Search Results (36)

The continuous advancement of modern weaponry has intensified the pursuit of next-generation ballistic protection systems that integrate lightweight architectures, superior flexibility, and high energy absorption efficiency. This review provides a technological overview of current trends in the design, processing, and performance optimization of metallic, ceramic, polymeric, and composite materials for ballistic applications. Particular emphasis is placed on the role of advanced surface coatings and nanostructured interfaces as enabling technologies for improved impact resistance and multifunctionality. Conventional materials such as high-strength steels, alumina, silicon carbide, boron carbide, Kevlar^®, and ultra-high-molecular-weight polyethylene (UHMWPE) continue to dominate the field due to their outstanding mechanical properties; however, their intrinsic limitations have prompted a transition toward nanotechnology-assisted solutions. Functional coatings incorporating nanosilica, graphene and graphene oxide, carbon nanotubes (CNTs), and zinc oxide nanowires (ZnO NWs) have demonstrated significant enhancement in interfacial adhesion, inter-yarn friction, and energy dissipation. Moreover, multifunctional coatings such as CNT- and laser-induced graphene (LIG)-based layers integrate sensing capability, electromagnetic interference (EMI) shielding, and thermal stability, supporting the development of smart and adaptive protection platforms. By combining experimental evidence with computational modeling and materials informatics, this review highlights the technological impact of coating-assisted strategies in the evolution of lightweight, high-performance, and multifunctional ballistic armor systems for defense and civil protection. Full article

This study investigates the ballistic performance and energy-absorption behavior of advanced multilayer ceramic composite armor systems composed of silicon carbide (SiC) ceramics, composite metal foam (CMF), rolled homogeneous armor (RHA), ultra-high-molecular-weight polyethylene (UHMWPE), aluminum, and rubber interlayers. The objective is to enhance impact resistance and optimize energy dissipation efficiency against armor-piercing (AP) projectiles. Ballistic tests were performed following the NIJ Standard 0101.06 Level IV specifications using .30” caliber AP M2 rounds with an impact velocity of 784–844 m/s. Experimental results revealed that the SiC front layer effectively fragmented the projectile and dispersed its kinetic energy, while the CMF and UHMWPE layers were the primary energy absorbers, dissipating approximately 70% of the total impact energy (≈3660 J). The aluminum and RHA layers provided additional reinforcement, and the rubber interlayer significantly reduced stress-wave propagation and suppressed crack growth in the ceramic. The most efficient configuration 0.5 mm RHA + 7 mm SiC + 7 mm EPDM + 7 mm CMF + 5 mm UHMWPE achieved an areal density absorption of 77.2 J·m²/kg and a unit thickness absorption of 190.6 J/mm. These findings establish a quantitative layer-wise energy dissipation framework, highlighting the synergistic interaction between brittle, porous, and ductile layers. This work provides practical design principles for developing lightweight, high-efficiency composite armor systems applicable to defense, aerospace, and personal protection fields. Moreover, this study not only validates the NIJ Standard 0101.06 ballistic performance experimentally but also establishes a reproducible methodology for quantitative, layer-wise energy analysis of hybrid ceramic-CMF-fiber armor systems, offering a scientific framework for future model calibration and optimization. Full article

This study investigates the ballistic performance of epoxy matrix composites reinforced with raffia fabric, aiming to evaluate their potential as the second layer in multilayered armor systems (MAS), replacing conventional synthetic aramid (Kevlar™) laminates. Composite plates with different volumetric fractions of raffia fabric (10, 20, and 30%) were manufactured and integrated with a ceramic front layer (Al₂O₃/Nb₂O₅) in MAS structures, which were then subjected to ballistic impact tests using high-energy 7.62 mm caliber ammunition. The backface signature (indentation depth) measured in ballistic clay, used as a human body simulant, showed that only the 10% raffia-reinforced composite (ER10) met the National Institute of Justice (NIJ 0101.06) safety threshold of 44 mm. Higher raffia contents (20% and 30%) led to increased indentation, compromising ballistic integrity. Scanning electron microscopy (SEM) of the fractured surfaces revealed typical energy dissipation mechanisms, such as fiber rupture, fiber pull-out, and interfacial delamination. The results indicate that raffia fabric composites with 10% fiber content can serve as a cost-effective and sustainable alternative to Kevlar™ in personal armor applications, while maintaining compliance with ballistic protection standards. Full article

Ceramic armor with improved ballistic performance, lower weight, and, in specific cases, complex geometry is of high importance for the armor integrators and users. The combination of a high level of consolidation and the tailored heterogeneous structures of these ceramics may be important for reducing fracturing and delaying crack propagation under high-velocity ballistic impacts, therefore improving their ballistic performance. This can be attained by a beneficial combination of advanced ceramic compositions and processing, e.g., through an additive manufacturing (AM) approach. For example, the functionally graded (FG) monolithic ceramic armor obtained by AM can encompass a few layers, where the front layer has higher hardness, and the layer(s) behind may have higher fracture toughness. The ingredients reinforcing the ceramic structure may also be involved. The graded architecture should provide the internal stress reduction under high-velocity mechanical (ballistic) impacts. The reaction bonding that provides consolidation of the AM-based ceramic armor may also be involved. The considered principles of the FG materials’ formation may be employed for personnel, vehicular, and structural armor systems. The possibility of formation of ceramic armor with graded structures and compositions using AM was reviewed and analyzed for the first time. The proposed armor designs, which can be obtained by AM, may provide enhanced ballistic performance combined with lower weight. Full article

Wood-derived ceramics represent a novel class of bio-based composite materials that integrate the hierarchical porous architecture of natural wood with high-performance ceramic phases such as silicon carbide (SiC). This review systematically summarizes recent advances in the fabrication of SiC woodceramics via two predominant sintering routes—reactive infiltration sintering and hot-press sintering—and elucidates their effects on the resulting microstructure and mechanical properties. This review leverages the intrinsic anisotropic vascular network and multiscale porosity and mechanical strength, achieving ultralightweight yet mechanically robust ceramics with tunable anisotropy and dynamic energy dissipation capabilities. Critical process–structure–property relationships are highlighted, including the role of ceramic reinforcement phases, interfacial engineering, and multiscale toughening mechanisms. The review further explores emerging applications spanning extreme protection (e.g., ballistic armor and aerospace thermal shields), multifunctional devices (such as electromagnetic shielding and tribological components), and architectural innovations including seismic-resistant composites and energy-efficient building materials. Finally, key challenges such as sintering-induced deformation, interfacial bonding limitations, and scalability are discussed alongside future prospects involving low-temperature sintering, nanoscale interface reinforcement, and additive manufacturing. This mini overview provides essential insights into the design and optimization of wood-derived ceramics, advancing their transition from sustainable biomimetic materials to next-generation high-performance structural components. This review synthesizes data from over 50 recent studies (2011–2025) indexed in Scopus and Web of Science, highlighting three key advancements: (1) bio-templated anisotropy breaking the porosity–strength trade-off, (2) reactive vs. hot-press sintering mechanisms, and (3) multifunctional applications in extreme environments. Full article

Ceramic armor protection with complex shapes is limited by the difficult molding or machining processing, and 3D printing technology provides a feasible method for complex-shaped ceramics. In this study, ZrO₂ ceramics were manufactured by 3D printing accompanied with microwave sintering. In 3D printing, the formula of photosensitive resin was optimized by controlling the content of polyurethane acrylic (PUA) as oligomer, and the photosensitive resin with 50% PUA showed excellent curing performance with a small volume shrinkage of 4.05%, media viscosity of 550 mPa·s, and low critical exposure of 20 mJ/cm². Compared to conventional sintering, microwave sintering was beneficial to dense microstructures with fine grain size, and microwave sintering at 1500 °C was confirmed as an optimized sintering process for the 3D-printed ZrO₂ ceramics, and the obtained ceramics showed a relative density of 98.2% and mean grain size of 2.1 μm. The PUA content further affected the microstructure and mechanical property of the ZrO₂ ceramics. The sample with 10%~40% PUA showed some pores due to the low viscosity and large volume shrinkage of photosensitive resins, and the sample with 60% PUA exhibited an inhomogeneous microstructure with agglomeration, attributed to the high viscosity of photosensitive resins. Finally, the ZrO₂ ceramics via 3D printing with 50% PUA showed superior mechanical properties, whose Vickers hardness was 3.4 GPa, fracture toughness was 7.4 MPa·m^1/2, flexure strength was 1038 MPa, and dynamic strength at 1200 s⁻¹ was 4.9 GPa, conducive to the material’s employment as armor protection ceramics. Full article

The development of ballistic materials has improved very rapidly in the last few years. Body armor plays an important role in protecting individuals during military threats. Body armor can be divided into hard and soft variants depending on the trade-offs between protection levels and wearer agility. Current research aims to optimize strength-to-weight ratios by using different combinations of synthetic or natural fibers or their combinations to achieve increasingly demanding requirements for ballistic materials. Moreover, it examines the various types of fibers utilized in the construction of body armor, ranging from traditional materials like metal and ceramic to synthetic and natural fibers. This paper discusses ongoing research efforts aimed at further enhancing the performance of these materials, such as the incorporation of modified natural fibers into advanced composite systems. The review provides a comprehensive analysis of the current state of the materials utilized in ballistic protection. Full article

Boron carbide ceramics are potentially ideal candidates for lightweight bulletproof armor, but their use is currently limited by their low fracture toughness. Recent experimental results have shown that sintered samples with high twin densities exhibit high fracture toughness, but the toughening mechanism and associated crack propagation process of nanotwinned boron carbide at the atomic scale remain a mystery. Reported here are molecular dynamics simulations with a reactive force field potential to investigate how nanoscale twins affect the fracture toughness of boron carbide ceramics. The results show that the strength disparity on either side of a twin boundary is the fundamental reason for the toughening effect; the twin boundary impedes crack propagation only when the crack moves to a region of higher fracture strength. The fracture toughness of nanotwinned boron carbide is greatly affected by the angle between the twin boundary and the prefabricated crack. At an angle of 120°, the twin boundary provides the maximum toughening effect, enhancing the toughness by 32.72%. Moreover, phase boundaries—another common structure in boron carbide ceramics—have no toughening effect. This study provides new insights into the design of boron carbide ceramics with high fracture toughness. Full article

Armor composite structures have attracted interest in structural health monitoring (SHM) for their applications in damage localization. The signal propagation and the frequency dispersion features of the Lamb wave signal on thick armor composite structures are more complicated than their counterparts on other composite plates. In this research, a time-reversal localization and imaging method for impact localization of armor composite structures is proposed. First, composite sandwich structures were designed that are typically composed of ballistic-resistant ceramic materials as the face panel and a composite material as the core layer, sandwiched between metal materials serving as the backplate. The results show that the proposed method can validate the position of impact efficiently, and radial error is within 4.12 mm and 5.39 mm in single-damage and multi-damage imaging localization, respectively. Full article

Alumina ceramic is an ideal candidate for armor protection, but it is limited by the difficult molding or machining process. Three-dimensional printing imparts a superior geometric flexibility and shows good potential in the preparation of ceramics for armor protection. In this work, alumina ceramics were manufactured via 3D printing, and the effects of different monomers on the photosensitive slurry and sintered ceramics were investigated. The photosensitive slurries using dipropylene glycol diacrylate (DPGDA) as a monomer displayed the optimal curing performance, with a low viscosity, small volume shrinkage and low critical exposure energy, and each of the above properties was conducive to a good curing performance in 3D printing, making it a suitable formula for 3D-printed ceramic materials. In the 3D-printed ceramics with DPGDA as a monomer, a dense and uniform microstructure was exhibited after sintering. In comparison, the sample with trimethylolpropane triacrylate (TMPTA) showed an anisotropic microstructure with interlayer gaps and a porosity of about 9.8%. Attributed to the dense uniform microstructure, the sample with DPGDA exhibited superior properties, including a relative density of 97.5 ± 0.5%, a Vickers hardness of 19.4 ± 0.8 GPa, a fracture toughness of 2.6 ± 0.27 MPa·m^1/2, a bending strength of 690 ± 54 MPa, and a dynamic strength of 3.7 ± 0.6 GPa at a strain rate of 1200 s⁻¹. Full article

The incorporation of ductile reinforcements into ceramics helps restrain crack deflection, which can enhance ceramics’ toughness and overcome the matrix’s brittleness. In this paper, we produced a ceramic composite reinforced by carbon fibers coated by multi-wall carbon nanotubes (shortened by C_f-MWCNT/SiC composites) for enhanced impact resistance at a high strain rate that commonly occurs in composite materials used in astronautics, marine, and other engineering fields. The fabrication process involves growing multi-wall carbon nanotubes (MWCNTs) on a carbon fiber woven fabric (C_f) to create the fibril/fabric hybrid reinforcement. It is then impregnated by polymer solution (precursor of the ceramics), forming composites after the pyrolysis process, known as the liquid polymer infiltration and pyrolysis (PIP) technique. To assess the impact resistance of the C_f-MWCNT/SiC under high-strain rate compressions, the split Hopkinson pressure bar (SHPB) technique is employed. Since the failure behavior of the C_f-MWCNT/SiC composites in the absence of the ductile phase is not well understood, the study employs the Hilbert–Huang transform (HHT) to analyze the stress–time curves obtained from the SHPB experiments. By applying the HHT, we obtained the frequency–time spectrum and the marginal Hilbert spectrum of the stress signals. These analyses reveal the frequency characteristics of the C_f-MWCNT/SiC composite and provide insights into the relationship between transformed signal frequency and fracture behavior. By understanding the dynamic fracture behavior and frequency response of the C_f-MWCNT/SiC, it becomes possible to enhance its impact resistance and tailor its performance for specific protective requirements. Therefore, the findings of this study can guide the future design and optimization of C_f-MWCNT/SiC structures for various protective applications, such as body armor, civil structures, and protections for vehicles and aircraft. Full article

TiB₂ is a promising material for several fields including impact-resistant armor, wear-resistant coatings, cutting tools and crucibles given its physical, mechanical and chemical properties, especially due to the combination of high hardness and exceptional wear resistance. It is however very difficult to sinter below 2000 °C, even under mechanical pressure; moreover, the low fracture toughness limits the applicability of the ceramic material. By using sintering additives, it is possible to improve the sintering process and increase the mechanical properties since the additives react with oxidized layers and form secondary phases. In this study, different preparation methods and various combinations of additives (B₄C, Si₃N₄ and MoSi₂) via hot pressing sintering have been explored. Through the synergy between optimized process and tailored composition, an almost fully dense material was obtained at 1700 °C with hardness of 24.4 ± 0.2 GPa and fracture toughness of 5.4 ± 0.2 MPa m^1/2. However, the highest hardness (24.5 ± 0.2 GPa) and density values were obtained for only the high-energy-milled sample with WC-Co media, featuring a core–shell grain structure. Finally, optical properties for selected samples were measured, identifying the high-energy-milled TiB₂ as the sample with the highest spectral selectivity α/ε and solar absorptance. Full article

Ceramic panel collapse will easily lead to the failure of traditional targets. One strategy to solve this problem is to use separate ceramic units as armor panels. Based on this idea, we propose an aluminum matrix composite using pressure infiltration, containing an array of ceramic balls, the reinforcement of which consists of centimeter-scale SiC balls and micron-scale B₄C particles. Three different array layouts were designed and fabricated: compact balls in the front panel (F-C), non-compact balls in the front panel (F-NC), and compact balls inside the target (I-C). The penetration resistance properties were tested using a 12.7 mm armor-piercing incendiary (API). The results show that there are no significant internal defects, and the ceramic balls are well-bonded with the matrix composite. The F-NC structure behaves the best penetration resistance with minimal overall damage; the I-C structure has a large area of spalling and the most serious damage. Finite element simulation reveals that the ceramic balls play a major role in projectile erosion; in the non-compact structure, the composite materials between the ceramic balls can effectively disperse the stress, thereby avoiding the damage caused by direct contact between ceramic balls and improving the efficiency of ceramic ball erosion projectiles. Furthermore, it is essential to have a certain thickness of supporting materials to prevent spalling failure caused by stress wave transmission during penetration. This multi-scale composite exhibits excellent ballistic performance, providing valuable insights for developing anti-penetration composite armor in future applications. Full article

It is of extreme importance to develop a reliable numerical prediction technique to simulate the ballistic response of ceramic armor subjected to high-velocity impact (HVI) to economize the test cost and shorten the design period. In the present manuscript, a series of experiments on tungsten heavy alloy (WHA) fragment’s penetration into 99.5% alumina (AD995) armors are systematically simulated by employing the FE-converting-SPH technique. The numerical results are compared with the experimental counterparts to find that the FE-converting-SPH method is fairly efficient in predicting the depth of penetration, the residual velocity, length and mass of fragment, and reproducing the crack forms of ceramic. The applicability and accuracy of the numerical model in terms of the algorithm, material model parameters and contact definitions are validated. Then, the relevant parameters of the calibrated numerical model are incorporated to explore the influence of cover-layer thickness on the armor performance. A few mechanisms regarding the cover plate have been identified to act on the armor performance, such as the alteration of fracture cone half-angle, proportion of energy absorbed by ceramic, mushrooming deformation of fragment, etc. The result of multi-mechanism superposition is that the best ballistic performance is endued with 1 mm cover-layer armor, which demonstrates a 24.6% improvement over the bi-layer armor with 4.96 g/cm² area density, only at the cost of 15.7% increase in areal density, when back-plate thickness is held as 2 mm; for a constant area density of 4.96 g/cm², a 1 mm cover-layer is also expected to be the best choice, with 10.7% improvement in armor performance. Full article

The work proposes the use of aluminum oxide-based ceramic objects with a TPMS-Q-surface geometry as elements of armor structures. The samples were produced using the SLA-DLP 3D printing method. The main properties of the sample were determined using physical-chemical analysis methods: apparent density ρ_ap = 3.6 g/cm³, open porosity P_opn = 8.5%, microhardness H_µ = 15.3 GPa, water absorption W = 2.4%, elastic modulus E = 405 GPa. The Stiglich criterion M = 1.72 EPa²·m³/kg, and the Shevchenko criterion K = 0.8. Full article