Lightweight Composite ArmorLightweight Composite ArmorAn Industry Transformation Opportunity

Armored Vehicles – IndiaNovember, 2010

© 2010 Owens Corning

About Owens Corning

• Founded in 1938, an industry leader in glass fiber insulation, roofing and asphalt and glass fiberinsulation, roofing and asphalt and glass fiber reinforcements

• 2009 sales: $4.8 billion• 16 000 employees in 26 countries• 16,000 employees in 26 countries• FORTUNE 500 company for

56 consecutive years

• Residential Insulation • Composite

Owens Corning Composite Solutions

Owens Corning Building Materials and Services

• Commercial & Industrial Insulation

• Manufactured Stone Veneer

pReinforcements

2

Veneer• Residential Shingles• Roofing Asphalts

Owens Corning History with the Militaryg y y

• Insulation for Warships (1939) – U.S. Navy Bureau of Ships specified OC insulation for new ships.Ships specified OC insulation for new ships.

• Structural Aircraft Parts (1942) – OC partnered with U.S. A.A.F. to develop plastic laminates.

B ® (1963) OC d l fib f• Beta® yarn (1963) – OC develops fiber for aerospace applications and use in NASA spacesuits.

• S-Glass® (1959-63) – Developed by OC under contract ith U S Nwith U.S. Navy.

• Piedmont Products, Inc. (1979) – OC manages reinforcements plant under government contract

• OC Armor (1989) – Product specified for NATO and US Military personnel carriers and first-aid trucks.

• ShieldStrand® Reinforcements (2007-2009)

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ShieldStrand® Reinforcements (2007 2009)– MRAP, HMMWV

Market Transformation Opportunitiespp

SOFT ArmorSOFT ArmorHARD Armor

Personnel protection

HARD Armor

Personnel protectionPersonnel protection

body armorGlovesClothes

Personnel protectionbody armorGlovesClothes

Personnel protectionBody armor insertsHelmetsShields

Armored vehicles

Anti-mine shoes, leg protection, …

Personnel protectionBody armor insertsHelmetsShields

Armored vehicles

Anti-mine shoes, leg protection, …

Light vehiclesBallistic panels for floor, door, bodywork, roof, interior armor ...

Cash in transit, ambulance,…Law enforcement, Army : car, 4x4, hummer, van, truck …Civilian: VIP car, 4x4, limousine, …

Light vehiclesBallistic panels for floor, door, bodywork, roof, interior armor ...

Cash in transit, ambulance,…Law enforcement, Army : car, 4x4, hummer, van, truck …Civilian: VIP car, 4x4, limousine, …

Heavy vehiclesBallistic panels for military vehicles. External & internal armor

Armored aerial vehiclesHelicopters : floor, seat (panels), cockpit…Aircraft : cockpit doors seat

Tank, char, wheeled vehicle, tracked vehicle

Heavy vehiclesBallistic panels for military vehicles. External & internal armor

Armored aerial vehiclesHelicopters : floor, seat (panels), cockpit…Aircraft : cockpit doors seat

Tank, char, wheeled vehicle, tracked vehicle

Aircraft : cockpit doors, seat, …

Armored marine vehicles

SubmarineShipboard : bridge, compartment, …

Fixed structure

Aircraft : cockpit doors, seat, …

Armored marine vehicles

SubmarineShipboard : bridge, compartment, …

Fixed structure

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Ballistic panels for structural partsBank counter, prison, bridge, shelter, vulnerable building (embassy, airport,…)

Ballistic panels for structural partsBank counter, prison, bridge, shelter, vulnerable building (embassy, airport,…)

Mobility & Lethality drives solution y y

High

• Helicopter• Defense Vehicles• Amphibious Assault

V hi l

• Fighter Jets• Tactical Vehicles• Personal Armor

Mob

ility

Vehicles

M

• Homeland Security • Bridges / Infrastructure• Embassies

• Marine Deckhouses• Marine Hull Components• Coast Guard

Battlefield ISO Shelters

Low

Low High

Embassies • Battlefield ISO Shelters

5

Low HighBallistic Lethality

History of Composite VehiclesFunctional Requirements

• weight (lighter)range of protection

• structural performance

• range of protection levels

• ballistic and blast performance

• fire performance• Electromagnetic

properties

Monocoque

• damage tolerance • maintainability• affordability

Technology Gaps:• Lightweight Multifunctional

Materials are needed

Appliqué

• Materials-by-design vs trial and error

• Multi-scale modeling across all l th l d l di

Integral

6

length scales and loading rates

• Systems Approach for Design and Optimization

Structure (A) + Armor (B)

Industry Needsy

P f D i

Protection Performance

P l dPerformance Drivers• Protection against blast and fragmentation

Payload

• Performance improved with vehicle mobility

• Payload capacity increased

• Lighter, faster, more fuel efficient vehicles

• Higher survivability at affordable price

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g y p

Design Drivers

Ballistic energy absorbing fracture mechanisms may be combined within same armor systems to meet requirements of different threats.

This combination is based on:

W i ht li it tiWeight limitation

Space constraints

Structural roleStructural role

Environment (moisture,FST)

Type of projectile(s)Type of projectile(s)

Need for single shot or multi-hit capability

And usually leads to armor systems which are based on

8

y ymultimaterials, multilayer arrangements, each providing a specific functionality.

Maximize energy absorption in composite integral armor while maintaining structural propertieswhile maintaining structural properties

• Potential mechanisms in composite layer– Delamination– Fiber and resin fracture/deformationFiber and resin fracture/deformation– Fabric deformation effects– Fiber-matrix interphase damage

F i ti l ff t i t l i fib t i– Frictional effects – interlaminar, fiber-matrix, etc.

9

Tailoring Composite Performance

Interphase & thermodynamic

Fiber designEnhancement of compressivethermodynamic

effectscompressive strength

Optimum Composites for Desired Properties• Ballistic

Micromechanical Characterization•Energy Absorption•Strain Rate

• Structure• Durability

Strain Rate•Durability

Grading of InterlaminarRegion

Effects of sizing & Resin Compatibility

Control of Resin Permeability

10

g

Material Choices for Armor Protection

•Shieldstrand® (High Strength Glass Fiber)( g g )•Aramid fiber

•UHMWPE fiber•UHMWPE fiber•Ballistic nylon fiber•Ceramics•Steel•Aluminum•Titanium

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Effectiveness vs. selected threats

Projectile Velocity Al Steel Aramid Shield CeramicMaterial System

j yKm/s

Shieldstrand

Ball 0.9

Armor Piercing 0.9

Sabot-light AP 1.1

Tungsten carbide AP 0.9

AP Discarding sabot 1.2

F t i l ti 0 5Fragment simulating 0.5

Fragment simulating 1.5

Self-forging fragment 2.0

Long rod penetrator 1 6Long rod penetrator 1.6

High velocity KE 2+

Shaped charge 7.0

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Effectiveness: < < <

Benefits of ShieldStrand Armor Solutions

Tangibles - Mitigates Behind Armor Debris from F t ti d O t h Th t f IED EFPFragmentation and Overmatch Threats of IED, EFP

• Stronger & Lighter

• ThinnerThinner

• Durable

• Excellent Processingg

• Affordable

• Consistent Supply Chain

• Phenolic Fire Resistance

• Ballistic Performance to Specifications for Composite Armor Systems MIL-DTL-64154

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Composite Armor Systems MIL DTL 64154

• Qualified for Spall Liner, Frag 5, Frag 6 and EFP

Benefits of ShieldStrand Armor Solutions

Intangibles – Heritage of Proven Spall Liner Field P f d P t t St t l A H llPerformance and Prototype Structural Armor Hull Performance for Aluminum and Steel Substitution

• Depot / Field Installation Capable

• Battle Damage and Repair Field Maintenance Capable

• Flat or Curved Plate or Complex Shape Demonstrated

• Installs with Fastener Systems typical to Metals

• Surface ready for CARC or adhesive for Metal and/or Ceramic Bonding / Joiningg g

• No Corrosion or galvanic corrosion

• Good Durability to Vehicle Environment

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• Complies with FMVSS 302 Flammability

ShieldStrand® Enables Lightweight Composite Armor Affordability

$60.00

Composite Armor Affordability

$40 00

$50.00 UHMWPE

$30.00

$40.00

ost (

$/lb

)

$10 00

$20.00

Co

Aramid/Phenolic S-2 Glass®

$-

$10.00

0 2 4 6 8 10 12

ShieldStrand® ShieldStrand® S Advantex® (E-glass) 5083 AL RHA Steel

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0 2 4 6 8 10 12

Weight required to meet MIL-DTL-64154B (lbs/sf)

ShieldStrand® Offers the opportunity for Hybridization with other materials for Optimum SolutionSolution

7000

5000

6000

7000

0 (f

t/s)

3000

4000

ic L

imit

V50

1000

2000

Bal

listi 0.25"AL5083/ ShieldStrand/ 0.25"RHA

ShieldStrand/ 0.25"RHAShieldStrand VERHAShieldStrand/HB2 50/50ADShieldStrand VE/ Spectra3124/EPS/0.14"RHA0.50"AluminaRE/ShieldStrand/0.14"RHA0.4"Alumina/ShieldStrand VE/AL Foam

00 10 20 30 40 50

Areal Density (lb/ft2)

16

Data shown for comparative purposes only and should not be construed as a guaranty or warranty of performance. Absolute performance will vary

by resin system or process

Integrated Structural ArmorgShieldStrand® is making new armor solutions

possiblep

• The strength of ShieldStrand® provides structure as well as protection, allowing armor to be integrated into the vehicle structure, reducing overall vehicle weight

Shi ldSt d® b ld d i t l l• ShieldStrand® can be molded into large complex-shaped structural parts using proven large scale composite manufacturing technologies.

• ShieldStrand® has been tested in combination with a steel or ceramic strike face to provide

t ti h i i d lti hit

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protection when armor piercing and multi hit capability is required or an overmatched threat exists.

ShieldStrand® Armor Solutions for Blast and Multi-hit Fragmentation Performanceand Multi hit Fragmentation Performance

• Offers good performance in blast – structurally d ith i i l l b l d fl tigood with minimal global deflection

• Local Deflection with Large Fragments

• FR Vinylester ShieldStrand V-hull passed blast & full scale diesel fuel fire test

• Minimal secondary behind armor effects V hull• Minimal secondary behind armor effects – V-hull vents Blast, Composite stops fragmentation, while structure absorbs Blast energy and dissipates shockdissipates shock.

Force vs. Time

4000

5000

6000

7000

8000

s)

18-2000

-1000

0

1000

2000

3000

0 0.005 0.01 0.015 0.02 0.025 0.03 0.035

Time (s)

Forc

e (lb

s

ShieldStrand® Phenolic Plate:Provides structure as well as protectionProvides structure as well as protection

Elastic Constants 106 PSILongitudinal Modulus D3039, D638 3.5 - 4.6

Ultimate Strains %Longitudinal Tension D3039, D638 1.5 - 4g

Transverse Modulus D3039, D638 3.5 - 4.6Axial Shear Modulus D3518 0.5 - 0.7Axial Comp Modulus D695 5.2 - 6.7Poisson's Ratio D3039 0.24 - 0.27

gLongitudinal Compression D3410, D695 0.7 - 2Transverse Tension D3039, D638 1.5 - 4Transverse Compression D3410, D695 0.7 - 2In-Plane Shear D3518 2 - 2.5

Strength Properties 103 PSILongitudinal Tension D3039, D638 60 - 100Longitudinal Compression D3410, D695 20 - 80Transverse Tension D3039, D638 60 - 100Transverse Compression D3410, D695 20 - 80

Physical PropertiesFiber Volume D2734 61 - 66%Resin Weight D2584 16 - 24%Water Absorption D570, D792 <1.5%Longitudinal Flexural, Wet Ret. D790 >70% p

Normal Compression D695 100 - 120In-Plane Shear D3518 17 - 30Interlaminar Shear D2344 1.9 - 4.0Longitudinal Flexural D790 20 - 45Longitudinal Bearing D953 35 - 80

Thickness (in.) 0.470 - 0.530Ply Thickness (in.) 25 ply 0.019 - 0.020Areal Density (lb/sf) 25 ply 4.6 - 5.4Density (lb/ci) D792 0.072 - 0.074Hardness (M scale) D785 >80Thermal Transition D4065 210 - 240Flammability UL 94 V0Time to Ignition @50kW/sm (s) E1354 500 - 600Total Heat Release (MJ/sm) E1354 25 - 60MAHRE (kW/sm) E1354 20 - 35

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FIGRA E1354 0.10 - 0.20

Data shown for comparative purposes only and should not be construed as a guaranty or warranty of performance. Absolute performance will vary

by resin system or process

Shieldstrand® Solution Case Histories

MRAP JLTVFCS

HMMWVSpall Liner

MRAP EFP KitIntegratedStructural

Cab

Composite

Frag 5 Door Kit

CompositeV-hull

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spall liners exterior armor modules v-hull structural components

Compression Molded Phenolic Infusion Molded FR Epoxy Vinylester

Shieldstrand® Solutions for Armor Protectionotect o

Shieldstrand® Fibers delivers optimum strength and stiffness

S-2 Glass UHMW Polyethylene

AramidMetal (Steel & Al)

ShieldStrand® S Plus

S-2 Glass UHMW Polyethylene

AramidMetal (Steel & Al)

ShieldStrand® S Plus

Ultimate energy absorption controlled by strain to failure of the fibres. Once fibres have ruptured the armour collapses and no further energy is absorbed.

Assumes equal ballistic threat for all materials

+

+

+

---+++Structural Capability

---+++++Cost

+++++-+Weight

Assumes equal ballistic threat for all materials

+

+

+

---+++Structural Capability

---+++++Cost

+++++-+Weight

+

++

+ ---+++Part thickness (thin is +)

-+-++Resistance to acid and chemical attack

-++++Fire, Smoke and Toxicity

+

++

+ ---+++Part thickness (thin is +)

-+-++Resistance to acid and chemical attack

-++++Fire, Smoke and Toxicity

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21A balanced solution ½ weight of Steel and 1/3 cost of UHMWPE

+ -++++Temperature Resistance

+ -++++Temperature Resistance