Protection of armored vehicles (5 final part)
Iveco MPV uses the latest IBD Deisenroth protection solutions, mainly based on nanotechnology.
Passive armor: the last barrier
Shells of armored vehicles are still made of steel, to which bolts are bolted complementary booking. However, the more a basic design can provide regarding ballistic and explosive protection, the higher the final level of protection will be. In addition, even with the installation of active protection systems that destroy the attacking projectiles while approaching, the resulting high-energy fragments can cause serious damage to the vehicle, which again requires good basic protection.
The Swedish company SSAB is one of the recognized experts in the field of materials for booking, its family of armor steel Armox is well known all over the world. The family includes six different types, the number in the designation of the steel grade shows the average Brinell hardness. While hardness directly affects ballistic protection, toughness is needed to ensure the absorption of blast wave energy — two characteristics that, in fact, cannot exist together. The ability to form reinforces this contradiction, since high-strength steels are usually less formable and often have problems with weldability.
Over time, the ballistic characteristics of SSAB steels gradually increased: in 1990, Armox 500T steel with a thickness of 9 mm was needed to stop the M193 / SS92 projectile flying at a speed of 937 m / s, but ten years later with the Armox 600T alloy, all 6 was needed to stop mm Another ten years and 4,5-mm Armox Advance does the same, although the number is not worth it, because the hardness is beyond the Brinell scale! From the initial 70,7 kg / m2, for ten years SSAB has managed to reduce the weight to 47,1 kg / m2, and in the next decade up to 35,3 kg / m2. According to SSAB experts, no further significant decrease is expected, the real figure for 2020 year is 30 kg / m2. The company's R & D department is more likely working more to improve the toughness and formability of the material available than its hardness, especially since the current explosion is the main threat. Its Armox 440T steel with a Brinell hardness of 420-480 HB is nicknamed the preferred “energy eater”, and its viscosity makes it easy to get any shape, such as a solid bottom of the case. Even the harder Armox 500T steel, with a hardness of 480-540 HB, is considered to be a blast protection material.
As mentioned above, the main characteristics of Armox Advanced are hardness, therefore this steel is considered by SSAB as a ceramic in fact. Therefore, the company strongly advises not to mold and not weld it, as for proper preservation of hardness it should not be heated above 100 ° C. How to achieve similar levels of protection and mass in the future with more formable materials is a very difficult task today.
Among the new armor steels, of course, Super Bainite, introduced in the fall of 2011, should be noted. Developed by the British Laboratory for Defense Science and Technology DSTL, the new steel is manufactured at the Tata Steel UK plant. It shows much better performance than standard armor steel. These characteristics are not only a consequence of the chemical composition, but also the manufacturing process, in particular the heat treatment with air cooling and molten salts. The final product has ballistic characteristics twice as high as that of rolled homogeneous armor.
South African company Aardvark Perroc makes extensive use of SSAB Armox 500 steel in its products. This demonstrates that even this steel with high hardness can absorb a large amount of energy.
SSAB manufactures complex-shaped elements from its Armox 440T steel, often referred to as an “energy eater”. It is very well suited for structures exposed to IEDs. SSAB is currently working to make its armor more moldable.
The use of IBD FlexiComp podboev allows you to make volumetric elements of protection, reducing the number of weak points in the overall protection system
Diagram of characteristics of IBD podcoil depending on temperature. The effect of high temperatures is a serious problem when deploying machines in areas with hot climates.
In December, 2012, Lockheed Martin UK and the University of Surrey, announced a new, simpler method to improve the protection and survivability of armored vehicles. Scientists have developed a method of processing ceramic materials to improve the adhesion strength of alumina ceramics and ceramics on silicon carbide with a composite substrate, which significantly increases the strength of armor. Attaching ceramic plates to their substrate has always been the Achilles' heel of this technology. The results showed that the new technique allows to increase the adhesion forces. Tests have shown that when the 14,5-mm armor-piercing incendiary bullet is fired at the armor plate, it remains unbroken.
Technological development remains the core business of IBD Deisenroth Engineering, while the production of passive solutions is currently given to Rheinmetall Chempro, whose 51% stake is owned by Rheinmetall Defense and 49% of the Deisenroth family.
When Dr. Ulf Deisenroth developed the fourth generation technology for various types of materials, they were designed to reduce weight while maintaining the level of protection or, conversely, increasing the level of protection for this mass, while new technologies promise savings in excess of 40%. They are based on the latest breakthroughs in the field of passive protection associated with nanomaterials, which include nanocrystalline ceramics, nanometric steel and high-strength fibers. In cooperation with steel manufacturers, IBD has developed high-strength Nitrogen steels that are almost equal in performance to standard ceramic materials. These new types of steel can be used for structural elements, while they allow for even greater weight loss if their application is laid at the initial design stages. As for high-strength fibers, for example IBD C1 HT Liner, they have characteristics almost 20% higher not only in comparison with standard podboyami, but even 10% higher than the rest of IBD; the deterioration of their parameters with increasing temperatures also occurs more slowly, which is especially important given the extreme temperatures on modern battlefields. In addition to nanometric steels and nanoceramics used on newly developed machines, IBD has also developed new solutions in the field of composite materials that allow the production of elements with complex curved geometry, which makes it possible to achieve one hundred percent coverage of the protected area with almost no ballistic gaps. This solution is applied in particular in the production of bottom elements, where the slightest gap can break all protection.
IBD is also successful in the development of nanocomposite laminates having such substantially increased strength that they can replace the structural parts of the machine and at the same time serve as a high level ballistic protection. Due to their low surface density, the overall weight of this level of protection is thus greatly reduced. These composite materials are based on the aforementioned nanotech materials from IBD. Special bonding processes have been developed, which are used to make nanocomposite laminated structural materials, known as IBD FlexiComp, with increased structural strength and ballistic characteristics. Having a lower density on 10% compared to standard laminates, the elastic properties of these materials are twice as high. Such high strength allows them to be integrated into the design of the machine, while ballistic characteristics make it possible to cope with high-level threats, while FlexiComp materials have good potential for weight reduction. Their use can be embodied in two different approaches. The direct approach is to use them to protect against mines and IEDs as additional armor in wheel bays, fenders, anti-mine plates and spaced internal floors. When molding volumetric parts, they can replace other solutions, such as assemblies, assembled by welding or bolts. The second approach is the integration of parts made of composite materials, such as hatches, engine hatches, aft doors and ramps. They constitute a large proportion of the total surface of the vehicle, and as a result, the absolute weight reduction will be very significant. For STANAG 4569 The 4 level is a similar weight reduction of 1500 kg for the 8x8 machine (see table). With regard to the cost of production, the processes developed by IBD allow the manufacture of composite parts without the use of autoclaves, providing a significant reduction in the cost especially for large components, their cost is comparable to the cost of components produced using standard technologies.
These components are currently manufactured by Rheinmetall Chempro, whose task is to master IBD Deisenroth Engineering technologies, develop them into the production process in order to achieve competitive prices, further develop specialized solutions and accompany them to the process of qualifying the machine. Deliveries of components manufactured using the latest advanced technologies began at the beginning of 2013, primarily for AMPV from KMW-Rheinmetall and Medium Protected Vehicle from Iveco DV-KMW. According to the Rheinmetall protection systems division, over a dozen original equipment manufacturers (Original Equipment Manufacturer) around the world will soon receive components that will allow them to actually reduce the weight of their machines and, thereby, increase the useful load capacity and reduce the life cycle cost.
The portfolio of passive solutions from Rheinmetall Chempro includes various versions of the Amap family (Advanced Modular Armor Protection - advanced modular reservation). This family uses the latest technology developed by IBD. Amap products are usually combined to provide the desired protection against a wide variety of threats. Among the various non-transparent products, we see the Amap-B ballistic solution, which provides protection against small weapons and medium-caliber ammunition, Amap-M mine protection, Amap-IED, designed to combat IEDs, Amap-L basements that protect the fighting compartment, absorbing secondary debris, Amap-SC against cumulative projectiles and, finally, the Amap-X solution, protecting against threats typical of urban conditions.
New bonding technology developed by Lockheed Martin UK and the University of Surrey can significantly increase the level of protection for armored vehicles, such as the Warrior BMP (above)
Optional SidePro-ATR Modules on Leopard MBT
It should be noted that inside the Rheinmetall Group another company is engaged in passive protection, Rheinmetall Ballistic Protection GmbH, which received its new name 1 January 2013 of the year. Previously, it was called Rheinmetall Verseidag Ballistic Protection GmbH. Fully owned by Rheinmetall, this company specializes in the design and manufacture of reservation solutions for light military machines that use materials such as ceramics, advanced metals and special fabrics.
Although Ruag Defense still has solutions for dynamic protection (active-reactive armor) in its portfolio, it no longer looks to consumers as an ultra-modern company that can increase the survivability of medium and heavy vehicles. In this regard, the Swiss company turned its attention to perfecting completely passive solutions that can cope with kinetic and shaped charges. The SidePro-ATR system goes far beyond the aggressiveness of the RPG-7, as it can handle the shaped charges used in symmetrical scenarios, while the base variant guarantees Level 5 ballistic protection. SidePro-ATR was first shown to the public in 2012, this system is scalable and thus it can be used both on armored personnel carriers and on tanks... In its basic version, it has a thickness of 400 mm, and its mass is comparable to the mass of a jet solution (that is, approximately 300 kg / m2). This system was qualified for the Leopard 2A4 tank. The level of ballistic protection can be significantly increased to the point that the system will withstand the impact of a 120-mm elongated core, although no data was provided in this regard.
The scalability of SidePro-ATR allows it to be used in symmetrical and asymmetrical combat scenarios. Another solution to combat kinetic ammunition and IEDs under the designation SidePro-KE / IED was tested on the Fennek armored reconnaissance vehicle, which is in service with Germany and the Netherlands. Basically based on ceramics, this solution was intended to fight the first-generation IEDs. New roadside bombs used in various theaters, form thousands of high-speed fragments, and therefore there is a need for very good multi-hit characteristics. Since then, Ruag has refined the KE / IED system by moving away from ceramics and using unpackaged multilayer packages. The new SidePro-KE / IED solution, available from 2012, protects the 4 level / 5 level from kinetic weapons and has extremely high multi-shock characteristics. Assuming that the chassis is made of ballistic steel 7 mm thick, the 30 mm panel could fully provide the required protection, while the KE / IED system allows for a minimum mass increment depending only on the type of machine. This solution is pending at several manufacturers.
Ruag has finalized the SidePro KE / IED. The photomontage shows the elements of the system created to counter the new devices forming multiple fragments.
M113 BTR, equipped with a passive anti-RPG system Iron Wall by Israel Military Industries, combining passive and lattice armor
Ceradyne and Cellular Materials International have developed bottom protection based on CMI MicroTruss aluminum cellular material, which absorbs up to a third of the energy created by the explosion. Below is a close-up view of MicroTruss material.
Weight reduction example for an 8 x 8 machine with components made from IBD FLEXICOMP
Weight in kg
Plasan Sasa remains one of the key players in passive booking. No technological details are given in this direction, while the company is active both in additional reservations and prefabricated buildings. The second approach was adopted in the development of Mrap from Navistar MaxxPro and M-ATV from Oshkosh. “This allows us to increase production using labor without qualification skills in welding, since our approach in the style of the Lego designer is based on blocks containing all the components that can be assembled in the shortest possible time,” said a source in the company. Some of the more than two hundred engineers of the company are working on new solutions that could be the result of the emergence of new materials or innovative geometric solutions. The systems approach remains at the heart of the protection cycle.
IMI has recently developed a number of solutions in the passive and reactive areas to counter the latest types of IEDs, including various types of EFP or SFF (Self Formed Fragmentation) “shock cores” and the latest RPG models. The company proposed a passive Iron Wall solution, it is based on a combination of metal and composites supplemented with lattice armor. Depending on the level of protection required, the thickness may vary between 110 and 150 mm, and the weight between 200 and 230 kg / m2. The Iron Wall is currently undergoing troop testing in the Israeli army.
IMI also offers its lattice armor as a separate system. L-VAS (Light Vehicle Armor System - light car booking system) is designed to protect BTR type vehicles. In order to reduce weight, the system is based on composite materials and reactive elements, the latter contain a minimum of energetic materials. This reduces indirect losses, and the type of material avoids the risk of secondary detonation of neighboring elements. According to IMI, the L-VAS system also protects against 14,5-mm armor-piercing shells and artillery splinters. The system was fully qualified in Israel for its M113 BTR and has a specific gravity of approximately 200 kg / m2.
A heavier Breakwater system is also proposed. This reactive armor, including metal and composite elements, is designed to combat three main threats: RPG, SFF and EFP. IMI has conducted rigorous testing and is now moving to qualifying to begin producing solutions with a thickness of 350 - 400 mm and a mass of 430 - 450 kg / m2 at the end of 2013 of the year.
Ceradyne is another major player in passive booking. According to Mark King, president of Ceradyne, steel remains the main material in the booking business, the goal here is to increase performance and reduce cost. “In the US, the driving factor is basically the cost of acquiring the vehicle, not the cost of its service life, and this works against upgrades,” King told the AUSA 2012 conference. A relatively small number of vehicles purchased by European armies led to large investments in defense, while in the US the emphasis was on quantity, which brought European developers of American forward protection systems. However, King emphasized that at present America is progressing, mainly focusing on the anti-explosion protection of the bottom, since ballistic protection is already considered as a solved problem. The interest of the American army, again shown to solve the problem of protecting the bottoms of such machines as, for example, the Humvee (20 million dollars only for development), is positively evaluated by King. Ceradyne is one of those who will definitely argue for a contract to modernize them. The requirement is to obtain maximum protection with a significant reduction in mass in order to reduce the effect on machine performance.
Ceradyne has developed a solution based on MicroTruss developed by Cellular Materials International Inc (CMI). This porous aluminum alloy material has a density 58 kg / m2 compared to a density 112 kg / m2 equivalent monolithic metal solution. This solution differs in the “V” body angle equal to the total 5 °, which is enough to repel the blast wave and has a mass of 300 kg. MicroTruss guarantees up to 30% absorption of blast energy, which not only limits the impact on the crew capsule, but also reduces the vertical movement of the vehicle. At Ceradyne, the company also actively participates in the Flyer Gen.2 reservation program, which focuses on the project of special operations forces on the GMV 1.1 vehicle. To maintain transportability inside the V-22, CH-47D and CH-53E helicopters, when the weight and width should be kept within certain limits, the company developed a kit that provides the level of B6 (.357 Magnum) ballistic protection for doors and roofs.
Polaris Defense and M9 Defense Armor Technology have developed hybrid steel composite structural armor to significantly reduce the own mass of the Humvee while maintaining the level of protection. The prototype in the photo on the right has its own total weight of 3400 kg, which is almost 50% less than the Humvee with 3 Level protection. (Pay attention to the car wheels below)
Protection also lies in the fact that it does not remain on the battlefield in case of a puncture. Polaris Defense non-pneumatic wheels offer significantly better durability compared to standard tires and can withstand a 12,7-mm bullet. Currently, they are available not only for cars, including the Hummer class, but now these wheels are being developed for heavier Mraps cars.
Ceradyne also participates in the Marines Personnel Carrier program in collaboration with Lockheed Martin and Patria in a Marine vehicle based on the Finnish Patria AMV. It is worth noting that 28 November 2012 was announced that Ceradyne was acquired by the 3M Group, which would allow it to invest more in R & D and innovative solutions.
Integrating design and protection is a very popular solution for lightweight machines. At AUSA 2012, Polaris Defense showed a prototype car based on the Humvee with a new concept that it developed with M9 Defense. The challenge is to reduce its own weight while maintaining and increasing levels of protection. To do this, the Polaris-M9 team removed all invoice armor to look at the concept of structural armor. Then everything was removed from the car, only the bare chassis was left, and then a light hybrid (steel-composite material) structure was put on it. This structural armor can provide 3 Level protection with 70 mass kg / m2, and with 83 weight kg / m2 it can withstand 12,7 x 99 mm bullet, although in the Polaris-M9 group they can reach the 3 + level (12,7 mm mm armor) ). The solution from Polaris-M9 also helps protect the engine. While the standard Hummer armored car weighs about 6350 kg, the proposed solution reduces its weight to 3400 kg. The hybrid structural armor uses non-exotic material, which allows the Polaris-M9 team to talk about the cost of a new solution, comparable to the cost of current solutions. In addition, this material is molded into complex shapes, which makes it possible to obtain among other things seamless V-shaped bottom. Reception of the set form is reached due to hydraulic formation - high-speed process promoting decrease in cost. According to the Polaris-M9 team, this technology reduces the mass by 40 percent.
Demonstration of non-pneumatic wheels from the company Polaris Defense
The protection equation includes another member directly related to mobility - the wheel. Following the acquisition of Resilient Technologies, Polaris Defense currently offers non-pneumatic wheels (NPT). Wheel consumption is one of the most basic logistical problems in theaters and solving NPT in many cases will help to solve it. According to the command of special operations forces in Afghanistan, regular tires pass approximately 1300 km, while the NPT wheel, a punctured 12,7-mm bullet can go over 8000 km and, therefore, displace spare wheels from the supply chain, while improving ride quality. For Hummer cars, NPT prototypes have already been manufactured. The current goal is the NPT wheel set for a 7,7 ton machine, which is almost the full mass of the JLTV General Purpose variant. According to representatives of the company, the simulation showed that the mass can reach 18 tons, in other words, the wheels can withstand the car class Mrap. With increasing payload technology remains the same, and the modeling programs developed by the company, you can make very accurate predictions. What will change is the material that has to adapt to the mass, which in turn has yet to appear in the future.
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