Comprehensive Evaluation of Layered Composite Protection Performance for Light Armored Vehicles

Abstract This study addresses the critical need for lightweight and effective ballistic protection in military applications, focusing on layered composite systems designed to meet NATO STANAG 4569 Level I standard. The layered ballistic protection combines Hardox 450 wear-resistant steel with Twaron CT 747 para-aramid fabric and Endumax Shield XF33 Ultra-High-Molecular-Weight polyethylene (UHMWPE). Three configurations of ballistic protection were evaluated, each differing in steel thickness and areal weight. Configurations 1 and 2, with 6-mm and 4-mm Hardox 450 steel, and areal weights of 84.3 kg/m 2 and 68.6 kg/m 2 , respectively, successfully resisted 7.62-mm NATO FMJ M80 projectile impacts while maintaining structural integrity. Configuration 3, comprising 2-mm Hardox 450 steel (52.9 kg/m 2 ), was not penetrated by the projectile but detached from the frame due to localized impact near the edge. Microscopic analysis identified delamination and cracking of the reinforcing fibers and matrix as dominant failure mechanisms. Combining experimental testing with numerical simulations confirms that these layered protection systems offer high ballistic resistance while maintaining low weight, offering significant advancements in the design of military vehicle protection systems.