Synergistic Effects of Boron Carbide and Graphene Nanoplatelets on the Ballistic Performance of Aluminum Matrix Hybrid Composites for Advanced Armor Applications

Abstract In this study, the metallurgical and ballistic properties of aluminum matrix composites (AMCs) reinforced with varying ratios of boron carbide (B 4 C) and 0.5% graphene nanoplatelets (GNPs) were experimentally investigated to determine the optimal structure for armor applications. Hybrid GNP/B 4 C/AA7075 AMCs were fabricated using the stir casting method, incorporating 0.5% GNP and B 4 C in the range of 2.5–22.5%. The influence of B 4 C reinforcement and GNP addition on the AA7075 alloy was systematically analyzed through structural, crystallographic, microhardness, and ballistic impact assessments. The bullet core and AA7075 plate used in the ballistic tests were modeled in Abaqus-2022 utilizing the Johnson–Cook (J–C) damage model parameters The ballistic test results, which were obtained using the 7.62 × 39 mm API BZ (former Soviet designation for Armor-Piercing Incendiary bullet) projectile, were found to behave consistently with the numerical modelling analyses. In conclusion, the optimal performance was achieved with a composition of 15% B 4 C and 0.5% GNP. Ballistic efficiency began to decline when the B 4 C reinforcement ratio exceeded 15%.