Ballistic Performance Testing of Aluminum Alloy 5059-H131 

and 5059-H136 for Armor Applications 

by Dwight D. Showalter, Brian E. Placzankis, and Matthew S. Burkins 

ARL-TR-4427 May 2007 

Approved for public release; distribution is unlimited. 
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Army Research Laboratory 

Aberdeen Proving Ground, MD 21005-5066 

ARL-TR-4427 May 2008 

Ballistic Performance Testing of Aluminum Alloy 5059-H131 

and 5059-H136 for Armor Applications

Dwight D. Showalter, Brian E. Placzankis, and Matthew S. Burkins 

Weapons and Materials Research Directorate, ARL 

Approved for public release; distribution is unlimited. 
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4. TITLE AND SUBTITLE

Ballistic Performance Testing of Aluminum Alloy 5059-H131 and 5059-H136 for Armor 

Applications 

5c. PROGRAM ELEMENT NUMBER 

5d. PROJECT NUMBER 

622618H8099 

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6. AUTHOR(S) 

Dwight D. Showalter, Brian E. Placzankis, and Matthew S. Burkins 

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U.S. Army Research Laboratory 

Weapons and Materials Research Directorate 

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13. SUPPLEMENTARY NOTES 

14. ABSTRACT 

The U.S. Army Research Laboratory (ARL) was tasked to investigate the ballistic performance of aluminum alloy (AA) 5059 to determine if 

it was a desirable alternate alloy for use as vehicle armor. Current alloys, such as AA5083 and AA7039, have high yield and tensile strengths 

and provide increased ballistic protection but have significantly less corrosion resistance than AA5059. AA5059 generally provides greater 

ballistic protection levels than AA5083 but did not match the levels of AA7039. However, it does contain some of the desirable characteristics 

of the lower strength AA5083, mainly superior corrosion resistance. The combination of increased strength and corrosion resistance makes 

AA5059 an ideal choice for consideration as an alternate aluminum armor. 

15. SUBJECT TERMS

aluminum, armor, armor piercing, FSP, 5059 

16. SECURITY CLASSIFICATION OF:

19a. NAME OF RESPONSIBLE PERSON

Dwight D. Showalter 

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(410) 278-7308 

Standard Form 298 (Rev. 8/98) 

Prescribed by ANSI Std. Z39.18 
Table of Contents 

List of Figures iv

List of Tables iv

1. Introduction 1

2. Experimental Procedure 3

3. Test Projectiles 3

4. Results and Discussion 6

5. Summary 14

6. Conclusions 15

References 16

Acronyms 17

Distribution List 18 

iii 
iv 

List of Figures 

Figure 1. The 0.30 cal AP M2.........................................................................................................4 

Figure 2. The 0.50 cal AP M2.........................................................................................................5 

Figure 3. A generic sketch of the FSP adapted from MIL-DTL-46593B.......................................5 

Figure 4. The 0.30 cal AP M2 versus AA5059 at a 30° obliquity..................................................7 

Figure 5. The 0.50 cal FSP versus 5059AA at a 0° obliquity.........................................................8 

Figure 6. The 20 mm FSP versus AA5059 at a 0° obliquity. .......................................................10 

Figure 7. The 0.30 cal AP versus AA5059 at a 0° obliquity ........................................................11 

Figure 8. The 0.50 cal AP versus AA5059 at a 0° obliquity. .......................................................13 

Figure 9. Comparison of (a) AA7039, (b) AA5083, and (c) AA5059..........................................14 

List of Tables 

Table 1. Chemical composition requirements for qualified military specification aluminum 

armor alloys (%). .......................................................................................................................2 

Table 2. Minimum mechanical requirements for military specification aluminum armor 

alloys..........................................................................................................................................2 

Table 3. Projectile and obliquity requirements for ordered thicknesses.........................................4 

Table 4. AA5059 versus 0.30 cal AP M2 at 30°.............................................................................6 

Table 5. AA5059 versus 0.50 cal FSP at 0°....................................................................................8 

Table 6. AA5059 versus 20 mm FSP at 0°. ....................................................................................9 

Table 7. AA5059 versus 0.30 cal AP M2 at 0°.............................................................................11 

Table 8. AA5059 versus 0.50 cal AP M2 at 0°.............................................................................12 
1. Introduction 

Current and future U.S. Army and U.S. Marine Corps (USMC) vehicle deployments require 

lightweight armor designs with improved survivability to maintain mission performance. 

Historically, Aluminum Alloy (AA) 5083-H131 has been used in systems such as the M1113, the 

M109, and the USMC Amphibious Assault Vehicle (AAV), in accordance with specification 

MIL-DTL-46027J (1). This alloy is preferable because of its lighter weight, ease of weldability 

for manufacturing purposes, level of performance against fragmentation based threats, and 

excellent corrosion resistance. 

With the advent of more lethal threats, recently designed aluminum armor based systems, such as 

the M2 Bradley Fighting Vehicle and the USMC Expeditionary Force Vehicle (EFV), have 

incorporated higher strength AAs, such as AA7039 (2), AA2219 (3) and AA2519 (4). These 

alloys provide increased ballistic protection against armor piercing (AP) threats due to their 

higher strength. The characteristically higher yield and tensile strengths are very desirable for 

hull designs as they allow for reduced weight. However, these alloys have significantly less 

corrosion resistance than AA5083-H131. This is due to stress corrosion cracking in AA7039 and 

from pitting and exfoliation in AA2519 (5). Irrespective of cause, the lack of corrosion 

resistance has serious detrimental implications for maintenance requirements and the ease of 

coating applications. These deficiencies can also have environmental consequences due to the 

need for mitigating hexavalent chromium based protection schemes. 

AA5083-H131 has many of the desirable traits discussed above, but the lower strength results in 

reduced survivability against robust AP threats. An alternate AA that delivered the positive 

characteristics of AA5083-H131 along with increased strength and mechanical properties for 

improved performance against AP threats would be an ideal future material for new vehicle 

production and repair of new and existing aluminum based systems. 

A possible solution to fill this role is AA5059-H131. This alloy is a magnesium (Mg) based non 

heat treatable alloy that is strengthened by mechanical strain hardening and is produced in 

Koblenz, Germany, by Aleris International, Inc. (6). This strain hardening process results in the 

5000 series alloy receiving the “H” designation rather than the “T” designation that is typical for 

heat treatable alloys. AA5059 contains greater amounts of Mg than AA5083 as well as some 

additional zinc (Zn) and zirconium (Zr) for grain refinement. Composition and mechanical 

properties for AA5083, AA5089, and other military specification armors are listed for 

comparison in tables 1 and 2, respectively. 

1 
Table 1. Chemical composition requirements for qualified military specification aluminum armor alloys (%). 

Element 5083 5456 5059 7039 2219 2519

Silicon 0.40 max 0.25 max 0.50 max 0.30 max 0.20 max 0.25 max

Iron 0.40 max 0.40 max 0.50 max 0.40 max 0.30 max 0.30 max

Copper 0.10 max 0.10 max 0.40 max 0.10 max 5.8 - 6.8 5.3 - 6.4

Manganese 0.4 - 1.0 0.5 - 1.0 0.60 - 1.2 0.10 - 0.40 0.20 - 0.40 0.10 - 0.50

Magnesium 4.0 - 4.9 4.7 - 5.5 5.0 - 6.0 2.3 - 3.3 0.02 max 0.05 - 0.40

Chromium 0.05 - 0.25 0.05 - 0.20 0.30 max 0.15 - 0.25 - - 

Zinc 0.25 max 0.25 max 0.40 - 1.5 3.5 - 4.5 0.10 max 0.10 max

Titanium 0.15 max 0.20 max 0.20 max 0.10 max 0.02 - 0.10 0.02 - 0.10

Zirconium - - 0.05 - 0.25 - 0.10 - 0.25 0.10 - 0.25

Vanadium - - - - 0.05 - 0.15 0.05 - 0.15

Others (each) 0.05 max 0.05 max 0.05 max 0.05 max 0.05 max 0.05 max

Others (max) 0.15 max 0.15 max 0.15 max 0.15 max 0.15 max 0.15 max

Aluminum Remainder Remainder Remainder Remainder Remainder Remainder

Table 2. Minimum mechanical requirements for military specification aluminum armor alloys. 

Property 5083 5456 5059 7039 2219 2519

Yield Stress (ksi) 

(0.2% offset min.) 35.0 35.0 44.0 51.0 46 58.0

Ultimate Stress (ksi) 45.0 45.0 57.0 60.0 62.0 68.0

Percent Elongation 888977

Marine grade tempers of 5059, such as H116 and H321, have been commercially available for 

quite some time on yachts, ferries, and catamarans, but little information is known on the H131 

temper applicable for use in armor plate. AA5059-H136 was also investigated to a lesser degree 

and the results will be discussed briefly in this report. The H136 designation indicates that 

during the production process, the plate was only stretched and not cold rolled. This resulted in a 

lower cost, more ductile version that may provide some benefit as structural material supporting 

ceramic tiles. 

In 2004, a Foreign Comparative Test (FCT) proposal was submitted to the Office of the 

Secretary of Defense (OSD) to investigate the possibility of using AA5059-H131 as an armor 

repair material for use on battle damaged or cracked armor plate sections on M2 Bradley 

Fighting Vehicle hulls. The project received initial approval but went unfunded for fiscal year 

(FY) 2005. It was eventually funded for FY 2006. Project goals included verifying ballistic 

performance (7), blast resistance, weldability, corrosion due to sensitization, general corrosion, 

and Chemical Agent Resistant Coatings (CARC) compatibility, with an ultimate goal to update 

or create a military specification to include this alloy if proven successful. 

2 
For the ballistic performance evaluation, V50 testing is currently required for all existing 

aluminum armor alloys. This testing produced corresponding minimum V50 acceptance 

standards for alloys AA5083 and AA7039. The results of the ballistic testing of the AA5059 

alloy and its comparison to the ballistic acceptance standards of the AA5083, due to its increased 

corrosion resistance, will be the main focus of this report. The acceptance standards for the 

higher strength AA7039 will also be used for some ballistic comparison as well, but the AA5083 

will remain the baseline. 

2. Experimental Procedure 

The main experimental procedure required to compare the AA5059-H131 to the existing 

specifications was to obtain the V50 ballistic limit for each thickness of aluminum plate against 

the corresponding specified threat. For this investigation, the AA5083 specification was used for 

testing of AA5059-H131. The test methodology is described in detail in MIL-STD-662 (8) 

specification. The V50 is the velocity at which an equal number of impact complete penetration 

(target is defeated) and partial penetration (target is not defeated) velocities are attained using the 

up-and-down firing method. Fair impact is defined as occurring when a projectile or fragment 

simulator with an acceptable yaw strikes the target at a distance of at least two projectile 

diameters from a previously damaged impact area or edge of plate. A complete penetration is 

determined by placing a 0.020 in. 2024 T3 aluminum witness plate 6 in. behind and parallel to 

the target. If any penetrator or target fragment strikes this witness plate with sufficient energy to 

create a hole through which light passes, it is considered a complete penetration. A partial 

penetration is any impact that is not a complete penetration. For the AA5083 specification, it is 

required that four velocities, resulting in two complete penetrations (CPs) and two partial 

penetrations (PPs), be obtained within a velocity spread of 60 ft/s. Alternately, the specification 

can be met if six velocities, three CPs and three PPs, are obtained within a velocity spread of 

90 ft/s. The average velocities are then computed to determine the V50 ballistic limit. This V50

ballistic limit can then be compared to the corresponding ballistic limits for other alloys to 

determine the relative performance. 

3. Test Projectiles 

The AA5059 samples ranged in nominal thickness from 0.500 up to 3.00 in. The corresponding 

test projectiles and plate obliquities required for each thickness are listed in table 3.

3 
4 

Table 3. Projectile and obliquity requirements for ordered thicknesses. 

Ordered Thickness 

(in.) Projectile Angle of Obliquity (°) 

0.500–0.749 0.30 cal AP 30 

0.750–1.000 0.50 cal FSP 0 

1.001– 1.700a 20 mm FSP 0 

1.001–2.000 a 0.30 cal AP M2 0 

2.001–3.000 0.50 cal AP M2 0 

Note: Cal = caliber and FSP = Fragment simulating projectile. 

a

Two types of projectiles are required for the thickness range of 1.001 to 1.700 in. 

The 0.30 cal AP M2 steel core weighs 5.2 g and with the copper jacket and lead filler, the total 

projectile weight is 10.6 g. The total length of the projectile is 35.6 mm (1.4 in.). This projectile 

is shown in figure 1. 

 

Figure 1. The 0.30 cal AP M2. 

The 0.50 cal AP M2 also has a steel core along with a copper jacket and lead filler. The steel 

core weighs 25.4 g while the total weight is 44.9 g. The total length is 57.5 mm (2.26 in.). 

Figure 2 shows this projectile in detail. 
57.5mm 

12.9mm 

Figure 2. The 0.50 cal AP M2. 

FSPs are a family of similarly shaped projectiles that are used to simulate artillery fragments. 

The 0.50 cal FSP, weighing 13.4 g, and the 20 mm FSP, weighing 53.8 g, are required for testing 

some thicknesses of aluminum according to MIL-DTL-46027. A generic sketch of the FSPs was 

adapted from MIL-DTL-46593B and provided as figure 3. 

35o

d 

1.17d

Steel, 

.46d Rc 29-31 

 0.50 Caliber 207 grains (13.4 g) 

 20mm 830 grains (53.8 g) 

Figure 3. A generic sketch of the FSP adapted from MIL-DTL-46593B. 

5 
4. Results and Discussion 

As previously discussed, for this investigation, the AA5083 specification (MIL-DTL-46027J) 

was used to determine the V50 testing requirements for the AA5509 plates. The thinnest of these 

plates (approximately 0.500 to about 0.750 in.) were tested against the 0.30 cal AP M2 at a 30° 

obliquity. The results are shown in table 4. 

Table 4. AA5059 versus 0.30 cal AP M2 at 30°. 

Temper Heat Number Thickness 

(in.) BHN Projectile 

Angle of 

Obliquity 

(°) 

V50

(ft/s) 

Standard 

Deviation 

(ft/s) 

H131 211029-1A2 0.505 118 0.30 AP M2 30 1428 29 

H131 162418 0.522 121 0.30 AP M2 30 1481 10 

H131 966377-1-15 0.529 116 0.30 AP M2 30 1475 21 

H131 975418 0.588 121 0.30 AP M2 30 1606 18 

H131 966378-1-5 0.742 121 0.30 AP M2 30 1834 22 

H131 211030-2A1 0.779 118 0.30 AP M2 30 1922 21 

H131 157241 0.782 124 0.30 AP M2 30 1915 22 

H136 186064-1A2 0.488 107 0.30 AP M2 30 1380 22 

H136 186063 0.751 112 0.30 AP M2 30 1822 11 

Note: BHN = Brinell Hardness Number 

The temper number for this table and all subsequent ones indicates how the material was 

produced. H131 indicates that during the production process, the material was strengthened by 

mechanical strain hardening. Temper number H136 indicates that the material was only 

stretched, and not cold rolled. These data are plotted in figure 4. 

6 
1300

1400

1500

1600

1700

1800

1900

2000

0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80

AA5059 - H131

2nd order fit - H131

2 sigma curve - H131

AA5059 - H136

MIL-DTL-46063

MIL-DTL-46027J

MIL-DTL-46027

THICKNESS (inches)

V50 LIMIT VELOCITY (ft/s)

Figure 4. The 0.30 cal AP M2 versus AA5059 at a 30° obliquity. 

Figure 4 plots the V50 versus the plate thickness for each plate and temper tested, as well as the 

military specification requirements for AA5083 (MIL-DTL-46027J) and AA7039 (MIL-DTL46063). The 2 sigma curve (V50 – 2 standard deviations) is also plotted for AA5059-H131. This 

2 sigma curve is required to account for the fact that the V50 only provides the velocity at which 

the armor defeats the penetrator 50% of the time. Subtracting the 2 standard deviations from the 

V50 velocity provides a velocity at which, statistically, the armor will defeat the penetrator about 

98% of the time. Therefore, the actual curve that is used to compare to the specification 

requirements is the 2 sigma curve. 

Using the 2 sigma curve that is depicted by the black dashed line, it can be determined that the 

V50 ballistic limit velocities for this range of thicknesses (0.488 to 0.782 in.) against the 0.30 cal 

AP M2 at 30° seem to lie almost exactly at the midpoint between the V50 limit velocities for the 

AA7039 and AA5083 minimum requirement. This indicates the material provides increased 

ballistic performance over the AA5083, but lower performance as compared to AA7039. 

However, the AA5083 (due to its increased corrosion resistance) is the baseline for comparison. 

For all thicknesses tested, the AA5059 provided increased ballistic performance over the 

AA5083 minimum requirement. 

7 
The MIL-DTL-46027J specification required plates with nominal gauge thicknesses from about 

0.750 to approximately 1.000 in. to be tested against the 0.50 cal FSP at a 0° obliquity. Table 5 

lists these results and the data from table 5 are depicted graphically in figure 5 

Table 5. AA5059 versus 0.50 cal FSP at 0°. 

Temper Heat 

Number 

Thickness 

(in.) BHN Projectile 

Angle of 

Obliquity 

(°) 

V50

(ft/s) 

Standard 

Deviation 

(ft/s) 

H131 966378-1-5 0.742 121 0.50 cal FSP 0 1830 33 

H131 211030-2A1 0.780 118 0.50 cal FSP 0 2070 32 

H131 157241 0.782 124 0.50 cal FSP 0 1991 8 

H131 966379-1-24 0.793 121 0.50 cal FSP 0 1990 16 

H131 799479-9 0.804 126 0.50 cal FSP 0 2126 24 

H131 966381-1-22 0.847 121 0.50 cal FSP 0 2267 16 

H131 966381-1-8 0.928 121 0.50 cal FSP 0 2534 31 

H131 966384-1-5 0.990 121 0.50 cal FSP 0 2810 16 

H131 211058 1.001 126 0.50 cal FSP 0 2978 22 

H131 162331 1.035 126 0.50 cal FSP 0 3202 31 

H136 186063 0.751 112 0.50 cal FSP 0 1834 24 

H136 185919-1B1 1.006 109 0.50 cal FSP 0 2848 31 

1700

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

3100

3200

3300

0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05

AA5059 - H131

2nd order fit - H131

2 sigma curve - H131

AA5059 - H136

MIL-DTL-46063

MIL-DTL-46027J

MIL-DTL-46027

THICKNESS (inches)

V50 LIMIT VELOCITY (ft/s)

Figure 5. The 0.50 cal FSP versus 5059AA at a 0° obliquity. 

8 
From this data, it can be seen that for each thickness plate tested, the AAA5059-H131 (black 

dashed line) provided increased ballistic protection in comparison to the AA5083 requirement 

and actually, at a thickness of 0.742 in., provided slightly increased protection as compared to 

the AA7039 requirement. Additionally, the H136 temper provided greater ballistic protection 

than the AA5083 at all thicknesses, though it did not outperform the AA5083-H131. 

Plates with thicknesses of approximately 1.0 up to about 1.8 in. were tested against both the 

20 mm FSP at 0° and the 0.30 cal AP M2 at 0°. Table 6 lists the results against the 20 mm FSP. 

These data are plotted versus the AA5083 and AA7039 specifications in figure 6. 

Table 6. AA5059 versus 20 mm FSP at 0°. 

Temper Heat 

Number 

Thickness 

(in.) BHN Projectile 

Angle of 

Obliquity

(°) 

V50

(ft/s) 

Standard 

Deviation 

(ft/s) 

H131 966384-1-15 0.990 118 20 mm FSP 0 1375 20 

H131 966384-1-5 0.990a 121 20 mm FSP 0 1396 28 

H131 7994890 1.003 a 116 20 mm FSP 0 1496 29 

H131 211058 1.001 126 20 mm FSP 0 1469 31 

H131 162331 1.035 126 20 mm FSP 0 1544 22 

H131 799480 1.197 116 20 mm FSP 0 1900 23 

H131 966383-1-10 1.364 114 20 mm FSP 0 2231 20 

H131 975421-1D3 1.491 116 20 mm FSP 0 2628 26 

H131 162335 1.531 121 20 mm FSP 0 2784 21 

H131 966388 1.881 107 20 mm FSP 0 3976 13 

H136 185919 1.006 109 20 mm FSP 0 1420 17 

H136 186092 1.522 107 20 mm FSP 0 2555 29 

H136 185932-1-2 2.005 105 20 mm FSP 0 4076 23 a

Repeat shots 

9 
1000

1500

2000

2500

3000

3500

4000

4500

0.75 1.00 1.25 1.50 1.75 2.00 2.25

AA5059 - H131

2nd order fit - H131

2 sigma curve H131

AA5059 - H136

MIL-DTL-46063

MIL-DTL-46027J

MIL-DTL-46027

THICKNESS (inches)

V50 LIMIT VELOCITY (ft/s)

Figure 6. The 20 mm FSP versus AA5059 at a 0° obliquity. 

The H131 temper, depicted by the black dashed line, provided increased ballistic protection 

compared to the AA5083 at all thickness above 1.00 in. However, at thickness of approximately 

1.00 in. (0.990–1.035 in.), the data shows some points where the ballistic protection, determined 

experimentally for AA5059-H131, falls below the performance provided by the AA5083. 

Because of this, some repeat tests were conducted at thickness around 1.00 in., which showed a 

slightly better performance that exceeded the AA5083 levels. At thickness ranging from 1.00 up 

to about 1.25 in., the H131 temper actually outperformed the AA7039 specification as well. The 

H136 temper provides a slight increase ballistic performance over the AA5083 specification at 

thicknesses greater than 1.25 in., but not at thicknesses less than 1.25 in. The AA7039 actually 

provides slightly less ballistic protection than the AA5083 at thickness below about 1.20 in., 

which is depicted graphically in figure 6. For the range of thicknesses from about 1.00 to 1.2 in., 

the H136 temper actually performed better ballistically that the AA7039 specification. 

The specification also called for these plate thicknesses to be tested against the 0.30 cal AP M2 

at 0°. The results for this threat are shown in table 7 and are shown graphically in figure 7. 

10 
Table 7. AA5059 versus 0.30 cal AP M2 at 0°. 

Temper Heat 

Number 

Thickness 

(in.) BHN Projectile 

Angle of 

Obliquity 

(

o

) 

V50

(ft/s) 

Standard 

Deviation 

 (ft/s) 

H131 966384-1-15 0.990 118 0.30 AP M2 0 1928 21 

H131 211058 1.001 126 0.30 AP M2 0 1935 34 

H131 162331 1.035 126 0.30 AP M2 0 2000 14 

H131 799480 1.197 116 0.30 AP M2 0 2168 26 

H131 966386-1-10 1.364 114 0.30 AP M2 0 2310 27 

H131 975421-1D3 1.492 116 0.30 AP M2 0 2502 28 

H131 162335 1.531 121 0.30 AP M2 0 2536 16 

H131 966388 1.881 107 0.30 AP M2 0 2818 20 

H131 211054 2.016 126 0.30 AP M2 0 2974 31 

H131 186497 2.022 121 0.30 AP M2 0 2992 21 

H136 185919-1B1 1.006 109 0.30 AP M2 0 1914 21 

H136 186092 1.522 107 0.30 AP M2 0 2422 26 

H136 185932 2.009 105 0.30 AP M2 0 2865 25 

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

0.75 1.00 1.25 1.50 1.75 2.00 2.25

AA5059 - H131

2nd order fit - H131

2 sigma curve - H131

AA5059 - H136

MIL-DTL-46063

MIL-DTL-46027J

MIL-DTL-46027

THICKNESS (inches)

V50 LIMIT VELOCITY (ft/s)

Figure 7. The 0.30 cal AP versus AA5059 at a 0° obliquity 

11 
For the .30 cal AP at 0°, the AA5059 alloy provided greater ballistic protection than the AA5083 

specification for all nominal thicknesses from 1.00 to 2.00 in., while falling short of the 

protection levels for AA7039. The H136 slightly exceeded the performance of the AA5083 

specification for thickness up to around 1.35 in., while providing essentially equal performance 

for thicker gauges. 

The thickest gauge plates (about 1.8 to 3.0 in.) were required by the specification to be tested 

against the 0.50 cal AP M2 round. The results for these tests are shown in table 8. This data is 

graphically represented against the other alloys in figure 8. 

Table 8. AA5059 versus 0.50 cal AP M2 at 0°. 

Temper Heat 

Number 

Thickness 

(in.) BHN Projectile 

Angle of 

Obliquity 

(

o

) 

V50

(ft/s) 

Standard 

Deviation 

 (ft/s) 

H131 966388 1.881 107 0.50 AP M2 0 2167 36 

H131 211054 2.016 126 0.50 AP M2 0 2230 15 

H131 186497 2.022 121 0.50 AP M2 0 2199 21 

H131 975423 2.427 121 0.50 AP M2 0 2481 25 

H131 186116 2.527 114 0.50 AP M2 0 2472 37 

H131 245382-1B1 2.539 114 0.50 AP M2 0 2522 19 

H131 966390-9 3.006 99 0.50 AP M2 0 2736 23 

H131 170077 3.014 105 0.50 AP M2 0 2689 31 

H136 185932 2.009 105 0.50 AP M2 0 2123 11 

H136 185996-1A2 2.530 103 0.50 AP M2 0 2436 24 

H136 185980-1H1 3.036 109 0.50 AP M2 0 2724 10 

12 
2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

1.75 2.00 2.25 2.50 2.75 3.00 3.25

AA5059 - H131

2nd order fit - H131

2 sigma curve - H131

AA5059 - H136

MIL-DTL-46063

MIL-DTL-46027J

MIL-DTL-46027

THICKNESS (inches)

V50 LIMIT VELOCITY (ft/s)

Figure 8. The 0.50 cal AP versus AA5059 at a 0° obliquity. 

For the 0.50 cal AP at 0°, it can be seen that the AA5059-H131 provided increased ballistic 

protection relative to AA5083 for thickness from about 1.8 up through 2.5 in. However, at 

thicknesses of approximately 3.00 in., the protection levels were about equal or slightly less than 

AA5083. The protection was significantly less than the levels provided by AA7039 for all 

thicknesses. As for the H136 temper, the protection provided was approximately equal to 

AA5083 for all thickness while substantially less than AA7039. 

It is necessary to say a few words about the failure modes of the various alloys with respect to 

FSPs. Figure 9 shows some interesting comparisons of the response of the three alloys 

investigated in this study. Figure 9a shows the response of AA7039 to a 20 mm FSP while 

figures 9b and 9c show the response of AA5083 and AA5089, respectively, to the same threat for 

equal thickness plates at approximately the same velocity. 

13 
 

 (a) (b) (c) 

Figure 9. Comparison of (a) AA7039, (b) AA5083, and (c) AA5059. 

The AA7039 (figure 9a) exhibits severe spalling, where large portions of the material have torn 

away from the exit hole and present a serious problem with respect to behind armor debris 

damage. The AA5083 in figure 9b shows the more ductile plugging effect where the material 

bulges with the FSP and there are no large chucks of metal breaking off to cause more damage 

behind the armor. Figure 9c shows the ductile behavior and plugging effects of the AA5059, 

which is very similar to the AA5083. This ductile behavior is an extremely desirable 

characteristic for armor materials to be incorporated in vehicle design, especially as a base armor 

to absorb shock and to support other armor materials. 

5. Summary 

AA5059 generally provides greater ballistic protection levels, based on the V50 limit velocity and 

2 sigma curve criteria, than the AA5083 specification. This holds true for almost every thickness 

against FSPs and AP rounds. In most cases, the ballistic protection levels do not match that of 

the higher strength AA7039 specification; however, AA5059, while providing an increased level 

of ballistic protection due to its higher strength, also has some of the very desirable 

characteristics of the lower strength AA5083 that are not present in AA7039. The main such 

trait is the vastly superior corrosion resistance of AA5059 as compared to AA7039, which is an 

invaluable quality in terms of maintenance and repair of existing systems. AA5059-H131 also 

exhibits the increased ductility in failure mode against FSP threats that is not present in the 

AA7039, which is also extremely beneficial in terms of overall performance. 

14 
6. Conclusions 

AA5083-H131 has many desirable traits, but is deficient against AP threats compared to 

AA7039 alloys due to its lower strength. AA5059 provides increased mechanical properties, 

most notably higher strength and thus increased ballistic performance against AP threats, while 

also having the positive corrosion resistance characteristics not present in AA7039. This 

combination of increased ballistic protection along with superior corrosion resistance makes 

AA5059 an ideal choice for consideration as an alternate aluminum armor for production and 

repair of existing systems. 

The performance of AA5059 in this study resulted in the preparation of a new military 

specification to include this alloy, MIL-DTL-46027K (9). It was rewritten from the 5083/5456 

MIL-DTL-46027J specification to cover three classes of 5000 series alloys: Class 1 (5083), 

Class 2 (5456), and Class 3 (5059). Under this revised format, additional 5000 series alloys can 

be added in the future. 

15 
16 

References 

1. Armor Plate, Aluminum Alloy, Weldable 5083 and 5456; MIL-DTL-46027J; U.S. 

Department of Defense: Washington DC, August 1992. 

2. Armor Plate, Aluminum Alloy, 7039; MIL-DTL-46063H; U.S. Department of Defense: 

Washington DC, December 1992. 

3. Aluminum Alloy Armor, 2219, Rolled Plate and Die Forged Shapes; MIL-DTL-46118E; 

U.S. Department of Defense: Washington DC, August 1998. 

4. Aluminum Alloy Armor Rolled Plate (1/2 to 4 Inches Thick), Weldable (Alloy 2519); MILDTL-46118E; U.S. Department of Defense: Washington DC, February 2000. 

5. Placzankis, B.; Hilgeman, A. Performance Assessment of CARC Coated Aluminum Alloy 

5059-H131 Using ASTM B 117 Neutral Salt Fog, GM 9540P, and ASTM D 4541 Pull-Off 

Adhesion for Three Different Pretreatment Methods, 2007 Tri-Service Corrosion 

Conference, Denver, CO, December 2007. 

6. Aleris International, Inc., 25825 Science Park Drive, Suite 400, Beachwood, OH, 44122-

7392. 

7. Gooch, W.; Burkins, M.; Squillacioti, R. Ballistic Testing of Commercial Aluminum Alloys 

and Alternate Processing Techniques to Increase the Availability of Aluminum Armor, 

Proceedings from the 23rd International Symposium on Ballistics, Tarragona, Spain, April 

16–22, 2007. 

8. V50 Ballistic Test for Armor; MIL-STD-662F; U.S. Department of Defense: Washington 

DC, 18 Dec 1997. 

9. Armor Plate, Aluminum Alloy, Weldable 5083, 5456, and 5059; MIL-DTL-46027K; U.S. 

Department of Defense: Washington DC, 31 July 2007. 
Acronyms 

AA Aluminum Alloy 

AAV Amphibious Assault Vehicle 

AP armor piercing 

BHN Brinell Hardness Number 

CARC Chemical Agent Resistant Coatings 

CPs complete penetrations 

EFV Expeditionary Force Vehicle 

FCT Foreign Comparative Test 

FSPs Fragment simulating projectiles 

FY fiscal year 

OSD Office of the Secretary of Defense 

PPs partial penetrations 

USMC U.S. Marine Corps 

Zn zinc 

Zr zirconium 

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