Ballistic Impact Tests on Fiber Metal Laminates: Experiments and Modeling

In the aviation industry the so-called ballistic impact of small accidental or human-made sources on aircraft elements during their service life encompasses several scenarios of practical interest. The experimental assessment of ballistic impact requires dedicated infrastructures (such as the light-gas gun system utilized in this study) and exhibits intrinsic difficulties, mainly concerning the proper acceleration of a projectile and the accurate measurement by a high-speed camera of its (inlet and outlet) velocity. As a first objective, this study aimed at characterizing the dynamic response of fiber metal laminates, manufactured ad hoc by the authors with two different stacking sequences currently not available in commerce. The layups included aluminum 2024 T3 and aramid fiber-reinforced prepregs, leading through specific treatments to excellent specific properties. The collision of the laminate with a 25 g, 9 mm radius steel sphere, traveling at speeds ranging from 90 to 145 m/s, caused a variety of scenarios: partial or complete penetration, with the projectile passing through and continuing its trajectory, remaining stuck in the sample (embedment) or even being bounced back (ricochet). The experimental information led to the estimation, for each typology of sample, of a conventional ballistic limit according to the Lambert-Jonas approximation, as a second objective, these data were utilized to validate an accurate heterogeneous model of the samples developed in the ABAQUS® platform, discretized by finite elements in explicit dynamics and including geometric nonlinearity and contact. We describe plasticity and damage of the metal layers by the Johnson–Cook phenomenological model, progressive failure in the fiber-reinforced plies through a 2D Hashin criterion with damage evolution, and interlaminar debonding at multiple cohesive interfaces governed by the Benzeggagh–Kenane criterion. The outlet speed of the bullet measured during the experiments was retrieved correctly by this model, and a satisfactory agreement of the finite element predictions was found with the deformation patterns and the damage mechanisms identified by post mortem visual inspection. Finally, several discussion points are raised, concerning the robustness of the numerical analyses, the reliability of the constitutive modeling and the identification of the governing parameters.