Suppression of Material Failure Modes in Titanium Armors 

by William J. Bruchey 

ARL-TR-3124 December 2003 

Approved for public release; distribution is unlimited. 
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Citation of manufacturer’s or trade names does not constitute an official endorsement or approval of the 

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Destroy this report when it is no longer needed. Do not return it to the originator. 
Army Research Laboratory 

Aberdeen Proving Ground, MD 21005-5066 

ARL-TR-3124 December 2003 

Suppression of Material Failure Modes in Titanium Armors 

William J. Bruchey 

Weapons and Materials Research Directorate, ARL 

Approved for public release; distribution is unlimited.
ii

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PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS. 

1. REPORT DATE (DD-MM-YYYY)

December 2003 

2. REPORT TYPE 

Final 

3. DATES COVERED (From - To) 

October 1998–September 2003 

5a. CONTRACT NUMBER 

5b. GRANT NUMBER 

4. TITLE AND SUBTITLE 

Suppression of Material Failure Modes in Titanium Armors 

5c. PROGRAM ELEMENT NUMBER 

5d. PROJECT NUMBER 

273808.E11 

5e. TASK NUMBER 

6. AUTHOR(S) 

William J. Bruchey 

5f. WORK UNIT NUMBER 

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 

U.S. Army Research Laboratory 

ATTN: AMSRD-ARL-WM-TA 

Aberdeen Proving Ground, MD 21005-5066 

8. PERFORMING ORGANIZATION 

 REPORT NUMBER 

ARL-TR-3124 

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR'S ACRONYM(S) 

PM-Combat Systems 

ATTN: SFAE-GCS-S 

USTACOM 

Warren, MI 48397-5000 

11. SPONSOR/MONITOR'S REPORT 

 NUMBER(S) 

12. DISTRIBUTION/AVAILABILITY STATEMENT 

Approved for public release; distribution is unlimited. 

13. SUPPLEMENTARY NOTES 

14. ABSTRACT 

Previous research by the U.S. Army Research Laboratory (ARL) has shown that the most common titanium alloy, Ti-6Al-4V, 

provides weight-effective protection against small-arms projectiles. In armor applications, titanium is susceptible to adiabatic 

shear and spall failure at the back surface. The large spall plugs that form can be a significant factor in behind-armor 

vulnerability and lethality. As the U.S. Army moves towards lighter and lighter Future Combat Systems class vehicles, thinner 

and lighter armors and structural elements will be needed. Particularly, the rear structural element in an armor must provide 

protection producing minimal behind-armor debris. 

ARL, in cooperation with the PM-Combat Systems, has undertaken a program to address this problem. Two-layer titanium 

composites were investigated. The initial or impact facing layer consisted of Ti-6Al-4V, with a backing layer of a 

nonplugging/spalling material. Backing layers consisted of commercially pure titanium, rolled homogeneous armor, steel, or 

aluminum. For each material combination, the two layers were either metallurgically bonded using explosive welding or 

diffusion bonded using hot isostatic pressing.

15. SUBJECT TERMS

armor, titanium, titanium alloy, material failure 

16. SECURITY CLASSIFICATION OF: 

19a. NAME OF RESPONSIBLE PERSON

William J. Bruchey 

a. REPORT 

UNCLASSIFIED 

b. ABSTRACT 

UNCLASSIFIED

c. THIS PAGE 

UNCLASSIFIED

17. LIMITATION 

OF ABSTRACT 

UL 

18. NUMBER 

OF PAGES 

24 

19b. TELEPHONE NUMBER (Include area code) 

410-278-6223 

Standard Form 298 (Rev. 8/98) 

Prescribed by ANSI Std. Z39.18
iii

Contents 

List of Figures iv

Acknowledgments v

1. Introduction 1

2. Background 1

3. Materials and Processing 3

4. Test Methodology 4

5. Results 5

6. Conclusions 7

Distribution List 8 
iv

List of Figures 

Figure 1. Comparison of penetration and perforation behavior of rolled homogeneous armor 

(RHA) and Ti-6Al-4V armor materials. ....................................................................................2 

Figure 2. Severe spall of unconfined back surface due to ballistic impact on finite thickness 

titanium armor plate...................................................................................................................2 

Figure 3. Schematic of explosive welding process.........................................................................3 

Figure 4. Sketch of 20-mm fragment simulating projectile (FSP)..................................................4 

Figure 5. Comparison of limit velocity performance of candidate titanium laminates vs. the 

weight equivalent monolithic titanium armor plate...................................................................5 

Figure 6. Comparison of limit velocity for titanium laminates and Ti-6A1-4V alloy....................6 

Figure 7. Typical penetration channel through HIP-bonded Ti-6Al-4V laminate. Penetration 

direction is top to bottom. ..........................................................................................................6 

Figure 8. Spall cone diameters for titanium and titanium laminates impacted by 20-mm 

FSPs. ..........................................................................................................................................7 
v

Acknowledgments 

The author would like to acknowledge the help and support of Mr. Matthew Burkins and 

Mr. David Mackenzie of the U.S. Army Research Laboratory, Weapons and Materials Research 

Directorate, Terminal Effects Division. Mr. Burkins provided guidance on ballistic testing and 

oversight of the data reduction and analysis. Mr. Mackenzie conducted all the target sectioning, 

specimen polishing, photographing, and target measurements.
vi

INTENTIONALLY LEFT BLANK.
1

1. Introduction 

As early as 1950, Pitler and Hurlich1 noted that titanium alloys showed promise as armors 

against small arms projectiles. By the early 1960s, Sliney2

 presented ballistic performance data 

for the Ti-6Al-4V alloy that demonstrated significant weight reductions over steel armors for a 

variety of small arms threats. Little follow-on work with larger threats was conducted due to the 

prohibitive cost of the titanium. 

Recently, the U.S. Army Tank-Automotive Research, Development, and Engineering Center, 

Warren, MI, funded the Weapons and Materials Research Directorate of the U.S. Army Research 

Laboratory, Aberdeen Proving Ground, MD, to complete a ballistic evaluation of thick titanium 

plates with tungsten alloy and depleted uranium penetrators.3

 The U.S. Department of Interior 

Bureau of Mines at Albany, OR, was funded to purchase 76.2- to 101.6-mm-thick Ti-6Al-4V 

plates manufactured to the common MIL-T-9046J4 specification. 

2. Background 

In the work of Burkins et al.3, the adiabatic shear and spalling behavior of the Ti-6Al-4V alloy 

were noted. The consequence of this behavior can be seen in figure 1, which shows how the 

ballistic behavior is effected by the free back surface of a Ti-6Al-4V armor plate. Due to the 

adiabatic shear and spall failure of the back face of titanium armor targets, an ~5%–10% greater 

thickness of titanium alloy can be perforated at the same velocity as compared to semi-infinite 

titanium alloy. 

Figure 2 shows an example of the severe back surface spalling that can occur in high-strength 

titanium alloys. Fragments resulting from this ballistic event would increase system 

vulnerability and result in damage to personnel and equipment behind the armor. This is a 

concern should titanium alloy be used as a rear structural material for armored vehicles. The 

intention of this study was to alleviate these problems and produce a titanium structural material 

that was suitable for the inner structural element of a combat vehicle. The approach taken was to 

 1

Pitler, R.; Hurlich, A. Some Mechanical and Ballistic Properties of Titanium and Titanium Alloys; 401/17; Watertown 

Arsenal Laboratory: Watertown, MA, March 1950 (ADA 951655). 

2Sliney, J. Status and Potential of Titanium Armor; Proceedings of the Metallurgical Advisory Committee on Rolled Armor; 

AMRA MS 64-04; U.S. Army Materials Research Agency: Watertown, MA, January 1964 (AD 354853). 

3

Burkins, M.; Paige, J.; Hansen, J. A Ballistic Evaluation of Ti-6A1-4V vs. Long Rod Penetrators; ARL-TR-1146; U.S. Army 

Research Laboratory: Aberdeen Proving Ground, MD, July 1996. 

4

MIL-T-9046J. Military Specifications—Titanium and Titanium Alloy (Sheet-Strip-Plate) 1993. 
2

Figure 1. Comparison of penetration and perforation behavior of rolled 

homogeneous armor (RHA) and Ti-6Al-4V armor materials. 

Figure 2. Severe spall of unconfined back surface due to ballistic 

impact on finite thickness titanium armor plate.
3

develop metallic laminates composed of titanium alloy plates with a backing plate of a dissimilar 

material to suppress the adiabatic shear failure and back face spalling. 

3. Materials and Processing 

The Ti-6Al-4V material used in all phases of the program was purchased to the military 

specification, MIL-T-9046J. Chemistries and typical properties can be found in Burkins et al.3 

The monolithic titanium alloy armor thickness was fixed at 38.1 mm. In the laminate armor 

tests, the thickness of the Ti-6Al-4V front plate was fixed at 31.75 mm and the rear plate at 6.35 

mm for the same total thickness of 38.1 mm. All the plates had 304.8- × 304.8-mm lateral 

dimensions. 

Three different backing plate materials were chosen for the bimetallic laminates: aluminum 

(1100), RHA steel, and commercially pure titanium (C.P.). These material combinations 

provided a wide range of strengths, toughnesses, densities, and metallurgical compatibilities with 

the Ti-6Al-4V armor front plate. Two methods were chosen for fabrication of the laminates: 

explosive welding and hot isostatic pressing (HIP). 

Explosive welding is a solid state welding process, which uses controlled explosive detonations 

to force two or more metals together at high velocities (figure 3). It has the advantage of 

effectively scrubbing clean both metal surfaces during the joining process. Because the time 

durations are so short, the reaction zones are extremely small with a correspondingly small heat 

effected zone. Because the base metals remain at near ambient temperatures, the formation of 

Figure 3. Schematic of explosive welding process. 
4

brittle intermetallics is suppressed. This technique was used to join all the combinations of 

materials used in the bimetallic laminates. 

HIP, figure 4, was chosen as an alternative to explosive bonding for joining the titanium alloy to 

the commercially pure titanium due to the compatibility of the two materials. HIPing is a solid 

state diffusion process carried out at high temperature and pressure. To join the titanium alloy 

and C.P. titanium, the materials were processed in the HIP press for 2 hr at 900 °C and 15-ksi 

pressure. HIP bonding offers the advantage of no explosives, and there is an industrial capability 

to produce parts in sizes suitable for combat vehicles. 

Figure 4. Sketch of 20-mm fragment simulating projectile (FSP). 

4. Test Methodology 

Ballistic limit velocities were determined at 0° obliquity to the target surface. Limit velocity 

perforation testing involves varying the impact velocity against a single thickness of plate and 

determining the minimum velocity necessary for perforation. The limit velocity (VL) is defined 

as the critical velocity at which the target is just perforated (i.e., the residual velocity is zero). 

The VL was calculated averaging the highest partial and lowest complete penetration velocity. 

The penetrator chosen for the evaluation was the standard 20-mm FSP shown in figure 5. This 

projectile was selected because the geometry of the nose tends to emphasize the spalling and 

plugging behavior of the materials. 

The penetrators were fired from a laboratory gun consisting of a 37-mm breech assembly with a 

26-mm smoothbore barrel. A custom-built polypropylene sabot system was used to launch the 
5

Figure 5. Comparison of limit velocity performance of candidate titanium 

laminates vs. the weight equivalent monolithic titanium armor plate. 

projectiles. The target was positioned 1.5 m downrange from the muzzle of the gun. The 

propellant weights were adjusted from shot-to-shot to achieve desired striking velocities. 

For this test penetrator, the performance of the modified titanium plates was compared to the 0° 

obliquity baseline performance of monolithic Ti-6Al-4V armor of the same weight or areal 

density. Comparisons were based on the areal density of the candidate armor material needed to 

defeat the projectile at a given striking velocity. Areal density is defined as the thickness of 

material perforated (or depth penetrated) times the density of this material. 

5. Results 

A series of shots were fired into each laminate combination to obtain the ballistic limit velocity. 

Figure 6 shows the ballistic limit velocity, VL, for each of the targets plotted as a function of 

their areal densities. Based on the data of Burkins et al.,3

 the solid diagonal line represents the 

VL of solid titanium alloy as a function of plate thickness or areal density. For the laminate 

armor data points lying above the diagonal, performance exceeds that of the monolithic titanium 

plate. For data points below the diagonal, the performance of the laminates are inferior to the 

monolithic plate. Both joining techniques show that the combination of Ti-6Al-4V laminated to 

C.P. Ti performs better than the monolithic titanium alloy on a weight basis. Both the Al and 

RHA laminates show performance decrements on a weight basis. The combination of HIP 

pressing and a laminate of titanium alloy and C.P. titanium shows a 5%–10% improvement in 
6

Figure 6. Comparison of limit velocity for titanium laminates and 

Ti-6A1-4V alloy. 

the VL. This improvement is the same magnitude as the loss in going from semi-infinite 

penetration to finite plate perforation shown in figure 1. 

Each of the targets was sectioned through the penetration channel to observe the integrity of the 

bond between the front and back plate and the degree of spalling produced. Figure 7 shows the 

penetration channel for the best performer, the Ti-6Al-4V/C.P. Ti. Note the absence of a spall 

ring as compared to figure 2 and the absence of any delamination of the layers. Similar 

Figure 7. Typical penetration channel through HIP-bonded Ti-6Al-4V 

laminate. Penetration direction is top to bottom. 
7

observations were made on each of the combinations of materials. Figure 8 shows the diameter 

of the spall ring for each bimetallic laminate material tested. Again, the HIP bonded laminate of 

titanium alloy and C.P. Ti was the best. The maximum diameter of the penetration channel was 

approximately the diameter of the original projectile, nearly eliminating secondary lethality 

effects from spall behind the armor. 

Figure 8. Spall cone diameters for titanium and titanium laminates 

impacted by 20-mm FSPs. 

6. Conclusions 

Laminated titanium armor designs offer enhanced performance of the baseline monolithic Ti6Al-4V alloy and identifies the advantages of using these bimetallic laminates as rear structural 

elements of an armored vehicle. Two joining techniques were investigated. Of the two, HIP 

bonding of Ti-6Al-4V to C.P. Ti had the best combination of ballistic performance and spall 

suppression. HIP bonding is an existing commercially available process with the capability to 

bond sections large enough for combat vehicles. 

Results to date address only one possible combination for the laminate: a biplate with fixed 

thicknesses of each component. Planned future efforts will examine different thickness ratios 

and multiple layer schemes. 

0

10

20

30

40

50

60

Ti-6Al-4V Explo

Bond

Ti64/Al

Explo

Bond

Ti64/Ti

Explo

Bond

Ti64/RHA

HIP

Bond

Ti64/Ti
8

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