Overview of Security Systems for Military Personnel and Military Equipment (Part 1)
Protecting your assets, including soldiers, is one of the main tasks of any military operation.
Future military scenarios, which will take into account the experience gained in Afghanistan, will challenge the soldiers and their equipment in the form of asymmetric and mixed hostilities. As a consequence, there is a growing need for more effective protection, which should also remain light.
The article will discuss only some of the latest Western innovations in the field of protecting soldiers, vehicles, aircraft and ships.
Glass
Before you start talking about transparent armor, you need to know more about the most basic, basic component of transparent armor, glass. Understanding how glass is formed will help you understand how something can be seen through an aluminum alloy.
Since there is a basic formula for making glass, there is also a recipe for creating bullet-proof glass. Squeeze together two thick layers of glass, and between them a layer of polycarbonate (this is called lamination - making a laminate). When a bullet hits, the layers of glass and polycarbonate absorb its energy. The outer layer (meeting the bullet) cracks and creates web-like cracks, illustrating the expansion of energy to the sides. However, the middle layer of polycarbonate, as a rule, withstands the impact and prevents the bullet from piercing through the inner glass. The thickness of the bulletproof glass varies, but usually varies from less than an inch to several inches. In cases of machine firing, this bulletproof glass often serves passengers as a transparent protection.
Bulletproof glass is usually mistakenly called "bulletproof glass." But such glass in its pure form does not exist in nature, since it is almost useless against a 12,7 caliber bullet. Basically, it is difficult to say how thick the bullet-resistant glass will be to stop what type of ammunition, since so many factors matter when hitting an object on a hardened surface: distance, speed, type weapons, ammunition type and even wind conditions.
Having similar uncertainty, the military reinforces the glass with another similar window block with a bulletproof, actually turning an 2 inch-thick window into an 4-inch window. This of course increases the level of protection of the machine, but at the same time increases its mass.
12,7 mm caliber armor-piercing bullets are also intended for piercing bullet-resistant glass. These bullets often have a copper sleeve in which a piercing tip, made of a harder material, such as depleted uranium or tungsten carbide (hardness like diamond), is placed. The outer shell cracks when meeting with the armor, but the piercing tip in the copper shell works in accordance with the name, it continues to move in the armor and causes serious damage in the protected space.
Transparent protection
Bulletproof glass has some significant drawbacks, specifically, it does not stop all bullets, and hanging a protective, but heavy material just slows down the vehicle. The researchers believe that the solution that could withstand the bullets is transparent aluminum armor. Transparent aluminum armor is a fine-polished ceramic alloy that is lighter and stronger than traditional bullet-proof glass. Transparent aluminum armor with the commercial name ALON is made of aluminum oxynitride - a chemical compound of aluminum, oxygen and nitrogen. Before this material turns into a durable transparent armor plate, it begins its journey in the form of powder. This powder, like all other ceramics, is molded by sintering at high temperature. Under the action of high temperature, the powder becomes liquid and then rapidly cooled to a solid state, while the molecules remain freely oriented, as if they are still stored in liquid form. The resulting rigid crystal structure of molecules provides strength and scratch resistance comparable to durable sapphire. Additional polishing hardens aluminum alloy, and also makes it extremely transparent.
Nowadays, transparent aluminum protection consists of three layers in the same way as bullet-proof glass (two panels of glass and between them a polycarbonate panel). The outer layer, which is directly hit by the bullets, is made of sintered aluminum oxynitride, the middle layer is glass and the inner layer is a polymer substrate. Aluminum armor can not only reflect the bullets of small-caliber weapons and remain clearly transparent compared with bullet-proof glass, which was hit by a bullet. It also passes a much more important test: it stops 12,7 mm armor-piercing bullets and anti-aircraft armament, which usually uses 7,62 mm bullets. This is an impressive result, especially considering that, compared with traditional armored glass, its weight and thickness are two times less.
Over time, a regular sheet of bulletproof glass wears out under the influence of sand particles carried by the wind, not to mention small arms bullets or fragments of roadside mines. Another advantage of transparent aluminum armor is its greater hardness. In comparison with traditional bulletproof glass, it withstands bullets of a caliber up to 12,7 mm, is less susceptible to the abrasive effect of sand and scratches on it are harder to apply. Researchers say that transparent aluminum armor has significantly outstripped glass, but at the same time they acknowledge that it is expensive and it is difficult to make large sheets of it.
Saint-Gobain Crystals was one of the first companies to offer SAFIRE transparent armor solutions in response to the ever-increasing need for ballistic protection with a reduced weight and thickness. The test results of newer samples showed more than 50% reduction in weight and thickness while maintaining the same ballistic characteristics that traditional glass solutions
Bulletproof glass can be supplied with a variety of levels of protection.
Transparent aluminum armor developed by Raytheon and currently being marketed by Surmet, although more expensive than bullet-resistant glass, is cheaper than sapphire, with which it has similar characteristics, such as strength and transparency. Sapphires are used in various fields, such as semiconductor manufacturing, and due to their strength in bar code readers. As various industries require more and more transparent aluminum for their needs, the price of production may fall to the point that will make it possible to build facilities for the production of larger parts.
While research is under way to develop material that could potentially save lives, 12,7-mm armor-piercing bullets will “mock” standard bullet-proof glass on and off the battlefield.
The need for a new technology of transparent protection becomes apparent when looking at the weight of current solutions. For example, in order to obtain the STANAG 4569 Level 3 protection level, armored glass must have a surface density of about 200 kg / m2. With a typical total window area of the truck 3 square. meters the mass of such glass will be 600 kg. Therefore, several companies have developed solutions in this area.
PERLUCOR from CeramTec-ETEC is a very pure material with exceptional mechanical, chemical, thermal and optical properties. PERLUCOR's high degree of transparency (ceramics has an optical degree above 92% relative transparency (more than 80%)) allows you to apply this ceramic material wherever bullet-proof glass is close to its limit. PERLUCOR is three to four times harder and stronger than ordinary glass, which allows its use in systems operating under conditions of extreme wear. In addition, PERLUCOR's unique properties include a higher thermal stability (three times), which makes it possible to use this material at temperatures up to 1600 ° C, as well as extremely high chemical stability, which makes it possible to use it in aggressive acidic and alkaline environments.
IBD Deisenroth Engineering has developed a transparent ceramic protection that has ballistic characteristics comparable to those of opaque ceramic armor. According to IBD, this new transparent material is lighter than armored glass by about 70% and also as opaque armor can have multi-hit characteristics. Transparent ceramic IBD protection is a by-product from the development of NANOTech ceramics. IBD has succeeded in developing special bonding processes that are used when assembling ceramic tiles (Mosaic Transparent Armor - mosaic transparent armor) and lamination of these assemblies with strong base layers to form large glazing panels. Due to the ballistic characteristics of the ceramic material, it is possible to manufacture panels of transparent armor with a significantly reduced weight. A substrate made of Natural NANO-Fiber laminates further enhances the already excellent performance of the new transparent protection due to its ability to absorb large amounts of energy.
OSG (Oran Safety Glass) recently developed a new ADI technology. In order to prevent the penetration of the machine with fragments, as a rule, a layer of plastic material is glued to the back of the glass. This plastic layer causes delamination and reduces the life of the glass. In addition, this plastic layer is often damaged during daily use and with improper cleaning methods, which leaves scratches on the windshield and impairs visibility.
While transparent armor on military vehicles usually counters the main ammunition that causes damage, such as bullets and shrapnel, glass does not withstand direct hits from flying high-speed objects. Although these objects do not cause much damage, they often cause the inner layers of the glass to split, resulting in costly repairs. This fully tested and proven product is a proprietary bulletproof glass that provides protection against stones and other incoming items. OSG ROCKSTRIKE is an improved alternative to traditional metal nets, often mounted on armored and unarmored glass to protect against damage from stones.
The new technology ADI from the company OSG provides a shatterproof environment inside the machine, while it allows you to significantly increase the expected service life of transparent armor and as a result extend the warranty on the windows of this glass
OSG transparent materials are constantly being tested in real life situations: repelling physical and ballistic attacks, saving lives and protecting property. All armored transparent materials were created in accordance with basic international standards.
A little guide to fiber materials
A fiber is a thread used as a component of composite materials. The strongest construction materials are made of fibers, for example carbon fiber or ultra-high molecular weight polyethylene Ultra-high-molecular-weight polyethylene (UHMWPE).
The two most important indicators for high performance fibers are their strength and how much they can stretch before breaking (tensile strength). Over the past few decades, various chemicals have been invented that have been continuously improved in order to obtain optimal properties. Modern fibers with high performance KEVLAR, TWARON, DYNEEMA and SPECTRA, which are most prevalent, are based on the chemical bonds of para-aramid and high-strength polyethylene.
••• Aramid fiber - A class of synthetic fibers durable and resistant to heat. The artificial word aramid is a derivative of the phrase "aromatic polyamide." Fibers in which chains of molecules are strongly oriented along the axis of the fibers, so that the strength of chemical bonds can be used. In addition to meta-aramid fibers like NOMEX, the other variations of the fibers belong to the aramid line. They mainly belong to the type of copolyamides better known under the trademark technora, developed by Teijin. Aramids have a high level of orientation with other fibers, such as UHMWPE; This characteristic prevails in their properties. Para-aramid fibers such as KEVLAR and TWARON, have outstanding specific strength. Para-aramids include KEVLAR, Technora, TWARON and Heracron.
••• DYNEEMA - high-strength polyethylene fiber, produced by DSM Dyneema, according to which it is the strongest fiber in the world. It is 15 times stronger than steel and 40% stronger than aramid with comparable mass; it is the only composite material in the world capable of stopping a bullet fired from an AK-47 machine itself.
••• KEVLAR - registered trademark of para-aramid synthetic fiber. DuPont's high-strength material in 1965 usually twists into threads or woven fabrics that are used by themselves or as a component of composite materials. With the same mass, KEVLAR is five times stronger than steel and at the same time its elasticity is incomparable with the elastic limit of steel. KEVLAR XP reduces potentially serious ballistic and traumatic injuries due to its structure.
••• NOMEX Is a registered trademark for non-combustible meta-aramid material developed at DuPont's early 60-s and first introduced to the market in 1967. It is known as meta-aramid.
••• Polybenzimidazole (PBI) synthetic fiber with a very high melting point, which is also difficult to ignite due to its excellent thermal and chemical stability. PBI is used for the manufacture of high-strength protective clothing.
••• Radius - synthetic regenerated cellulose fiber. Because it is made from natural polymers, it does not belong to either truly synthetic or natural fibers; This is a semi-synthetic or artificial fiber.
••• SPECTRA manufactured by Honeywell. This fiber is known as one of the strongest and lightest man-made fibers. Using its patented SHIELD technology, Honeywell also designs and manufactures SPECTRA SHIELD, GOLD SHIELD and GOLD FLEX ballistic materials, which have been trusted by the military and police around the world for more than two decades. SPECTRA is a bright white polyethylene fiber with high resistance to chemicals, water and ultraviolet radiation; according to the company, it is stronger than steel and is 40% stronger than aramid fibers and is able to withstand high-speed loaded deformations.
••• Synthetic fiber - This is the result of extensive research by scientists to improve the properties of natural fibers of animal and vegetable origin. As a rule, synthetic fibers are created by feeding under pressure (usually by extrusion) into the holes (called spinnerets) of fiber materials that are formed in air in a thread.
••• TWARON - trademark paraaramid from the company Teijin Aramid. It is a refractory and durable synthetic fiber. According to the company, the mass can be reduced by 30% - 60% compared to ballistic steel by including TWARON in the armor of the car. Its LFT (laminated fabric technology) SB1 technology is a very flexible and thin multi-layer material consisting of two fabric layers laid between three layers of ultrathin polyethylene film, whose special structure retards the penetrating bullets that push the fibers apart. TWARON LFT SB1 reduces the deformation of the back surface by about 30% without compromising wearing comfort.
••• ultra-high molecular weight polyethylene Ultra-high-molecular-weight polyethylene (UHMWPE), also known as high-modulus high-modulus polyethylene (HMPE) or high-performance polyethylene (HPPE), belongs to the group of thermoplastic polyethylene. The UHMWPE gel is extruded through dies to form structurally oriented synthetic fibers. These are exactly the materials DYNEEMA и SPECTRA. Ultra-high molecular weight polyethylene has extremely long chains with a molecular weight of millions, and usually 2-6 millions. It is very resistant to aggressive substances with the exception of Brönsted (aprotic) acids; extremely poorly absorbs moisture and has a very low coefficient of friction. It has good self-lubricating properties and a very high resistance to abrasion, in some of its forms the coefficient of resistance to abrasion is 15 times more than that of carbon steel. The friction coefficient is significantly lower than that of nylon and acetal and comparable to the friction coefficient of polytetrafluoroethylene (Teflon); UHMWPE is more durable than Teflon. It is odorless, tasteless, and non-toxic.
Enhanced Combat Helmet Superior Battle Helmet
Modern ceramics
Protection systems made of ceramic composite armor can be used for personnel, vehicles, ships, helicopters and aircraft. Advanced industrial ceramics have a relatively small mass and provide innovative ballistic protection solutions for durable reservation systems.
Ceradyne, a company 3M, for example, will supply 77 000 enhanced ECH (Enhanced Combat Helmet) combat helmets to the US Marine Corps under a contract worth 80 million dollars as part of a corps and army program to replace combat helmets of all United States armed forces. These helmets use ultra high molecular weight polyethylene (UHMWPE) fibers embedded in thermoplastic resin, unlike current generation helmets in which aramid fibers are embedded in a thermosetting resin. The ECH helmet profile is very similar to an advanced combat helmet, except that it is thicker. The new helmet should protect against some rifle bullets, as well as have a higher level of protection against shell splinters compared with the current combat helmet. In July, 2013, the infantrymen ordered 3850 helmets for delivery to the deployed infantrymen by the end of 2013. The Marine Corps plans to buy a total of 77000 helmets, which is enough for a large deployed contingent of the corps.
Polaris Defense and M9 Defense have developed light armor for the US military. The photo is shown in the configuration for a light tactical vehicle, but this armor can also be installed on any wheeled tactical vehicle or combat platform. According to the company, this new armor is made from certified materials using proprietary bulletproof materials and manufacturing processes and has the lowest specific gravity in pounds per square meter. foot. Steel-composite armor in combination with a high-speed manufacturing process, comparable to the speed of sheet metal production, allows the Polaris / M9 team to create capsules and other ballistic elements from this armor with a significant reduction in overall costs
Flying defenses and armored ships
It is not only people who require protection. Aircraft require protection to ensure that vital systems, their crews and passengers are not damaged by ground fire. Several important programs have been launched in recent years to develop innovative solutions in the field of aircraft protection. The same applies to ships, which do not have the same coverage area as the armor designed for aircraft, soldiers and vehicles, but nevertheless play an important role in protecting ships from a variety of threats. The focus on combating piracy, drugs, illegal migration and counter-terrorism operations in the maritime environment has resulted in ships now being exposed to a variety of threats, such as small arms fire, artillery and anti-tank grenade launchers.
TenCate, specializing in protection in both elements, provides protection for large ships. Aircraft armor from TenCate Advanced Armor is designed to provide maximum protection with minimal weight added. A high level of protection is achieved through the use of the lightest materials available today, such as TenCate LIBA CX or TenCate CERATEGO CX. These solutions are highly resistant to multiple hits, protecting the aircraft from the effects of multiple bullets or fragments. TenCate Advanced Armor also offers customized lightweight protection solutions, especially for use on small vessels and large ships. Armor intended for ships is used to protect critical areas on board, including ammunition stores, captain bridges, combat information centers, communications equipment and weapon systems.
Tencate recently delivered its Tactical Naval Shield, a tactical naval shield designed to protect the shooter. Having good operational flexibility, it can be delivered or removed in three minutes.
Tencate Tactical Naval Shield
The main contractor for the Embraer KC-390 project, Aerotron Brazil, has chosen TenCate Advanced Armor as its technical and industrial partner and supplier of materials and special processes. Aerotron Brazil and TenCate Advanced Armor are working together to complete the project and create prototypes of ballistic protection in accordance with the schedule, as well as the mass and performance requirements of the Embraer KC-390 program.
Aircraft protection kits created and manufactured by QinetiQ North America are based on the same simplified logistics philosophy as the reservation kits for ground vehicles. There is no need to modify the aircraft to install the LAST vessel reservation kit; these kits are completely self-sufficient from a logistic point of view. They can be installed in adverse environmental conditions, and if necessary, only by the crew using only the materials that are included in the kit. The entire system of additional protection can be transferred from one aircraft to another in one hour.
The Nexter VBCI crew and assault forces are protected from various threats, including shrapnel 155-mm shells and small and medium caliber shells. The welded housing made of steel and aluminum alloy is equipped with anti-splinter lining and additional titanium plates for protection against anti-tank weapons. Box construction of the bottom and undercarriage provide protection from mines.
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