Presentation 8 • November 18 • 10:00 AM

Lightweight Composite Integrated Structural Armor

~ presented by ~

Al Chan, Grey Chapman, David Hartman Owens Corning Science & Technology Center

8101 Iron Bank Court Raleigh, NC 27606 USA

Tel: 919-518-7855 Email: grey.chapman@owenscorning.com

“High Performance Reinforcements for

Integrated Structural Armor”

Al Chan High-Performance Fibers 2009

October 18, 2009

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Lightweight Composite Material Enables

High

Low

Mob

ility

Low HighBallistic Lethality

• Helicopter• Defense Vehicles• Amphibious Assault

Vehicles

• Homeland Security • Bridges / Infrastructure• Embassies

• Marine Deckhouses• Marine Hull Components• Coast Guard• Battlefield ISO Shelters

• Fighter Jets• Tactical Vehicles• Personal Armor

Improved Mobility and Ballistic Performance

3

Tactical Mobility and Strategic Deployability Drive the Need for Lighter Weight Vehicles

• System of systems• Integrated Survivability

– Advanced armor– Active Protection– Situational Awareness

• Advanced Weapons• Agility/mobility

Multifunctional Integration

Future< 20 ton

Bigger guns, more armor to counter

incremental increase in threats

4

Stronger for Better Protection in Lightweight Composite Structures

Typical Stress-Strain Curves of Fibers

-4000

-2000

0

2000

4000

6000

-4.0 -2.0 0.0 2.0 4.0 6.0 %

MPa

E Glass

S Glass

HS Carbon Aramid

Advantex

HiPer-texR Glass

Typical Stress-Strain Curves of Fibers

-4000

-2000

0

2000

4000

6000

-4.0 -2.0 0.0 2.0 4.0 6.0 %

MPa

E Glass

S Glass

HS Carbon Aramid

Advantex

HiPer-texR Glass

Tension

Compression

Fiber surface silane chemistry provides adhesive compatibility engineered for ballistic and structural performance

5

• 1939: OCV invented E-glass – Boron added to glass for electrical properties

• 1968: OCV developed S-2 Glass®

– High Performance Glass (high melting power needed)– Small capacity furnaces due to limits in melting technologies

• 1980: OCV developed E-CR Glass®

– Corrosion resistant glass.

• 1997: OCV developed Advantex® Glass and Technology– Boron free E-glass (higher melting power than traditional E-Glass)– ECR-glass (superior corrosion resistance to traditional E-glass)– Breakthrough in melting technology for large capacity furnaces

• 2006: OCV developed High Performance Glass Technology– Combines High-Performance Glass (HPG) and melting technology– Production of High-Performance Glass in large capacity furnaces

• 2009: OCV developed SS--glassglass formulation based on HPG – High-Performance Glass formulation meets all international standards for S-glass

• ASTM C-162, DIN 1259, ISO 2078, ASTM D578, and JIS R3410 standards.– Results in lower cost and increased capacity

Glass and Melting Technology Innovation

Large capacity furnaces provide a readily available supply of high performance glass fibers

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1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

5.00 5.10 5.20 5.30 5.40

Areal Density (psf)

30 c

al F

SP V

50 (f

ps)

ShieldStrand S Molder 1

ShieldStrand S Molder 2

ShieldStrand S Molder 3

ShieldStrand R GlassClass A

Class B

ShieldStrand® Levels of Performance

Ballistic Performance per MIL-DTL-64154B

7

ShieldStrand® Hybrid Armor Comparison 20mm FSP MIL-STD-662 Ballistic V50 Performance

0

1000

2000

3000

4000

5000

6000

7000

0 10 20 30 40 50

Areal Density (lb/ft2)

Bal

listic

Lim

it V5

0 (f

t/s)

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

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Areal Density Includes 10.5 lb/ft2 RHA Steel Door Skin

M61AP 2850 ft/sAP and FRAG5 Screening Tests

20mm FSP 3500 ft/s

IED/EFP notWorse than AL

ShieldStrand® Armor Exterior Modules Ballistic Multi-threat Performance

Ref: UDRI, AMG NTS, BAES testing

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ShieldStrand® Phenolic Plate Properties

Elastic Constants 106 PSILongitudinal Modulus D3039, D638 3.5 - 4.6Transverse 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

Strength Properties 103 PSILongitudinal Tension D3039, D638 60 - 100Longitudinal Compression D3410, D695 20 - 80Transverse Tension D3039, D638 60 - 100Transverse Compression D3410, D695 20 - 80Normal Compression D695 100 - 120In-Plane Shear D3518 17 - 30Interlaminar Shear D2344 1.9 - 4.0Longitudinal Flexural D790 20 - 45Longitudinal Bearing D953 35 - 80

Ultimate Strains %Longitudinal Tension D3039, D638 1.5 - 4Longitudinal Compression D3410, D695 0.7 - 2Transverse Tension D3039, D638 1.5 - 4Transverse Compression D3410, D695 0.7 - 2In-Plane Shear D3518 2 - 2.5

Physical PropertiesFiber Volume D2734 61 - 66%Resin Weight D2584 16 - 24%Water Absorption D570, D792 <1.5%Longitudinal Flexural, Wet Ret. D790 >70% 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 - 35FIGRA E1354 0.10 - 0.20

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$-

$10.00

$20.00

$30.00

$40.00

$50.00

$60.00

0 2 4 6 8 10 12

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

Cos

t ($/

lb)

UHMWPE

Aramid/Phenolic S-2 Glass®

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

ShieldStrand® Enables Lightweight Composite Armor Affordability

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Evolution of Composite Armor from flat plate to complex shapes for integration with steel

spall liners exterior armor modules v-hull structural components

HMMWV MRAP

BRADLEY LAVM113 STRYKER

JLTVFCS

CompositeV-hull

Compression Molded Phenolic Infusion Molded FR Epoxy Vinylester

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

• Effective Blast Management – structurally good with minimal global deflection for up to 20lbs C4 or equivalent CB with 18 and 32 inch standoff.

• FR Vinylester ShieldStrand V-hull Passed 155mm mortar buried flush with standoff at 32 inch… V-hull was then subjected to full scale diesel fuel fire test and Passed.

• Minimal Secondary Effects Behind Armor – V-hull vents Blast, Composite stops fragmentation, while structure absorbs Blast energy and dissipates shock.

• Blast Simulation Modeling at UDCCM, UDRI and OSU for Composite Structures with comparison to LS Dyna with Johnson Cook parameters.

• (Ref: SwRI, BAE, AMG, ARL/ATC pending reports, DAAL04- 92-C-0014, DAAL04-86-C-0079 armor reports)

Force vs. Time

-2000

-1000

0

1000

2000

3000

4000

5000

6000

7000

8000

0 0.005 0.01 0.015 0.02 0.025 0.03 0.035

Time (s)

Forc

e (lb

s)

13

macromacro--scalescale

Simulation of Damage Evolution in a Clamped Plate Subjected to Blast Loading

Blast Pressure (P)

P

Time

micromicro--scalescale

Comparison of HCDM and HMMComparison of HCDM and HMM

-1.5E-02

-5.0E-03

5.0E-03

1.5E-02

2.5E-02

0.E+00 2.E-04 4.E-04 6.E-04 8.E-04 1.E-03

Time (s)

Stre

ss

HMM S11HCDM S11HMM S22HCDM S22

Distribution of Distribution of ( )dW

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Evaluation of ShieldStrand® Material and Process Parameters for Complex Shapes• Resin Infusion of large V-hull structure of ShieldStrand,

foam core and metal inserts resulted in good structural, blast and fragmentation performance.

• FR synergists allowed excellent vinylester resin infusion process resulting in good fire performance.

• QuickStep process consolidation of phenolic prepreg in complex shapes gave 90 - 95% of the ballistic performance of compression molded phenolic.

• QuickStep demonstrated capability to produce 4 inch thick complex parts with reasonable process time.

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Integrated Structural Armor

ShieldStrand® is making new armor solutions possible• The strength of ShieldStrand® provides structure as well as

protection, allowing armor to be integrated into the vehicle structure, reducing overall vehicle weight

– Lower weight means increased vehicle payload, mobility and increased warfighter survivability

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

• ShieldStrand® reinforcements are produced on a large scale using OCV innovative breakthrough glass fiber technology making it available and affordable. Production can support surges common in defense applications.

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ShieldStrand® Makes Lightweight Structures with Durable Protection

Delivering Performance• Validated MIL-DTL-64154B ballistic performance• 40% weight savings versus aluminum for equivalent FSP protection,

increasing vehicle protection, payload and mobility • Use with a steel or ceramic strike face to provide protection when armor

piercing and multi hit capability is required or an overmatched threat exists• Meets all fire, smoke and toxicity requirements• Provide better durability in high temperature, corrosive environments.

Enabling Possibilities• Provides structure as well as protection, allowing armor to be integrated into

the vehicle structure, reducing overall vehicle weight• Can be molded into large complex-shaped structural parts using proven large

scale composite manufacturing technologies. • Because it is affordable, at 1/3 the cost of UHMWPE, more vehicles can be

protected, increasing warfighter survivability

Readily Available• Produced on a large scale using OCV innovative breakthrough glass fiber

technology making it available and affordable• Production can support surges common in defense applications.• Provide an alternative supply chain that is less volatile