A Novel Concept of Lightweight Composite Armor for Ballistic Protection of Tactical Vehicles

We propose to develop a new capability of using lightweight composite hybrid structures for ballistic protection of tactical ground vehicles. The new composite armor concept proposed in this proposal will be developed using the function-oriented material design tool developed at MKP Structural Design Associates, Inc. In the Phase I program, we will: 1) lay out in details the new composite armor concept, especially detailed designs of the three major components; 2) develop the enabling techniques, including design methodologies and manufacturing processing techniques; 3) conduct a feasibility study through virtual prototyping and laboratory tests; 4) fabricate sample prototypes for proof of concept; and 5) develop a Phase II plan for actual physical prototyping and field tests. In the Phase II program, the composite armor prototypes will be developed to achieve a particular performance specification and to meet and/or even exceed the required standard in ballistic testing. The feasibility and effectiveness of the new armor system will be tested and evaluated for mass production and commercialization in the Phase III and thereafter. The proposed composite armor system will have the following features: 1) Ultra-lightweight compared with other existing armor structures; 2) Flexibility to fit various vehicle bodies and contours; 3) Superior impact energy absorption capability due to the the unique design of the armor unit; 4) Superior strength for structural integrity due to the tendon-reinforcements; 5) Capability to resist heat and flame due to the flexibility to select desirable parent materials for the composite; 6) Ease of manufacture, maintenance and repair, and low life-cycle cost due to the fact that armor units can be installed and removed individually; 7) Applicability to other military applications and to commercial vehicle systems.