Improving the energy and physical-mechanical characteristics of armor-protective elements of a new design

This study focuses on the improvement of multilayer armor-protective elements that integrate high-hardness materials, viscoelastic layers, and porous components to optimize energy dissipation and impact resistance. A mathematical model for numerical simulation of the damage process of armor-protective elements was developed, including an iterative procedure for defining material behavior in the Ansys/AutoDYN system. Convex multilayer armor structures were manufactured using explosive welding (steel–aluminum–steel; titanium–aluminum–titanium), and their ballistic resistance was evaluated through standardized NIJ 0101.06 tests. Numerical simulations demonstrated up to 70 % energy dissipation and a 5–6-fold reduction in damaging effect compared to flat layered armor. Experimental ballistic testing confirmed the feasibility of the proposed elements: neither 5.56 × 45 mm NATO nor 7.62 × 39 mm MSC projectiles penetrated the multilayer structures. Back-face deformation values remained below 3 mm, significantly lower than NIJ standards, validating both protective efficiency and structural integrity. The study confirms that convex multilayer armor elements produced by explosive welding provide enhanced ballistic resistance through combined mechanisms of plastic deformation, viscoelastic energy absorption, and geometric deflection. These findings support the practical application of the proposed structures in military vehicles, protective vests, and security systems, and open directions for future research on adaptive armor systems.