The Resonance Ultrasonic Vibration (RUV) Portable System for Non-Destructive Inspection of Ballistic Armor

This SBIR Phase I proposal aims at the development of a new technology for a non-destructive quality evaluation and service assessment of composite ceramic Body Armor Plates (BAP). Specifically, this technology provides a robust capability to inspect BAPs at a unit level. This ensures that BAPs are functional, contain no cracks or delamination and are serviceable for use in the field. This capability is acknowledged as critically needed to support inspection and recertification of composite ceramic BAPs used by military personnel for personal protection.  The proposed technical solution is based on innovative Resonance Ultrasonic Vibration (RUV) technology capable of non-destructive inspection of mechanical quality and structural integrity of composite ceramic armor plates. Intended application of the technology is for BAPs used by U.S. military both in the field and stocked in storage at USMC units. RUV technology allows detection of both cracks in ceramic face-plate and delamination (de-bonding) of plate components, which compromises BAP’s integrity and reduces its overall performance. The RUV Ballistic Armor Measurement system (RUV-BAM) will be a portable unit to allow relocation of the tool between test sites. Following feasibility testing, RUV-BAM system prototype will be designed, manufactured, and tested within this SBIR Phase I project. Initial experiments on ESAPI plates were performed using internal company investment and customer funding, which will serve as a baseline for RUV-BAM tool. RUV method is described as follows: ultrasonic vibrations are generated in a standard size BAP using an external piezoelectric transducer spring loaded to front side of the plate. The transducer creates resonance vibration modes in the plate at specific resonance frequencies, which can be analyzed with a broadband ultrasonic probe. The probe is spring loaded and touches the plate periphery at a predetermined location. Using a frequency sweep through a selected resonance mode, a computer-controlled RUV system acquires accurate measurements of the amplitude, peak frequency, and bandwidth of the resonance curve. Specific objectives for Phase I include: (1) Perform feasibility test on cracked and delaminated plates; (2) Design, manufacture and assemble operational RUV-BAM prototype, and (3) Perform RUV-BAM prototype functional testing, verification, and qualification to ensure its performance matches production grade RUV system and specifications of weight, throughput, mobility, sensitivity, and accuracy of crack/delamination inspection.