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Despite its relevance for law enforcement applications, the design of soft armor has mainly been based on a trial-and-error approach. In this paper, a combined experimental, machine learning, and finite element analysis framework is used to build a predictive numerical model for the analysis and hence, design of soft armor. The material models for major components of the soft armor certification system--bullet, shoot pack, straps, and clay backing, are first constructed using laboratory tests and publicly available data. Next, three metrics, namely, back face signature (BFS), number of penetrated shoot-pack layers, and mushrooming of the bullet are established to gauge the model's accuracy with respect to the laboratory ballistic test data. A machine learning (ML) model is used as a surrogate to predict the BFS and the number of eroded elements. Finally, optimized material model parameters are obtained through ML-based surrogate model and Bayesian optimization algorithm. The final validation of the developed framework is carried out using laboratory ballistic test data involving multiple shots on the shoot pack. The results indicate that reliable predictive data can be obtained using the developed process, and likely, can be extended for use in modeling other impact simulations. [ABSTRACT FROM AUTHOR]

In the present research, glass and basalt fiber-reinforced polypropylene composites' behaviour in quasi-static and dynamic conditions is studied. Composites were fabricated by vacuum assisted Compression molding method. Composites failure under quasi-static tension and compressive conditions was studied along with its failure behaviour under low-velocity impact and super-sonic shock loading under dynamic conditions. The study results showed that basalt fiber-reinforced polypropylene (Basalt/PP) composite's tensile and compressive strength is higher than glass fiber-reinforced polypropylene (Glass/PP). The Basalt/PP showed no penetration against low velocity impact (LVI) with negligible deformations till 50 J. However, the Glass/PP perforated at 50 J with various failure patterns occurring at back side. The fiber-matrix interface adhesion plays an important role in super-sonic shock loading by absorbing shock wave energy due to ductile nature of polypropylene and the two composites absorbed energy via matrix and fibers failure, no brittle failure of laminates occurred under shock loading. [ABSTRACT FROM AUTHOR]

• High hardness steel (HHS) sheet with UHMWPE composite backing were tested against a hardened steel core projectile. • The projectile core was eroded by the HHS sheet and stopped in UHMWPE composite. • It is observed that only a core eroded to a certain length and weight by armor system can be defeated. • In numerical modeling core failure strain was determined from the residual weight of cores. • The numerical model can be used to evolve armor design. Thin high hardness steel sheets can be an alternative to expensive ceramic armor systems designed to defeat hardened core projectiles. A thin high hardness steel sheet backed with UHMWPE fiber-reinforced composite was ballistically tested against a 7.62 × 39 mm hardened steel core projectile in a single-stage gas gun. Thin steel sheets of 530 BHN hardness were adhesively bonded with UHMWPE fiber-reinforced composite to fabricate armor plates. Armor plates were able to defeat the projectile showing considerable potential. Tensile strength of steel sheet and UHMWPE-fiber reinforced ply was also determined. A detailed numerical simulation of the impact event was also performed to understand the phenomenon of defeat and penetration in greater detail. The numerical model was calibrated from the recovered projectile's core after the ballistic test. [ABSTRACT FROM AUTHOR]

Quasi-static tensile test of UHMWPE fiber-reinforced composite laminate is challenging to perform due to low interlaminar shear strength and low coefficient of friction. Tensile tests proposed in the literature were conducted and limitations associated with each method led to the evolution of a new method. Tensile test of single-ply was realized as the best representative of tensile strength of a composite than tensile test of UHMWPE laminate. A fixture was developed for single-ply tests which increased friction and provided the mechanical constraint to slipping. The fixture is easy to fabricate and has provided repeatable results for eight grades of UHMWPE fiber-based (0/90) fabrics. Reported tensile strengths are in quite high range of 900–1500 MPa. • Ballistic composites are quite different from structural composites. • Tensile strength difficult to determine with standard methods. • All available methods tested for efficacy. • A new method is suggested for efficient testing. • Properties of wight commercial grades determined by suggested method. [ABSTRACT FROM AUTHOR]

The dynamic behaviour of the High Strength Low Alloy (HSLA) Steel before and after heat treatment was examined experimentally by performing quasi-static and high strain rate testing at room temperature and cryogenic temperatures. The high strain rate tensile testing of the material was performed on a Split Hopkinson Tensile Bar (SHTB) setup. A customized liquid nitrogen chamber equipped with UTM and SHTB was used to perform the cryogenic temperature testing. The stress–strain response of the material under different loading conditions was recorded and a modified Johnson–Cook material model was derived. It was observed that the flow stress of the material increased when tested at a high strain rate and it further increased at a cryogenic high strain rate loading environment. The microstructure of the material before and after heat treatment was also observed to identify the dominant phase change in microstructure contributing towards improvement in strength after heat treatment. The failure analysis of each category of the samples was examined under the Scanning Electron Microscope (SEM) after the testing. The formation of small and deep dimples for as-received samples and bigger and shallow dimples for heat-treated samples distinguished the type of failure between the quasi-static, high strain rate and cryogenic high strain rate material testing. • High Strength Low Alloy Steel (HSLA) were characterized at Quasi-Static and high strain rate tensile testing at room temperature and cryogenic temperature in both annealed and post heat treated conditions. • The customized Split Hopkinson Tensile Bar equipped with liquid nitrogen chamber and on-board temperature measurement system was developed to perform high strain rate cryogenic testing of HSLA steel. • The fractured surface of annealed and post heat treated samples were examined to understand the underlying effect contributing towards improvement in mechanical properties of the HSLA steel. • The modified Johnson–Cook material model parameters were derived based on the experimental results. The numerical simulations were performed to verify the developed constituent model. [ABSTRACT FROM AUTHOR]

Material systems capable of handling both the ballistic impact and blast waves are necessary for security forces. In this study, the high strain rate performance of monolithic and bonded ultra‐high molecular weight polyethylene (UHMWPE) with high‐temperature resistant basalt/polyetherimide (B/PEI) composite is presented. Individual composite laminates were fabricated using vacuum‐assisted compression molding. Subsequently, cylindrical test coupons were cut using a high‐pressure waterjet. A suitable adhesive grade was used for the bonding of two different composite types. The dynamic compression studies were conducted on a split‐Hopkinson pressure bar (SHPB). For identical incident energies, the range of strain rates attained by monolithic UHMWPE, B/PEI and bonded composites differed significantly. Monolithic UHMWPE achieved the highest rates of loading, whereas higher stresses were recorded for the B/PEI composite. Yet, monolithic UHMWPE, owing to higher constant stress plastic flow, results in higher toughness. Bonded composites revealed hybrid properties with delamination of UHMWPE as the primary failure mode. High‐speed imaging exposed severe deformation of UHMWPE during dynamic compression. SEM micrographs revealed fiber pull‐out and deforming behavior of UHMWPE and brittle failure of B/PEI composite. B/PEI in a bonded composite system never failed under dynamic compression within the experimental range, thus providing a window of opportunity to tailor‐make better ballistic and blast protection materials. [ABSTRACT FROM AUTHOR]

• Vacuum compression moulded Basalt-Polyeteherimide (PEI) composites manufacturing. • Optimization of Basalt-PEI composite manufacturing moulding parameters. • Basalt-PEI composite under quasi-static and dynamic high strain rate loading. • Elastic recovery of Basalt-PEI composite can help in reflecting the blast wave. High temperature blast and ballistic resistant light weight fibre reinforced plastic composites are very much in demand. Accordingly, the present investigation is focused on the quasi-static and high strain rate behaviour of Basalt/Polyetherimide (PEI) composite. Nine different types of composite samples were fabricated by compression moulding. The moulding pressures and temperatures were varied in the range of 15–25 bars and 325 °C−375 °C, respectively. Quasi-static testing was done at the rate of 3 mm/min to establish the optimum moulding parameters. High strain rate compression tests in the strain rate range of 900/s−3200/s were performed on the optimum moulded composite specimens. High strain rate testing revealed that 40 layered Basalt/PEI composite moulded at 25 bar pressure and 350 °C attained highest stress of 932 MPa whereas, the same was found to attain 446 MPa under quasi-static loading conditons. Thus, establishing the rate depedency of Basalt/PEI composite. Damage studies revealed that Basalt/PEI undergoes brittle damage, typically resulting in shear plane angle of 42°−45°. SEM micrographs revealed brittle fibre failure and matrix free fibre bundles, indicating the importance of process parameter optimiation. [ABSTRACT FROM AUTHOR]