Experimental Investigation on Mechanical and Microstructural Properties of Hybrid Composite Materials for Ballistic Armor Applications

Recently, industries have increasingly required lightweight materials with high strength for specific applications, such as in the manufacturing of ballistic armor. In this work, three synthetic fibers are used: Kevlar, carbon, and glass fiber, and two different sample laminates are fabricated. The fibers are arranged using a hand lay-up process. Out of the two samples, one includes Expanded Polyethylene (EPE) foam--to increase the thickness--while the other does not contain EPE foam. The samples are fabricated in a specific fiber sequence, starting with Kevlar, followed by carbon, and then glass fiber. In the sample with foam, two EPE foam sheets are used and placed between two sequential layers of fibers. Mechanical and microstructural characterization was performed, including tensile testing, flexural testing, DMA testing, and SEM analysis, and the corresponding results were obtained. These fiber laminates are intended for ballistic armor applications, where the three fibers contribute by reducing weight, increasing strength, and enhancing performance, thereby preventing bullet penetration and ultimately saving human life. Advanced materials like Kevlar, ceramic plates, and ultra-high molecular weight polyethylene are used in modern ballistic armour to offer lightweight, yet effective, protection against a range of threat levels, including rifle and handgun ammunition. With continuous research aimed at enhancing protection-to-weight ratios and multi-threat capabilities, these protective systems go beyond personal body armour to include vehicle armouring, aircraft protection, and stationary barriers for critical infrastructure.