Ballistic performance of multi-layered armor combinations under 7.62 × 51 mm FMJ bullet impact

Abstract This work performed a nonlinear numerical analysis of Armox 500T and Hardox 450 armor steels, Kevlar 29/epoxy laminate, and aluminum honeycomb materials under ballistic conditions, validating the results via experimental data. The ballistic performance of 20 distinct armor configurations was investigated, including monolithic steel, steel-composite, and steel-composite-honeycomb panels produced by various material arrangements. Ballistics tests were conducted using 7.62 × 51 mm full metal jacket bullets with a muzzle velocity of 838 ± 15 m s −1 under the NIJ 0108.01 III protection level standard. The effect of Kevlar29/epoxy layer thickness in multi-layered panels was examined extensively. The results showed that the ballistic performance of the composite armors was significantly improved due to the combination of monolithic steel plates with Kevlar 29/epoxy and aluminum honeycomb layers. Steel-Kevlar 29/epoxy and steel-Kevlar 29/epoxy-honeycomb multi-layered plates provide identical ballistic protection to monolithic steel counterparts while being 51 wt.% and 57 wt.% lighter than monolithic steel armor. Comprehensive finite element simulations of the ballistic impact events were conducted to elucidate the phenomena of defeat and penetration with greater precision.