Unveiling the armor: experimental study on ballistic impact resistance of silica aerogel, sorbothane, and graphite sandwich composites

Ballistic armour is intended to save lives by absorbing the impact of bullets and preventing them from entering the wearer’s body. Especially for police enforcement, security, and military professionals. However, the research on armor that withstanding the impacts of shockwaves during the explosives are limited. This study evaluates a singular sandwich composite of silica aerogel, Sorbothane, and graphite (SiSG) against explosive shockwaves and ballistic impacts, marking the inaugural dual-mode assessment of lightweight structural armour. This optimised structure surpasses traditional materials in explosive and ballistic situations due to the unique amalgamation of aerogel’s exceptionally low density and thermal resistance, Sorbothane’s exceptional damping characteristics, and graphite’s elevated stiffness. To more accurately replicate real-world settings, we may get insights on item reactions upon impact near the target by conducting ballistic experiments at a confined range of 2 m, far less than the standard 55 m. The optimal, previously unreleased layer sequence—graphite strike face, aerogel intermediate, and Sorbothane backing—was established by combining these trials with extensive ANSYS finite-element simulations. The absence of apparent surface damage in shockwave-treated SiSG panels sets a new standard for the blast resistance of lightweight composites. This extensive set of testing and computer simulations establishes the foundation for next-generation multifunctional armour systems are the novelties which elicits this research. The experimental findings reveal that the sandwich composite, comprising silica aerogel, Sorbothane, and graphite layers, demonstrates superior resilience against both shockwaves and bullet impacts. The shockwave-treated materials exhibit no physical damage on their outer surfaces, affirming their ability to withstand explosions. This research underscores the critical role of material selection and design in enhancing structural resilience, contributing significantly to the advancement of material science and engineering.