Development of a New Generation of Composite Ballistic Armor and Related Manufacturing Processes

The proposed work focuses on an improved armor system based on the use of a new and innovative ceramic/metal composite material (ONNEXT) combined with high performance polymer composite backings. The key element in this study is a unique class of tough ceramic-metal composite materials that contain both interconnected metal and a large fraction of boron carbide. The metal phase provides significant toughness and damage tolerance, and the boron carbide provides high hardness and outstanding ballistic performance. These materials are processed by a unique manufacturing method allowing thin and complex shapes to be formed at a reasonable cost. The overall goal of this effort is to develop and demonstrate armor that will defeat current SAPI threats at a mass less than the current areal density specification. Three key variables in the ceramic/metal system will be optimized: ceramic layer thickness and morphology, carbide loading and distribution, and manufacturing parameters. Longer term, the flexible ONNEX system is capable of producing complex shapes to enable new designs for armor systems.