Reidy Design of MultiLayer Ceramic Ballistic Plates Final Report Spring 2015 Classification Projectile Caliber Projectile Weight Velocity Type IIA 357 Magnum jacketed soft point 9mm ID: 800841
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Slide1
By: Jacob ScottAdvisor: Dr. Rick Reidy
Design of Multi-Layer Ceramic Ballistic Plates: Final Report
Spring 2015
Slide2Classification
Projectile Caliber
Projectile WeightVelocityType II-A.357 Magnum jacketed soft point9mm full-metal jacketed10.2 g (158 gr)8.0 g (124 gr)1,250 ft/s1,090 ft/sType II.357 Magnum jacketed soft point9mm full-metal jacketed10.2 g (158 gr)8.0 g (124 gr)1,395 ft/s1,175 ft/sType III-A.44 Magnum lead semi-wadcutter9mm full-metal jacketed15.55 g (240 gr)8.0 g (124 gr)1,400 ft/s1,400 ft/sType III*7.62 mm full-metal jacketed9.7 g (150 gr)2,750 ft/sType IV*.30-06 armor-piercing 10.8 g (166 gr)2,850 ft/s
Standards- National Institute of Justice3
*Type III and IV both contain hard or semi-rigid plates, while the rest are “soft/concealable”
3
NIJ Guide 100-98. US Department of Justice.
Selection and Application Guide to Police Body Armor
Slide3Standards- NIJ Testing
Slide4(Enhanced) Small Arms Protective Inserts (SAPI + ESAPI)First put through a selection of hot, cold, saltwater, oil, fuel, and then dropped
SAPI must stop 3 shots “against threats A,B,C”
ESAPI must stop 3 shots “against threats A,B,C” and 2 shots “against threat D”Threats A, B, C, D are classifiedStandards- Department of Defense44Report No. D-2009-047. Inspector General US:DOD. DoD Testing Requirements for Body Armor
Slide5US Patent- US7556855 B2Uses layered tape cast yttria stabilized zirconia (YSZ)/alumina in a strain rate sensitive polymer
Recommends minimizing grain growth of YSZ to promote crack deflection
Only specifies overall weight percents, does not go into detail on types of YSZ, or casting proceduresLiterature ReviewItem 101- Strain rate sensitive polymerItem 110- Ceramics to break projectileItems 12X- Interconnected ceramics to further break and/or catch fragmentsItem 140- Ballistic fiber to catch fragments
Slide6US Patent- US7803732 B1Mixing zirconia with silicon carbide increases controlled defects
Leads to increased surface area that is fractured during a ballistic event
Leading to the spreading and dispersion of the impact i.e. can disperse a larger projectileLiterature Review (Continued)
Slide7Literature Review (Continued)
3
mol% YSZ8 mol% YSZStructureTetragonalCubicSpace Group#137- P42/nmc#225- Fm3mDefect Equations: (Anti-Frenkel)ZrO2 = ZrZrX+2VO**+2Oi’’ Y2O3= 2YZr’+VO**+3OOX
Slide8Research has shown that 3 mol% YSZ has a 2-3 times higher flexural strength versus 8 mol% YSZ. 1
8mol% is generally used for solid oxide fuel cells
The recipe featured in Fabrication of electrolyte materials for solid oxide fuel cells by tape-casting, was investigated and found that the materials used are no longer available. Literature Review (Continued)1Fabrication of electrolyte materials for solid oxide fuel cells by tape-casting. P. Timakul et al.
Slide9Tape casting of 3mol% YSZ with the recipe from C.
Suciu
et al2 created thin tapes with minimal cracking, clean burn out. Literature Review (Continued)2Water-based tape-casting of SOFC…. Of their pellets. C. Suciu et al. PartWeight PercentPowder (TZ-3Y-E)48.1Binder (WB4101)21Defoamer (DF002)0.3Solvent (DI Water)30.1PH balancer (Ammonium Hydroxide)0.2
Slide10Design a plate that will stop a single 200 joule impact force (equivalent to typical .22LR caliber bullet impact)
Design Goal
Slide11The main constraints for this project are the thickness and the weight of the plates.
Constraints
Slide12Tape cast crack-free YSZ tapesLayer tapes to increase thicknessSinter tapes to achieve full tetragonal phase
Achieve 95% theoretical density (6.0 g/cm^3)
Achieve Vickers hardness value 1250 HVObjectives
Slide13Create and mill slurry of YSZ, binder, defoamer, water
Tape cast slurry forming tape
Section tape, and layer increasing thicknessSinter layered tapes into plates to join layersCharacterize though SEM, XRD, impact testing, hardness testing, density measurements, etcIncrease number of layers until design goal metDesign of Experiment
Slide14Gantt Chart
Slide15Pert Chart
Slide16Tape Casting Diagram
Slide17Run 1- “Trial Run”
Slide18Run 1 Results
Appears to have pink tint- Believed to be caused by incorrect amount of ammonia hydroxide added due to calculation error
Significant crackingCracking believed to be caused by too high of bed heat and too large of doctor blade heightLarge amount of batch wasted from spillage
Slide19Run 2
Slide20Run 2 Results
Changes
Lowered bed temperatureLowered doctor blade heightAdded correct amount of ammonia hydroxideAdded slightly more defoamerUsed wider film to cast onto to help with spillageResultsCracks formed on thicker sideThickness gradient resulting from unlevel tableWhite color achievedHave a large section of useable crack free tape Still small amount of spillage
Slide21Run 3
Slide22Run 3- Results
Changes
Leveled tableCreated slurry as directed by recipeUsed similar doctor blade height as first test to observe if having table level would reduce cracking along with the appropriate amount of ammonium hydroxide addedResultsNo spillage from film, but the slurry did still spread on filmLarge amount of cracking
Slide23Run 4
Slide24Run 4
Slide25Run 4- Results
Changes
Reduced doctor blade height to 0.35 ± 0.02mmIncreased casting speedAdded similar amount of defoamer as Run 2ResultsFirst ~70% of casting had lots of crackingLast ~30% of casting had a mostly crack free zone of good useable tape
Slide26Run 5
Slide27Run 5- Results
Changes
Slightly reduced doctor blade height to 0.25 ± 0.02mmCast using 12” doctor bladeDid not add ammonium hydroxideResultsVery small cracking in first few inchesOverall very uniform and crack free tape
Slide28Run 6
Slide29ChangesRaised bed cover to vent humidity
Followed recipe from run 5, now standard
Increased doctor blade height slightly to 0.30 ± 0.02mmResultsLeading edge had some crackingSeveral small cracks dispersed throughoutTape dried noticeably quickerOverall very good, useable tapeFound better way to remove tape from Mylar™ backingRun 6- Results
Slide30Run 7
Slide31ChangesBed cover was replaced, not vented
Doctor blade increased slightly to 0.33
± 0.02mmResultsFirst ~3 inches and 0.5 inch border cracked, rest of tape was pristine minus a couple small flawsRun 7- Results
Slide32Sintering
Slide33Sintering
Schedule: 40*C/hour until 650*C > 145*C/hour until 1200*C/held for 4 hours cooled at 145*C until room temperature
Sintering was done in 1 of 4 different batchesTime at max temperature not confirmed in first batchForth batch max temperature time was lengthened 1 hourStrong texturing in first 2 batches from the “sandwich plates” Some plates have small gaps where tapes are layeredTapes that were sintered without weight on top didn’t adhere together
Slide34Run
Average Density g/cm
3Std Dev22.760.13543.320.25952.680.16563.120.41873.130.540Density MeasurementsGreenBatch(run)Average Density g/cm3Std Dev% Theoretical Density1 (5)2.990.45150%2 (5)4.220.21871%3 (6)4.890.20381%4 (7)4.170.618
69%
Sintered
The highest density from a single plate came from the third sintering batch with a density of 5.15 g/cm^3 (~85% TD)
Slide35SEM
Sintering Batch
Average Grain Size (nm)Standard DeviationAppears Porous13120.089Yes22800.098No32830.077No
Slide36XRD
Values in black represent tetragonal reflections, while values in orange represent monoclinic reflections. Using formulas found in [6] that compare relative intensity ratios, the raw powder was calculated to be 67.5% tetragonal 32.5% monoclinic; the green tape was calculated to be 63.6% tetragonal 36.4% monoclinic. The increase of monoclinic content can be attributed from phase transformation toughening that occurred during ball milling and tape casting. The sintered plates were completely tetragonal as expected based on sintering temperature.
Slide37Batch
Hardness (HV)
Standard Deviation2950240.443139065.084153071.48VickersVickers microhardness testing was performed on 3 samples from 3 different sintering batches. The average hardness value is based on 10 tests per sample. The average hardness value in literature ranges from 1250-1300 HV.
Slide38Impact testing was performed by dropping a rod of ATI 718Plus
© that weighed 1.22 kg from various heights.
Impact TestingDrop Height (cm)ResultEnergy (J)Thickness (mm)Layers7.45Pass0.890.4589.58Pass1.140.458
21.59Pass
2.57
0.79
8
21.59
Fail
2.57
0.48
8
21.59
Pass
2.57
0.65
8
21.59
Pass
2.57
1.05
16
21.59
Pass
2.57
1.05
16
21.59
Pass
2.57
1.21
16
32.385
Pass
3.86
0.52
6
32.385
Fail
3.86
0.5
6
Slide39Using the 100% success rate of the 16 layer samples stopping 2.57 J at minimum, and assuming a linear trend, it would take 78 plates with combined 1248 layers, with a mass of 229.75 g, and a total thickness of 8.58 cm to stop a single 200 J impact.
Achieving 95+% theoretical density should reduce this thickness dramatically
Meeting the Design Goal
Slide40YSZ was tape casted, sintered, characterized, and impact tested. To meet the design goal it would take an estimated 1248 layers with an estimated thickness and mass off 8.58 cm and 229.75 g respectively.
Summary
Slide41I would like to thank Dr. Rick Reidy for his insight and help with the project, Polymer Innovations for supplying a sampling of their products for use, David Bryce for performing SEM and XRD on the samples,
Oseoghaghare
Okobiah for sputter coating the SEM samples, Dr. Rajiv Mishra for letting me use his Vickers microhardness tester, and the UNT Materials Science department for providing the funding for the rest of the materials and equipment use. Acknowledgements
Slide42US Patent: US7556855 B2 US Patent: US7803732 B1
[1]
Fabrication of electrolyte materials for solid oxide fuel cells by tape-casting. P. Timakul et al. [2] Water-based tape-casting of SOFC composite 3YSZ/8YSZ electrolytes and ionic conductivity of their pellets. C. Suciu et al. [3] NIJ Guide 100-98. US Department of Justice. Selection and Application Guide to Police Body Armor [4] Report No. D-2009-047. Inspector General US:DOD. DoD Testing Requirements for Body Armor [5] Tape Casting Theory and Practice. R. E. Mistler, E. R. Twiname. The American Ceramic Society, 2000. [6] Quantitative Analysis of Pholymorphic Mixes of Zirconia by X-ray Diffraction. H. K. Schmid.[7] H. McMurdie, Pow. Diff. Jour., 1, 1986, 275.[8] G. Teufer, Acta. Cryst., 15, 1962, 1187.References