used for normalizing the damage zone data to a common velocity of 

2,700 fps. A similar procedure was used for the 7-psf target data normalized to 1,550 fps. 

10 

i 
Figure 

80 

70 

60 

50 

40 

30 

20 

IO 

0 

6. 

0 500 1000 1500 2000 2500 3000 3500 

Velocity (fps) 

Plot of 20-mm Vinyl-Ester Panel Delamination Data Showing Normalization 

Procedure. 

Figure 7 shows a cross section of one of the nonstitched 7-psf targets after ballistic impact. 

Figure 8 shows the ultrasonic scan images for the panel of Figure 7 for each of the four gates, 

with the fkst gate being near the top surface of the target. 

11 
Figure 8. Ultrasonic Scan Plots for the 7-psf Panel Shown in Figure 7. 

3.4.2 7-psf Target Data. Figure 9 shows the outer surface (impact side) of one of the 7-psf 

panels after ballistic impact. The extent of damage near the first gate is clearly visible. Table 5 

provides the delamination data for all the 7-psf targets. 

Figure 10 depicts the average delamination sizes at each gate for the data of Table 5, showing 

the conical shape of damage through the thickness of the laminates. The areas under the curves 

in Figure 10 are approximate estimates of the volume of damage and, since the delamination data 

is normalized to a common velocity, the volume of damage is a useful comparison of damage 

density between panels. The shape of the curves in Figure 10 is important to consider. A convex 

curve indicates an armor that delaminates primarily near the back surface and does not absorb 

energy uniformly through its thickness. A concave curve is indicative of an armor that more 

evenly distributes its damage through the thickness. A superior damage-tolerant armor is one 

that uniformly absorbs energy through the thickness and that offers the potential for high residual 

12 
Figure 9. Front Surface of a 7-psf Panel After Ballistic Impact. Gate 1 Delamination Zone 

Is Visible. 

Table 5. Delamination Data for the 7-psf Targets 

VI? unstitched 7-psf vinyl-ester VARTM CompoSite. 

CYCOM: unstitched 7-psf polyester prepreg composite. 

SC-4-s: stitched 7-psf SC-4 epoxy VARTM composite. 

YE-s: stitched 7-psf vinylester VARTM composite. 

SC-4-t: unstitched 20-psf SC-4 epoxy VARTM composite with alumina tile. 

VE-t: unstitched 20-psf vinyl-ester VARTM composite with alumina tile. 

CYCOM-t: unstitched 20-psf polyester prepreg composite with alumina tile. 

SC&-s: 

V&t-s: 

stitched 20-psf SC-4 epoxy VARTM composite with alumina tile. 

stitched 20-psf vinyl-ester VARTM composite with alumina tile. 

13 
18.00 

16.00 

8.00 

6.00 

4.00 

2.00 

0.00 

I / f SC4 AVE 

+,CYCOM AVE 

+-E-S AVE 

1 2 3. 4 

Gate Locations 

Figure 10. Averaged Gate Delamination Data for 7-psf Panels Normalized to 1,550 fps. 

strength. Based on these materials, VE-S outperforms VE, SC-4, and CYCOM. The benefits of 

stitching are shown in the figure for vinyl-ester panels (lower extent of damage) but most 

dramatically in the case of SC-4 panels. Thus, while the SC-4 toughened epoxy does not appear 

to outperform the lower-toughness vinyl ester, stitching does appear to provide a greater damage 

tolerance and, in the ‘case of SC-4, provides for a beneficial transition from a convex to a 

concave damage zone shape through the thickness. 

Figure 11 compares damage volumes (calculated as the average of the four gates} and 

maximum delaminations. A lower maximum delamination is preferable for damage tolerance 

and multihit performance. It is also preferential to minimize the damage volume for the same 

reasons; however, for a given maximum delamination size, a higher damage volume may be 

indicative of more efficient energy dissipation in the panel. 

14 
18 

t 

18 “g AVERAGE 

MAX DELAM 

SC4 VE CYCOM sc4-s VE-S 

Figure 11. Average and Maximum Delamination Data for 7-psf Panels. 

Another way of comparing panels is to compare the ratio of the average delamination to the 

maximum delamination. Figure 12 shows this ratio (hatched bars), and, for ease of comparison, 

the solid bars indicate the average-to-maximum ratios normalized to the SC-4 panel. A ratio of 

unity would be the ideal situation since it represents the case where damage is uniform through 

the thickness and the entire thickness has contributed to the dissipation of energy providing a 

more damage tolerant postballistic structure and, possibly, increasing the ballistic performance of 

the armor through more efficient dissipation of energy. However, since it is important to 

consider both the desire to minimize the maximum extent of delamination (Figures 10 and 11) 

and the desire to optimize the uniformity of damage through the thickness (Figure 12), the ratio 

of these two (AV13MAXz) is insightful for comparison of armors. AVFJMAX’ is simply the 

ratio of the normalized average (AVEMAX) to the maximum (MAX). Consider two panels in 

which one has a conical delamination pattern through the thickness and one has a uniform 

(cylindrical) delamination pattern through the thickness. If both have an average delamination 

diameter (AVE) of 2 in, then the conical pattern has a maximum delamination diameter (MAX) 

of 4 in and the cylindrical pattern has a maximum delamination of 2 in. The MAX value is 

15 
q AVE/MAX 

n AVE/MAX (Norm) 

SC4 VE CYCOM sc4-s VE-S 

Figure 12. AVEIMAX Delamination Data for 7-psf Panels. 

indicative of an armor’s damage tolerance. The AVE value is indicative of the energy 

absorbtion. However, to distinguish between armors with different delamination patterns, the 

ratio of AVEIMAX can be used to indicate the relative uniformities of energy absorption 

between different armors. For example, the conical delamination pattern results in an 

AVIYMAX value of 0.5, while the cylindrical pattern obviously results in an AVE/MAX value 

of unity. Values closer to unity are desirable. Now, consider a third armor that results in a 

desirable cylindrical delamination pattern but with a 4-m maximum delamination. For this 

armor, the apparent energy absorption indicator (AVE) is 4 in. However, the AVEIMAX 

uniformity indicator is still unity. To quantitatively compare these two armors, it is useful to use 

a third performance indicator by taking the ratio of uniformity to the maximum value 

AVE/MAX2. Maximizing this value maximizes the efficiency of the armor at absorbing energy 

while maintaining high structural and multihit damage tolerance. For the 4-m conical example, 

the “efficiency” parameter is 0.125. For the 4iu cylindrical delamination, the efficiency is 0.25, 
t 

and, for the 2-in cylindrical delamination, the efficiency is maximized at OS. In terms of these 

definitions, delamination patterns closer to cylindrical (e.g*, concave vs. convex conical 

curvatures) are more efficient. Stitching tends to limit delamination in latter plies through the 

thickness and energy is absorbed through delamination of plies nearer the front of the armor 

backing plate, resulting in a transition from convex conical patterns to concave conical patterns. 

As shown in Figure 13, this comparison brings out the value of stitching for both the VE and 

SC-4 panels. 

3*5* 

SC4 VE CYCOM sc4-s VE-S 

Figure 13. AVEMAX2 Delamination Data for 7-psf Panels. 

. 

3.4.3 2U-psf Target Data. Figure 14 shows the front surface of a stitched vinyl-ester 20-psf 

panel prior to ballistic testing. The stitching pattern and the placement of the tile is apparent in 

the photograph. Table 6 shows the delamination data at each of the four’gates for each 20-psf 

test panel. 

17 
Figure 14. Front Surface of a Stitched Vinyl-Ester 20-psf Panel Prior to Ballistic Impact. 

Table 6. Delamination Data for the 20-psf Ballistic Panels 

lr- Pan- - -- l 

II 

1 ‘VI \ ‘U) \ ‘“I 

SC-44 2715-5 47 49 46 50 2,680 

c1#- *c 2715-6 30 47 47 45 2,683 

*-. * - n-l r).K QL ST -#-in It-e ’ ‘I I ‘T- I ’ / I , ,n ’ J” ’ ’ ‘.-““1 

Figures 15-18 for the 20-psf panel delamination results follow the same logic presented in 

Figures 10 through 13 for the 7-psf panels. Note that, for the 20-psf panels, that are tested with a 

heavier projectile at a higher velocity (20 mm at 2,700 fps for the 20-psf panels 

18 
60-oo I 

z 20.00 / 

.- +SC4 AVE 

E +VE AVE 

$ 10.00 

-x-CYCOM AVE 

P 

‘+SC4-S AVE L 

+VE-S AVE 

0.00 ! I I I 

1 2 3 4 

Gate Location 

Figure 15. Averaged Gate Delamination Data for 20-psf Panels Normalized to 2,700 fps. 

60 

aAVERAGE 1 

VE CYCOM sc4-s VE-S 

Figure 16. Average and Maximum Delamination Data for 20-psf Panels. 

19 
1.20 

z 

a 1.00 

m 

5 

2 0.80 

: 

0' 

*= 0.60 

: .d 

E 

; 0.40 

p" 

% 

o 0.20 

.I 

;; 

PC 

0.00 

I q AVE/MAX I 

IIAVE/MAX (Norm) I 

CYCOM sc4-s VE-S 

Figure 17. AVEMAX Delamination Data for 20-psf Panels. 

1.8 

SC4 VE CYCOM sees VE-S 

Figure 18. AVE/MAX2 Delamination Data for 20-psf Panels. 

20 
I vs. .50 cal. at 1,550 fps for the 7-psf panels), the ceramic tile absorbs most of the impact energy 

and changes the characteristics of damage through the thickness of the composite panel. 

Minimal penetration into the backing plate occurs during the tests, and delamination occurs due 

. 

I to stress-wave propagations during impact. As in the 7-psf targets, vinyl-ester appears to 

outperform both SC-4 epoxy and polyester prepreg panels in terms of armor efficiency, as 

defined previously. In the case of VE, the benefits of stitching will become significant at high 

velocities where penetration and arrest of the projectile will occur, leading to a higher V50 per 

area1 density. For SC-4, stitching provides a more damage-tolerant armor resulting in a smaller 

damaged region. 

4. Conclusions 

VARTM techniques were demonstrated to be viable low-cost methods for producing 

structural laminates with integrated armor for ground combat vehicles by UDLP. Damage 

tolerance and multihit performance of the integral armor system over conventionally fabricated 

targets were significantly improved by stitching. CIRTM was the enabling technology that 

provided the capability to manufacture a single composite article in a single step, with discrete 

resin layers optimizing the structural, ballistic, and FST performance of the integral armor 

system. 

, 

A methodology was developed to evaluate lightweight armor for ballistic- and 

damage-tolerance performance. Metrics for efficiency were defined for superior 

damage-tolerant armors that uniformly distribute damage through the thickness, while 

minimizing the extent of in-plane damage. Hybrid composite integral armors offering this 

balance of energy dissipation offer potential for improving V50 for a given area1 density or 

significantly improving damage tolerance measured through improved residual strength after 

ballistic impact. 

The VARTM-manufactured panels demonstrated equivalent ballistic performance to that of 

the prepreg material system at reduced cost. The through-thickness stitching reduced the extent 

21 
of damage to the composite targets in both direct impact from a projectile and when the 

composite is used as a backing plate for ceramic armor. In the case where damage tolerance 

drives the design of the structure, the use of through-thickness stitching may permit the designer 

to reduce the area1 density of the laminate while maintaining the same effective damage size for 

the composite. 

Future work will focus on the stitching density to optimized apparent toughness of the 

system, while limiting the reduction of in-plane properties. 

22 
5. References 

1. 

. . 

2. 

3. 

4. 

5. 

6. 

7. 

8, 

9. 

n 

Pike, T., M. MeArthur, and D. Schade. “Vacuum Assisted Resin Transfer Molding of a 

Layers’ Structural Laminate for Application on Ground Combat Vehicles.” Proceedings of 

the 28th International SAMPL? Technical Conference, pp. 37&380, Seattle, WA, 

4-7 November 1996. 

Fink, B. K. “Performance Metrics for Composite Integral Armor.” Proceedings of 

Fourteenth Annual Technical Conference of the American Society for Composites, Dayton, 

OH, September 1999. 

Fink, B. K., J. W. Gillespie, Jr., K. R. Bernetich, and E. F. Gillio. “One-Step Resin Transfer 

Molding of Multifunctional Resin Composites Consisting of Multiple Resins.” U.S. Patent 

Application No. 08/956,595, October 1997. 

Fink, B. K., S. H. M&night, and 9. W. Gillespie Jr. “Co-injection Resin Transfer Molding 

for Optimization of Integral Armor.” Proceedings of the Army Science Conference, 

Norfolk, VA, 15-17 June 1998. 

Gillio, E. F. “Co-injection Resin Transfer Molding of Hybrid Composites.” Masters Thesis, 

Department of Mechanical Engineering, University of Delaware, 1997. 

Gillio, E. F., J. W. Gillespie, Jr., R. F. Eduljee, K. R. Bernetich, S. G. Advani, and 

B. K. Fink. “Manufacturing of Composites With the Co-Injection Process.” American 

Institute of Aeronautics and Astronautics 38th Structures, Structural Dynamics and 

Materials Conference, American Institute of Aeronautics and Astronautics, 7-10 April 1997. 

Irnmordino, K. M. “Characterization of the Polysulfone/Epoxy Interphase for Bonding 

Thermoplastic Composites.” Masters Thesis, Materials Science Program, University of 

Delaware, 1996 (also published as Center for Composite Materials Technical Report No. 

96-29). 

Don, R. C., S. H. McKnight, and J. W. Gillespie, Jr. “A Study of Improved Bonding 

Techniques for High Performance Thermoplastic Composites.” Proceedings of the 10th 

Annual ASMIESD Advanced Composites Conference, Dearborn, MI, 7-l 0 November 1994. 

Monnard, V., P. E. Bourban, J. A. Manson, D. A. Eckel II, J. W. Gillespie, Jr., 

S. H. McKnight, and B. K. Fink. ‘Processing and Characterization of Welded Bonds 

Between Thermosets and Thermoplastic Composites.” I8th International SAMPE European 

Conference, Parts, h Defense, France, 23-25 April 1997. 

. . 

10. Bernetich, K., B. K. Fink, and J. W. Gillespie, Jr. “Co-Injection Resin Transfer Molding of 

Vinyl Ester and Phenolic Composites.” 43rd International SAMPE Symposium and 

Exposition, Anaheim, CA, 31 May-4 June, 1998. 

23 
11. Newton, C-H., B. K. Fink, S. H. M&night, G. R. Palmesc, and J. W. Gillespie, Jr. 

“Non-Polluting Composites Repair and Rknanufacturing for Military Applicatious: An 

Environmental and Cost-Savings Analysis.” Special Interim Report to the Strategic 

Environmental Research and Development Program Ofice, September 1998. 

12. Hartmann, B., and S. Jones. “Activity Based Cost Analysis for Manufacturing of the 

Composite Armored Vehicle.” ARLITuskegee University Annual Program Review, 

November 1997. 

13. Chou, S. C., and E. DeLuca. “Dynamic Response of S-2 Glass Reinforced Plastic Structural 

kmor, A Progress Report.” ARL-SR-5, U.S. Army Research Laboratory, Aberdeen 

Proving Ground, MD, December 1993. 

14. Bless S. J., et al. “Ballistic, Penetration of S-2 Glass Laminates.” Third TACOM Army 

Coordination Conference for Light Combat Vehicles, vol. II, 17-19 Febuary 1987. 

15. Bless S. J., et al. “Ballistic Penetration Study of S-2 GlassIPhenolic Spa11 Liner Materials.” 

Combat Survivability Symposium, vol. II, U.S. Army Tank-automotive and Armaments 

Command, Warren, MI, 15-17 April 1991. 

24 

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US DEPT OF ENERGY 

OFC OF ENVIRONMENTAL 

MANAGEMENT 

P RITZCOVAN 

19901 GERMANTOWN RD 

GERMANTOWN MD 208741928 

DIRECTOR 

LLNL 

F ADDESSI MS B216 

PO BOX 1633 

LOS ALAMOS NM 87545 

DIRECTOR 

LLNL 

R CHRISTENSEN 

S DETERESA 

F MAGNESS 

MFINGER MS 313 

MMURPHYL282 

PO BOX 808 

LIVERMORE CA 94550 

OAK RIDGE NATIONAL 

LABORATORY 

R M DAVIS 

PO BOX 2008 

OAK RIDGE TN 378314195 

NO. OF 

COPIES ORGANIZATION 

7 NIST 

R PARNAS 

J DUNKERS 

M VANLANDINGHAM MS 8621 

J CHIN MS 8621 

D HUNSTON MS 8543 

J MARTIN MS 8621 

DDUTHINHMS 8611 

100 BUREAU DR 

GAITHERSBURG MD 20899 

1 OAK RIDGE NATIONAL 

LABORATORY 

C EBERLE MS 8048 

PO BOX 2009 

OAK RIDGE TN 3783 1 

1 OAK RIDGE NATIONAL 

LABORATORY 

C D WARREN MS 8039 

PO BOX 2009 

OAK RIDGE TN 37922 

1 LOCKHEED MARTIN MISSILES 

& FIRE CONTROL 

R TAYLOR 

PO BOX 650003 M S WT 93 

DALLAS TX 752650003 

1 HYDROGEOLOGIC INC 

SERDP ESTCP SPT OFC 

S WALSH 

1155 HERNDON PKWY STE 900 

HERNDON VA 20170 

4 DIRECTOR 

SANDIA NATIONAL LABS 

APPLIED MECHANICS DEPT 

DIV 8241 

WKAWAHARA 

K PERANO 

D DAWSON 

P NmLAN 

PO BOX 969 

LIVERMORE CA 94550-0096 

33 
NO. OF 

COPIES 

3 

1 

1 

1 

ORGANIZATION 

NASA LANGLEY RSCH CTR 

AMSRL vs 

W ELBER MS 266 

F BARTLETT JR MS 266 

G FARLEY MS 266 

HAMPTON VA 23681-0001 

NASA LANGLEY RSCH Cl-R 

T GATES MS 188E 

HAMPTON VA 23661-3400 

USDOT FEDERAL R4lLRD 

MFATEHRDV31 

WASHINGTON DC 20590 

DOT FHWA 

J SCALZI 

400 SEVENTH ST SW 

3203 HNG 32 

WASHINGTON DC 20590 

FHWA 

E MUNLEY 

6300 GEORGETOWN PIKE 

MCLEAN VA 22101 

CENT&U, INTLLGNC AGNCY 

OTI WDAG GT 

w L WALTMAN 

PO BOX 1925 

WASHINGTON DC 20505 

Mm CORPS INTLLGNC ACTVTY 

D KOSITZKE 

3300 RUSSELL RD STE 250 

QUANTICO VA 221345011 

DIRECTOR 

NATIONAL GRND INTLLxiNC CTR 

IANGTMT 

220 SEVENTH ST NE 

CHARLOTTESVILLE VA 

22902-5396 

DIRECTOR 

DEFENSE INTLLGNC AGNCY 

TA5 

K CRELLING 

WASHINGTON DC 203 10 

NO. OF 

COPIES 

1 

ORGANIZATION 

GRAPHITE MASTERS INC 

J WILLIS 

3815 MEDFORD ST I 

LOS ANGELES CA 90063-1900 

ADVANCED GLASS FIBER YARNS 

T COLLINS 

281 SPRING RUN LANE STE A 

DOWNINGTON PA 19335 

F 

COMPOSITE MATERIALS INC 

D SHORTT 

19105 63 AVE NE 

PO BOX 25 

ARLINGTON WA 98223 

COMPOSITE MATERIALS INC 

R HOLLAND 

11JEWELC-r 

ORLNDA CA 94563 

COMPOSrrE MATERIALS INC 

CREEY 

14530 S ANSON AVE 

SANTA FE SPRINGS CA 90670 

coMPosIx 

DBLAKE 

L DIXON 

12OONElLLDR 

HEBRUN OHIO 43025 

CYTECFIBERITE 

RDUNNE 

D KOHL1 

M GILL10 

R MAYHEW 

1300 REVOLUTION ST 

HAVRE DE GRACE MD 21078 

SIMULA 

J COLTMAN 

RHUYETT 

10016 S 51ST ST 

PHOENIX AZ 85044 

SIOUX MFG 

BKRIEL 

PO BOX 400 

FT TOTTEN ND 58335 

34 
NO. OF 

COPIES 

2 

3 

I 

2 

1 

I 

2 

1 

ORGANIZATION 

PROTECTION MATERIALS INC 

M MILLER 

F CRILLEY 

144KmNW58 CT 

MIAMI LAKES FL 33014 

FOSTER MILLER 

J J GASSNER 

M ROYLANCE 

W ZUKAS 

195BEARHILLRD 

WALTHAM MA 02354-l 196 

ROM DEVELOPMENT CORP 

ROMEARA 

136 SWINEBURNE ROW 

BRICK MARKET PLACE 

NEWPORT RI 02840 

TEXTRON SYSTEMS 

T FOLTZ 

MTREASURE 

201 LOWELL ST 

WILMINGTON MA 08870-2941 

JPS GLASS 

L CARTER 

PO BOX 260 

SLATER RD 

SLATER SC 29683 

0 GARA HESS & EISENHARDT 

M GILLESPIE 

9113 LESAINT DR 

FAIRFIELD OH 45014 

MILLIKEN RSCH CORP 

HKUHN 

M MACLEOD 

PO BOX 1926 

SPARTANBURG SC 29303 

CONNEAUGHT INDUSTRIES INC 

J SANTOS 

PO BOX 1425 

COVENTRY RI 02816 

NO. OF 

COPIES 

1 

3 

1 

2 

ORGANIZATION 

BATIELLE 

CR HARGREAVES 

505 KING AVE 

COLUMBUS OH 43201-2681 

BATTELLE NATICK OPNS 

J CONNORS 

BHALPKN 

209 W CENTRAL ST STE 302 

NATICK MA 01760 

BATIELLE NW DOE PNNL 

THALLMSK231 

BATIELLE BLVD 

RICHLAND WA 99352 

PACIFIC NORTHWEST LAB 

MSMITH 

G VAN ARSDALE 

R SHIPPELL 

PO BOX 999 

RICHLAND WA 99352 

ARMTEC DEFENSE PRODUCTS 

S DYER 

85 901 AVE 53 

PO BOX 848 

COACHELLA CA 92236 

ADVANCED COMPOSITE 

MATERIALS CORP 

P HOOD 

J RHODES 

1525 S BUNCOMBE RD 

GREER SC 2965 l-9208 

GLCC INC 

JRAY 

M BRADLEY 

103 TRADE ZONE DR STE 26C 

WEST COLUMBIA SC 29170 

AMOCO PERFORMANCE 

PRODUCTS 

M MICHNO JR 

J BANISAUKAS 

4500 MCGINNIS FERRY RD 

ALPHARETTA GA 30202-3944 

35 
NO. OF 

COPIES 

1 

1 

1 

1 

1 

12 

3 

ORGANIZATION 

SAIC 

M PALMER 

2109AIRPARKRDSE 

ALBUQUERQUE NM 87 104 

SAIC 

G CHRYSSOMALLIS 

3800 W 80TH ST STE 1090 

BLOOMINGTON MN 5543 I 

AAI CORPORATION 

T G STASTNY 

PO BOX 126 

HUNT VALLEY MD 21030-0126 

JOHN HEBERT 

PO BOX 1072 

HUNT VALLEY MD 21030-0126 

AFPLIED COMPOSITES 

w GRISCH 

333 NORTH SIXTH ST 

ST CHARLES JL 60174 

ALLIANT TECHSYSTEMS INC 

CCANDLAND 

CAAKHUS 

R BECKER 

B SEE 

NVLAHAKUS 

R DOHRN 

S HAGLUND 

D FISHBR 

w WORRELL 

RCOPENHAFER 

M HISSONG 

DKAMDAR 

600 SECOND ST NE 

HOPKINS MN 55343-8367 

ALLIANT TECHSYSTEMS INC 

J CONDON 

E LYNAM 

J GERHARD 

WV01 16 STATE RT 956 

PO BOX 210 

ROCKET CENTER WV 

26726-0210 

NO. OF 

COPIES 

1 

1 

2 

5 

3 

I 

ORGANITATlON 

PROJECTILE TECHNOLOGY INC 

515 GILES ST 

HAVRE DE GRACE MD 21078 

CUSTOM ANALYTICAL 

ENG SYS INC 

A ALEXANDER 

13000 TENSOR LANE NE 

FLINTSTONE MD 21530 

LORAL VOUGHT SYSTEMS 

G JACKSON 

K COOK 

1701 W MARSHALL DR 

GRAND PRAllUE TX 7505 1 

AEROJBT GEN CORF 

D PJLLASCH 

T COULTER 

CFLYNN 

D RUBAREZUL 

M GREINER 

1100 WEST H0LLYVAJ.B ST 

AZUSA CA 9 1702-0296 

HEXCEL INC 

RBOE 

F POLICELLI 

J POESCH 

PO BOX 98 

MAGNA UT 84044 

HERCULES INC 

HERCULES PLAZA 

WILMINGTON DE 19894 

BRIGS COMPANY 

J BACKOFEN 

2668 PETERBOROUGH ST 

HERNDON VA 22071-2443 

ZERNOW TECHNICAL SERVICES 

L ZERNOW 

425 W BONITA AVE STE 208 

SAN DIMAS CA 91773 

36 
NO. OF 

COPIES ORGANIZATION 

2 OLIN CORPORATION 

FLINCHBAUGH DIV 

E STEINER 

B STEWART 

PO BOX 127 

RED LION PA 17356 

1 OLIN CORPORATION 

L WHITMORE 

10101 NINTH ST NORTH 

ST PETERSBURG FL 33702 

5 SIKORSKY AIRCRAFT 

G JACARUSO 

T CARSTENSAN 

BKAY 

S GARBO MS S33OA 

J ADELMANN 

6900 MAIN ST 

PO BOX 9729 

STRATFORD CT 06497-9729 

1 GKN AEROSPACE 

D OLDS 

15 STERLING DR 

WALLINGFORD CT 06492 

1 PRATT&WHITNEY 

D HAMBRICK 

4OOMAlNSTMS 11437 

EAST HARTFORD CT 06108 

1 AEROSPACE CORF 

G HAWKINS M4 945 

2350 E EL SEGUNDO BLVD 

EL SEGUNDO CA 90245 

2 CYTEC FIBERITE 

MLIN 

WWEB 

1440 N KRAEMER BLVD 

ANAHEIM CA 92806 

1 HEXCEL 

T BITZER 

11711 DUBLINBLVD 

DUBLIN CA 94568 

NO. OF 

COPIES 

1 

ORGANIZATION 

BOEING 

R BOHLMANN 

PO BOX 516 MC 5021322 

ST LOUIS MO 63166-0516 

BOEING DFNSE & SPACE GP 

W HAMMOND 

J RUSSELL S 4X55 

PO BOX 3707 

SEATTLE WA 98 1242207 

BOEING ROTORCRAFT 

P MINGURT 

P HANDEL 

800 B PUTNAM BLVD 

WALLINGFORD PA 19086 

BOEING 

DOUGLAS PRODUCTS DIV 

LJHARTSMJTH 

3855 LAKEWOOD BLVD 

ID80019 

LONG BEACH CA 90846-0001 

LOCKHEED MARTIN 

SREEVE 

8650 COBB DR 

D 73 62 MZ 0648 

MARIETTA GA 30063-0648 

LOCKHEED MARTIN 

SKUNK WORKS 

D FORTNEY 

1011 LOCKHEED WAY 

PALMDALE CA 93599-2502 

LOCKHEED MARTIN 

R FIELDS 

1195 IRWIN CT 

WINTER SPRINGS FL 32708 

MATERIALS SCIENCES CORP 

B W ROSEN 

500 OFC CENTER DR STE 250 

FT WASHINGTON PA 19034 

37 
NO. OF 

COPrES 

1 NORTHRUP GRUMMAN CORF 

ELECTRONIC SENSORS 

& SYSTEMS DIV 

E SCHOCH MS V 16 

1745A W NURSERY RD 

LINTHJCUM MD 21090 

2 NORTHROP GRUMMAN 

ENVIRONMENTAL PROGRAMS 

R OSTERMAN 

AYEN 

8900 E WASHINGTON BLVD 

PICO RIVERA CA 90660 

UDLP 

D MARTIN 

PO BOX 359 

SANTA CLARA CA 95052 

UDLP 

G THOMAS 

PO BOX 5X 123 

SANTA CLARA CA 95052 

UDLP 

R BARRETT MAIL DROP MS3 

V HORVATICH MAIL DROP M53 

328 W BROKAW RD 

SANTA CLARA CA 95052-0359 

3 TJDLP 

GROUND SYSTEMS DIVISION 

M PEDRAZZl MAIL DROP NO9 

ALEEMAJLDROPNll 

M MACLEAN MAIL DROP NO6 

1205 COLEMAN AVE 

SANTA CLARA CA 95052 

3 UDLP 

R BRYNSVOLD 

PJANKEMS 170 

T GIOVANETTI MS 236 

BVANWYKMS389 

4800 EAST RIVER RD 

MINNEAPOLIS MN 55421-1498 

NO. OF 

COPIES 

2 

1 

ORGWATION 

GDLS 

D REES 

M PASM 

PO BOX 2074 

WARREN MI 48090-2074 

GDLS DIVISION 

D BARTLE 

PO BOX 1901 

WARREN MI 48090 

1 GDLS 

MUSKEGON OPERATIONS 

W SOMMERS JR 

76 GETTY ST 

MUSKEGON MI 49442 

1 

5 

GENERAL DYNAMICS 

AMPHIBIOUS SYS 

suRvIvABILITYLEAD 

G WALKER 

991 ANNAPOLIS WAY 

WOODBRIDGE VA 2219 1 

INST FOR ADVANCED 

TECH 

TKJEHNE 

HFAJR 

P SULLIVAN 

WREINECKE 

I MCNAB 

4030 2 W BRiKER LN 

AUSTIN TX 78759 

2 CIVIL ENGR RSCH FOUNDATION 

PRESIDENT 

H BERNSTEIN 

R BELLE 

1015 15TH S,T NW STE 600 

WASHINGTON DC 20005 

1 ARROW TECH ASS0 

1233 SHELBURNE RD STE D 8 

SOUTH BURLINGTON VT 

05403-7700 

1 R EICHELBERGER 

CONSULTANT 

409 W CATHERINE ST 

BEL AIR MD 21014-3613 

38 
NO. OF 

COPIES 

2 

1 

ORGANIZATION 

UCLA MANE DEPT ENGR IV 

HTHAHN 

LOS ANGELES CA 900241597 

U-NIV OF DAYTON 

RESEARCH INST 

RYKIM 

AKROY 

300 COLLEGE PARK AVE 

DAYTON OH 45469-0168 

P LAGACE 

‘77 MASS AVE 

CAMBRIDGE MA 01887 

IIT RESEARCH CENTER 

D ROSE 

201 MJLLST 

ROME NY 13440-6916 

GA TECH RSCH JNST 

GA INST OF TCHNLGY 

P FRIEDERICH 

ATLANTA GA 30392 

MICHIGANSTUNIV 

MSM DEPT 

R AVERILL 

3515 EB 

EAST LANSING MI 488241226 

UNIV OF KENTUCKY 

L PENN 

763 ANDERSON HALL 

LEXINGTON KY 40506-0046 

UMV OF WYOMING 

D ADAMS 

PO BOX 329s 

LARAMIE WY 82071 

UNIVOFUTAH 

DEPT OF MECH & 

INDUSTRIAL ENGR 

S SWANSON 

SALT LAKE CITY UT 84112 

NO. OF 

COPIES 

2 

I 

1 

1 

7 

ORGANIZATION 

PENN STATE UNIV 

R MCN-ITT 

C BAKIS 

212 EARTH ENGR SCIENCES BLDG 

UNIVERSITY PARK PA 16802 

PENN STATE UNIV 

R S ENGEL 

245 HAMMOND BLDG 

UNIVERSITY PARK PA 16801 

PURDUEUNLV 

SCHOOL OF AERO & ASTRO 

CTSUN 

W LAFAYETTE IN 47907-1282 

STANFORD UNJV 

DEPT OF AERONAUTICS 

& AEROBALLISTICS 

S TSAI 

DURANT BLDG 

STANFORD CA 94305 

UN-IV OF DAYTON 

JMWHITNEY 

COLLEGE PARK AVE 

DAYTON OH 45469-0240 

UNIV OF DELAWARE 

CTR FOR COMPOSITE MTRLS 

J GILLESPIE 

M SANTARE 

G PALMESE 

S YARLAGADDA 

s ADVANI 

D HEIDER 

DKUKICH 

201 SPENCER LABORATORY 

NEWARK DE 19716 

UNIV OF ILLINOIS AT 

URBANA CHAMPAIGN 

NATIONAL CENTER 

FOR COMPOSITE 

MATERIALS RESEARCH 

J ECONOMY 

216 TALBOT LABORATORY 

104SWlUGHTST 

URBANA IL 61801 

39 
NO. OF 

COPIES ORGANIZATION 

3 THEUNIVOF 

TEXAS AT AUSTIN 

CTR FOR ELECTROMECHANICS 

J PRICE 

A WALLS 

J KITZMILLER 

10100 BURNET RD 

AUSTIN TX 7875X-4497 

3 VA POLYTECHNICAL 

mST & STATE TJNIV 

DEFT OF ESM 

MWHYER 

K REIFSNIDER 

R JONES 

BLACKSBURG VA 24061-0219 

1 NORTH CAROLINA STATE LJNIV 

CIVIL ENGINEERING DEPT 

W RASDORF 

PO BOX 7908 

RALEIGH NC 27696-7908 

1 UNIV OF MARYLAND 

DEPT OF AEROSPACE ENGNRNG 

AJVIZZlNI 

COLLEGE PARR MD 20742 

1 DREXELUNIV 

ASDWANG 

32ND & CHESTNUT ST 

PHJLADELF’HIA PA 19104 

1 SOUTHWEST RSCH INST 

ENGR & MATL SCIENCES DLV 

J RIEGEL 

6220 CULEBRA RD 

PO DRAWER 285 10 

SAN ANTONIO TX 78228-05 10 

Nn t-G 

LTV. VI 

COPIES ORG- ATION 

1 us ARMY MATERIEL 

SYSTEMS ANALYSIS 

P DIETZ 

392 HOPKINS RD 

AMXSY BTD 

APG MD 21005-5071 

1 DIRECTOR 

US ARMY RESEARCH LAB 

AMSRLOPAPL 

APG MD 21005-5066 

108 DIR USARL 

AMSRL CI 

AMSRL CI H 

w STUREK 

AMSRL CI s 

AMARK 

AMSRL cs IO FI 

M ADAMSON 

AMSRL SL B 

J SMITH 

AMSRL SL BA 

AMSRL SL BL 

D BELY 

RHENRY 

AMSRL SL BG 

A YOUNG 

AMSRL SL I 

AMSRLWMB 

A HORST 

E SCHMIDT 

AMSRL WM BA 

W D AMICO 

F BRANDON 

AMSRL W-M BC 

P PLOSTINS 

D LYON 

J NEWILL 

S WILKERSON 

A ZIELINSKI 

AMSRL WM BD 

B FORCH 

RFIFER 

R PESCE RODRIGUEZ 

BRICE 

40 
NO. OF 

COPIES ORGANIZATION 

ABERDEEN PROVING GROUND (CONT1 

AMSRL WM BE 

C LEVERITT 

D KOOKER 

AMSRL WM BR 

C SHOEMAKER 

J BORNSTEIN 

AMSRLWMM 

D VIECHNICKI 

G HAGNAUER 

J MCCAULEY 

B TANNER 

AMSRL WM MA 

R SHUFORD 

P TOUCHET 

N BECK TAN 

D FLANAGAN 

L GHtORSE 

DHARRIS 

S MCKNIGHT 

P MOY 

S NGYUEN 

P PATTERSON 

G RODRIGUEZ 

A TEETS 

RYIN 

AMSRLWMMB 

BFINK 

J BENDER 

T BLANAS 

T BOGETTI 

R BOSSOLI 

L BURTON 

K BOYD 

S CORNELISON 

P DEHMER 

R DOOLEY 

W DRYSDALE 

G GAZONAS 

S GHIORSE 

D GRANVILLE 

D HOPKINS 

C HOPPEL 

D HENRY 

R KASTE 

M KLUSEWTTZ 

M LEADORE 

R LIEB 

NO. OF 

COPIES ORGANIZATION 

AMSRLWMMB 

E RIGAS 

J SANDS 

D SPAGNUOLO 

W SPURGEON 

J TZENG 

EWET’ZEL 

AABRAHAMXN 

M BERMAN 

AFRYDMAN 

T LI 

W MCINTOSH 

E SZYMANSKI 

AMRSL WM MC 

J BEAT-L-Y 

J SWAB 

ECHIN 

J MONTGOMERY 

A WERECZCAK 

J LASALVIA 

J WELLS 

AMSRLWMMD 

W ROY 

S WALSH 

AMSRLWMT 

B BURNS 

AMSRL WM TA 

W GILLICH 

T HAVEL 

J RUNYEON 

M BURKINS 

E HORWATH 

B GOOCH 

W BRUCHEY 

AMSRL WM TC 

R COATES 

AMSRLWMTD 

A DAS GUPTA 

T HADUCH 

T MOYNIHAN 

F GREGORY 

ARAJENDRAN 

M RAFI’ENBERG 

M BOTELER 

T WEERASOOFUYA 

DDANDEKAR 

A DIETRICH 

41 
NO. OF 

COPIES ORGANIZATION 

ABERDEEN PROVING GROUND (CONTj 

flMsRLwMTE 

A NIILER 

J POWELL 

AMSRL SS SD 

H WALLACE 

AMSRL SS SE R 

R CHASE 

AMSRL SS SE DS 

R REYZER 

R ATKINSON 

AMSRL SE L 

RWEINRAUB 

J DESMOND 

D WOODBURY 

42 
NO. OF 

iTcaL! 

1 

- 

1 

1 

1 

1 

ORGANIZATION 

LTD 

R MARTIN 

MERL 

TAMWORTH RD 

HERTFORD SG13 7DG 

UK 

PW LAY 

SMC SCOTLAND 

DER4 ROSYTH 

ROSYTH ROYAL DOCKYARD 

DUNFERMLINEFIFEKY 112XR 

UK 

CIVIL AVIATION 

ADMINSTRATION 

T GOTTESMAN 

PO BOX 8 

BEN GURION INTERNL AIRFORT 

LOD 70150 ISRAEL 

AEROSPAT’IALE 

SAN-DIE 

A BTE CC RTE MD132 

316 ROUTE DE BAYONNE 

TOULOUSE 3 1060 

FRANCE 

DAIMLER BENZ AEROSPACE 

J BAUER 

D 81663 MUNCHEN 

MUNICH 

GERMANY 

DRA FORT HALSTEAD 

P N JONES 

D SCOTT 

M HINTON 

SEVEN OAKS KENT TN 147BP 

UK 

DEFENSE RESEARCH ESTAB 

VALCARTIER 

F LESAGE 

COURCELE’TTE QUEBEC COA 

lR0 CANADA 

NO. OF 

GQg&j 

2 ROYAL MILITARY COLLEGE OF 

SCIENCE SHRIVENHAM 

D BULMAN 

B LAWTON 

SWINDON WLLTS SN6 8LA 

UK 

1 

1 

1 

1 

1 

1 

SWISS FEDERAL ARMAMENTS 

WKS 

w LANZ 

ALLMENDSTRASSE 86 

3602 THUN 

SWITZERLAND 

ISRAEL INST OF 

TECHNOLOGY 

S BODNER 

FACULTY OF MECHANICAL ENGR 

HAIFA 3200 ISRAEL 

DSTO MATERIALS RESEARCH LAB 

NAVAL PLATFORM VULNERABILITY 

SHIP STRUCT’URES & MTRLS DIV 

NBURMAN 

PO BOX 50 

ASCOT VALE VICTORIA 

AUSTRALIA 3032 

ECOLE ROYAL MILITALRE 

E CELENS 

AVE DE LA RENAISSANCE 30 

1040 BRUXELLE 

BELGIQUE 

DEF RES ESTABLISHMENT 

VALCARTIER 

A DUPUIS 

2459 BOULEVARD PIE XI NORTH 

VALCARTIER QUEBEC 

CANADA 

PO BOX 8800 COURCELETTE 

GOA IRO QUEBEC CANADA 

INSTITUT FRANC0 ALLEMAND 

DE RECHERCHES DE SAN-IT LOUIS 

DE M GIRAUD 

5 RUE DU GENERAL CASSAGNOU 

BOITE POSTALE 34 

F 68301 SAINT LOUTS CEDEX 

FRANCE 

43 
NO. OF 

COPIES 

1 

1 

2 

2 

1 

ORGANJZATION 

ECOLE POLYTECH 

J MANSON 

DMX LTC 

CH 1015 LAUSANNE 

SWlTZERLAND 

TN0 PRJNS MAURJTS 

LABORATORY 

R IJSSELSTEJN 

LANGE KLEIWEG 137 

PO BOX 45 

2280 AA RIJSWIJK 

THENETHERLANDS 

FOA NAT L DEFENSE RESEARCH 

ESTAB 

DIR DEFT OF WEAPONS & 

PROTECTION 

B JANZON 

R HOLMLIN 

S 172 90 STOCKHOLM 

SWEDEN 

DEFENSE TECH & PROC AGENCY 

GROUND 

ICREWTHER 

GENERAL HERZOG HAUS 

3602 THUN 

SWITZERLAND 

MINISTRY OF DEFENCE 

RAFAEL 

ARMAMENT DEVELOPMENT 

AUTH 

M MAYSELESS 

PO BOX 2250 

HAIFA 31021 ISRAEL 

DYNAMEC RESEARCH AB 

A PERSSON 

BOX 201 

S 15123 SODERTALJE 

SWEDEN 

ERNST MACH INSTITUT EMI 

DIRECTOR 

HAUPTSTk4SSE 18 

79576 WHL AM RHEIN 

GERMANY 

NO. OF 

COPIES ORGANIZATION 

1 ERNST MACH JNSTITUT EM1 

ASTJLF’ 

ECKERSTRASSE 4 

7800 FREIBURG 

GERMANY 

1 TN0 DEFENSE RESEARCH 

I H PASMAN 

POSTBUS 6006 

2600 JA DELFT 

THENETHERLl4Nl3s 

1 B HIRSCH 

TACHKEMONY ST 6 

NETAMUA 426 11 

ISRAEL 

1 DEUTSCHE AEROSPACE AG 

DYNAMICS SYSTEMS 

M HELD 

PO BOX- 1340 

D 86523 SCHROBENHAUSEN 

GERMANY 

44 
Bruce K. Fink and John W. Gillespie* 

RWORT NUMBER 

Am: AMsFtL-WM-MB 

Aberdeen Proving Ground, MD 21005-5069 AFL-TR-23 19 

kUniversity of Delaware, Newark, DE 19716-3144 

2a. DlSTRlBUTlONlAVAll.ABU’w STATBMENT 

4pproved for pulbic release; distribution is unlimited. 12b. OISTRIBUIION WOE 

The U.S. Army Research Laboratory (ARL) and the University of Delaware (UD) have developed an enabling 

ethnology to produce a polymer matrix composite-based integral armor with improved multihit ballistic capability. 

Current applications for integral armor composites in&de the Composite Armored Vehicle (CAV) technology 

kmonstrator and Crusader &f-pro@led howitzer platforms. Present integral armor manufacturing processes involve 

adhesive bonding of a composite shuctue with ballistic armor tilw, spaU shield, and nuisance cover. ARL, UD, ant 

he CAVKnuder composite &rucmre contractor, United Defe= Limited Partnership (UDLP), - 

hrough-thickness stitching to improve the multihit capability and reduce mantichuing costs. The patent-pendinE 

Mnjection resin-transfer molding (CIRTM) process was used to produce a stitched, c&njected integral armor panel 

hat demonstmted improved mukihit capability. The spall shield was fabricated with a phenolic resin for fire, smoke: 

md toxicity protection, while the remainder of the integral armor (strum composite resin enqsulating the tila 

md the nuisance cover) m fabricated with an epoq resin for shuctufal performance. Throngh-thickness stitchirq 

uul ClRTM were used to enhance the damage tolerance and to reduce the cost of the armor. 

4. SUBJECT TERMS 15. NUMBER OF PAGES 

omposite material, damage tolerance, ballistic testing integral armor, c+injection resin 51 

ransfer molding IS. PRICE COOE 

7. SECURITY clAsslPlcATloN 48. SBCURI-W ClASSlPlcATlON 1% SECURITY CLASSlPlCATDN m. LIMITATION OP ABSTRACT 

OFREPORT OfTHlSPAGE oPABsTRAcT 

UNCLASSIFIED UNCLASSIFIED UNCLASSIFIED UL 

4 . -.------- Clnl*a =- -3-p asv. 2s\ 

45 298102 
INTENTIONALLY LEFT BLANK. 

46 
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the items/questions below will aid us in our efforts. 

1. ARL F&port Numlx~/Author~F~ Date of Report Seotember 2000 

2. Date Report Received 

3. Does this report satisfy a need? (Comment on purpose, related project, or other area of inter& for which the report will be 

4. Specifically, how is the report being used? (Information source, design data, procedure, source of ideas, etc.) 

5. Has the information in this report led to any quantitative savings as far as man-hours or dollars saved, operating costs 

avoided, or efficiencies achieved, etc? If so, pkse elaborate. 

6. General Comments. What do you think should be changed to improve future reports? (Indicate changes to organktios 

technid ConteIq fbrmat, etc.) 

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7. lfindicating a Change of Address or Address Correction, please provide the Current or Correct address above and the Old 

or Incorrect address below. 

Organization 

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ADDRESS 

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Street or P.O. Box No. 

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POSTAGE WILL BE PAID BY ADDRESSEE 

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US ARMY RESEARCH LABORATORY - 

AlTN AMSRL WM MB 

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