naa CR 3006 GGA Lu be Linge AU pRoourr Fins CENTRE Des WarEmiAUx coMrosiTEs ARMOUR SYSTEM LITERATURE AND INDUSTRY SURVEY FOR BALLISTIC PROTECTION Technical Report Document n° 2017-RT-001 Revision n° B Date January 16 1998 Scient Fe Author ty. Manon Bolduc ferre Vallée P. Eng. Engineering Manage} Reviewed by faitial Missinolld P. Eng. Project Manager oe CR a Groupe Balistique Terminale Y Section Effets d'Armes : 2459, Bivd Pie XI Plerre Vallée P. Eng agar Oe Engineering ManagereS SSE a> > — SSS Document n’_2017-RT-001 Revision a’ B Date January 16,1998 Page 1 of 140 ABSTRACT This reports provides in one source of information, a comprehensive analysis regarding all facets of the protective clothing equipment technologies. The evaluation of. the technological trends and developments related with the protective clothing equipment is also discussed. The report summarizes the standards used for the specification and evaluation of personal armour system for ballistic protection. Identification of material, equipments and suppliers related with personal protection afe also reported as function of threat types (projectiles, fragments, knives, etc.) and levels. The effect on the performance of several materials due to extreme environmental conditions exposure is discussed. Finally, the information for materials and armour system products availability are organized per country. RESUME Ce rapport technique présente sous un méme recueil d'information, une revue détaillée des équipements et des technologies utilisés pour la protection balistique personnelle. L’évaluation des tendances technologiques et des développements en cours sont traités. Ce rapport résume les spécifications utilisées dans les secteurs civils et militaires afin de classifier les matériaux en relevant les similarités et les différences de chacun. L'identification des matériaux et des fournisseurs connexes a la protection balistique personnelle est également répertoriée pour différents types de menace (projectiles, fragments, couteaux) et de niveau de protection. La performance et l'effet d'une ‘exposition prolongée sous des conditions environnementales et climatiques sévéres pour certains matériaux sont également discutés. Enfin on retrouve un répertoire de compagnie par type de systéme de protection et classée selon le pays d'origine.Document n’_2017-RT-001 vision B ‘January 16,1998 Page 2 of 140 TENT: ABSTRACT/RESUME EXECUTIVE SUMMARY 1. SCOPE. 2. INTRODUCTION. 2.1. Format 2.2 Sources 3. STANDARDS COMPILATION. 3.1 Military 3.2 Police 3.3. Other. 3.4. Standards/Specifications Classification 3.4.1 Fragments...oneeene 3.4.2 Bullets.. 3.4.3. Stabs/Punctures 4, THREAT CLASSIFICATION 4.1. Fragment Simulator Projectiles (FSP, RCC, 4.2 Hand Gun And Rifle Bullets (Up To 12.7 mm)... 4.3 Knives. nn : 4.4 Flechettes .. 4.5 Saboted Light Armour Penetrator (SLAP).. 4.6 Anti-Personnel Mines [16].. 4.6.1. Claymore mines..... 5. MATERIAL SYSTEMS IDENTIFICATION AND COMPILATION FOR BALLISTIC PROTECTION APPLICATION 5.1 Fiber. 5.1.1. Aramids (Polyaramids).. 5.1.2 Ultra High Molecular Weight (JHMW) Polyethylene ( 5.1.3 Glass. 5.1.4 Liquid Crystal Polymer. 5.1.5 PBO.. 5.2 Fabric... 5.2.1 Weaving styles. 5.2.2. Non-Woven Fabrics. 5.2.3 Typical fabric supplied by AKZO. 5.2.4 Felts.. 5.2.5 Cost overview 5.3 Composites...Document n’_2017-RT-001 Revision’ 8 Date January 16,1998 Pagy 3 of 140 5.4 Thermoplastics .. 5.5 Ceramic 5.5.1, Alumina-oxide Al,O, 5.5.2 Silicon Carbide SiC: 5.5.3 Boron carbide B,C 5.5.4 Ceramic configuration pattern 5.6 Foamed materials. 5.7 Metals. 77 5.7.1 Steel and aluminum armour. 77 5.7.2 Titanium... 79 5.8. Transparent materials (face and eye protection) . 6. ARMOUR SYSTEM CONFIGURATION... 6.1 Current US Military Soldier Systems 6.1.1 Individual Body Armour 6.1.2 Ranger Body Armour 6.4.3. Interim Small Arms Protective Overset 6.2 Equipment Description and Manufacturer of military, civilian, police equipment.84 6.2.1 CONSULTANTS. 6.2.2 FIBER PRODUCERS. 6.2.3 PREPREG PRODUCERS. 6.2.4 BODY-ARMOUR MANUFACTURERS .. 6.2.5 HELMET MANUFACTURERS 118 6.2.6 SHIELD MANUFACTURERS. 6.2.7 PLATE MANUFACTURERS 6.2.8 CERAMIC / PLATE MANUFACTURERS. 6.2.9 EOD EQUIPMENT PRODUCERS. 6.2.10 FABRIC WEAVERS 6.2.11 TRANSPARENT ARMOUR PRODUCERS - 6.2.12 CLOTHING PRODUCERS... 6.2.13 FOOT PROTECTION PRODUCER 6.2.14 METAL ARMOUR PRODUCERS ... 6.2.15 THERMOPLASTIC MATERIAL PRODUCERS. 7._ PERFORMANCE AND DATA COMPILATION. 7.1. Balistic protection for different materials and configuration 7.1.1, Fragment resistant configurations 7.1.2. Bullet resistant configurations 7.2. Ballistic resistance variation due to environmental conditions (T°, Humiity)..... 8. REFERENCES .APPENDIX A APPENDIX B APPENDIX C APPENDIX D APPENDIX E APPENDIX F APPENDIX G Document n’_2017-RT-001 Revisions’ 6 Date wa Page 4 of 140 LIST OF APPENDIX US military specifications. Other military specifications. Ballistic protection standards for police operations issued by various governments including Canada, United States and European countries. Other standards or specifications not categorized in APPENDIX C. Directory of Armour Materials, Manufacturers per Country. Drawings of Ceramic front and back plate. Distribution listDocument Revision Date Page 3 of 140 EXECUTIVE SUMMARY The Canadian Forces (CF) soldiers require lightweight, comfortable and reliable ballistic protection , against the various battlefield threats to which they are exposed to, in order to safely meet their various mission objectives within Canada and throughout the world. It is essential to the CF to know what is currently available on the market prior procurement of new or additional sets of body armour. A comprehensive literature and industry survey of the various armour systems for ballistic protection for the head, neck and torso was prepared. Flexible and rigid materials (composites, ceramics and metals) used in personal protection system e.g. helmet, visors, body armour, and shield plate were reviewed. The relative ballistic performance (e.g. V50) of the various armour material systems as a function of areal density is included in graphical form. The importance on specific process parameters and material and their influence with the performance are discussed. An extensive compilation of military, civilian and police standards related to personal armour equipment, materials and ballistic testing was performed. A detailed description of threats including, handgun and rifle bullets (up to 127 mm), fragment simulators (FSP, RCC,..), anti personnel mines, flechettes and knives was compiled. Finally, a detailed description established by type and country of the state-of-the-art military, civilian or police equipment available or in development, with complete information on manufacturer's products is provided.eee eee eee ee ee ee Document n’_2017-RT-001 Revisionn’ Date “anuary 16,1998 Page 6 of 140 1. SCOPE The main objective of this report is to provide in one source of information, a comprehensive analysis regarding all facets of the protective clothing equipment technologies. The evaluation of the technological trends and developments related with the protective clothing equipment is also discussed. The report summarizes the standards used for the specification and evaluation of personal armour system for ballistic protection. Identification of material, equipments and suppliers related with personal protection are also reported as function of threat types and levels. The effect on the performance of several materials due to extreme environmental conditions exposure is discussed. Finally, the information for materials and armour system products availability is organized per country. 2. INTRODUCTION Body or transparent armour systems provide a certain level of protection to the user against various threats and are designed to meet specifications that are different for each nation or application such as military, police, correctional services or explosive ordnance disposal activities. Because the protective equipment industry was challenged by an increasing demand to meet higher performance requirements including protection against specified threats, weight reduction and optional configuration, new technological advancement having an impact on products performance was introduced. Upon the application and needs, tradeoff between performance and financial constraint limitations of armour system design can be done. As an effort to update the actual data base on existing specifications, threats and new materials with regards to personal ballistic protection, a survey was realized and the information compiled in order to compare various protective material configurations with their advantages and disadvantages against specified threats. The protective equipment has been organized with its country of origin. The following sections will initially identify the standards and test methodology used for evaluation of armour systems followed by a detailed review of potential threats that are encountered either by military or police forces. The threat level, even though using similar projectile, will vary upon its striking velocity against the armour system. ahsSs SSS eS = e a — SS SS Document n° _2017-AT-001 Revision’ 8 Date January 16,1998 Page 7 of 140 24 Format The report is broken down into the following sections : Standards and specifications compilation (Section 3), Threats classification (Section 4), Protective materials identification (Section 5), Protective materials classification per country of origin (Section 6), Technical and performance data compilation (Section 7). In order to review existing standards and compare the requirements and test methods available, a list has been generated and organized per armour system type. It was also necessary to update the list of the potential threats encountered by military and law officers on duty. Because materials used for protective equipment fabrication are unique, and garments are dependent upon their individual properties and manufacturers, a section devoted just for materials has been included in this report. Major materials used in protective equipment are discussed in terms of end uses, properties, producers and new developments. Finally, a section describing the company profiles of major protective clothing producers, man-made fiber producers, and textile manufacturers with their respective product lines and new developments are included. 2.2 Sources Of Information And Methodology The information was initially collected from the existing CMC producers data base followed by a comprehensive search of literature on protective equipment from technical journals, technical books, marketing literature, other product/promotional literature, and other publications available via Internet. As a result from this preliminary search, formal and informal interviews were conducted with engineers, sales and marketing managers of protective equipment companies. In addition, interviews were also conducted with man-made fiber and other raw material suppliers, distributors, other technical experts, government officials, and trade/technical association officials.Document n’_2017-AT-001 ion’ 8 Da ‘January 16,1998 Page 8 of 140 aS-o- Among the companies that were visited and conferences organized or attended are included: Visit of Canadian weavers and manufacturers of body armour; composite materials center Visit of Army Research Laboratory in Aberdeen Proving Ground, MD Visit of Dupont and AlliedSignal in Richmond, VA Visit of AKZO NOBEL in Wuppertal, Germany Visit of UK manufacturer of personal protective equipments: Courtaulds, Meggitt, Morgan Matroc Participation to the Personal Armour Systems Symposium PASS 96 in UK ‘* Organization of the Soldier Modernization Conference on October 24-25, 1996 in Ottawa Participation on the committee on Personal Body Armour with CGSB Participation at the |ACP conference and exhibition in Phoenix, AZ composite materials center ES = Sa S—-S-e Standards writing organizations and other trades, technical and professional associations were contacted for discussions and reviews of existing and new standards. IS ee eae eee eeeI 1 t t i Document n’ 2017-RT-001 Revisionn” 8 Date January 16,1998 Page 9 of 140 3. STANDARDS COMPILATION This section summarizes the standards which are used by various organizations and nations that define the testing methodology, the protective equipment specifications and requirements. 3.1 Military The US military specifications related with ballistic protection are reported in Appendix A. Other military specifications are reported in Appendix B. 3.2 Police The following standards were issued by various governments from Canada, United States and European countries and are more applicable to ballistic protection for police operations. Appendix C lists the standards identified during the survey. 3.3 Other The remaining standards or specifications not categorized in the above sections such as H.P. White, ULC, ASTM, etc., are reported in Appendix D. 8.4 Standards/Specifications Classification This section highlights the similarities and differences of the standards mentioned above developed for the following threats: * Fragments, * Bullets, © Stabs. 3.4.1 Fragments ‘The fragment configuration used for various testing is discussed in detail in section 4.1. The standards which are mostly used for fragment testing are the STANAG 2920 and MIL-STD-662E. Both methods refer to the V50 as the performance criteria which is defined [1] as the velocity at which the estimated probability of complete perforation is 0.5, that is, the velocity at which 50% of the projectiles would perforate and 50% would be stopped for a specific material and configuration armour system. UaeSS" — a a a ee ee ee ee — € Document n° 2017-AT-001 8 January 16,1998 10 of 140 STANAG 2920 standard is in the final process of being revised. It will be segmented in 6 parts: © Partt Fragmentation-Protective Materials © Part2 Bullet-Protective Materials © Part3 Military Helmet Shells © Part4 Face And Eye Protection © Part ‘Combat, Clothing And Footwear © Parté Flechettes And Flechette Type Materials It is more adapted for personal armour system testing. The revised STANAG 2920 allowed the use of a backing material to replace the witness plate. The calibration of backing material, type of target conditioning, the selection of various types of fragment, V50 and VO calculations are significant improvements over the actual version. This test method is intended to be used only in personal protection. The revised STANAG 2920 calls for up to six varieties of Fragment Simulating Projectile (FSP) including FSP from MIL-P-46593, UK Drawing A3/6723, steel cylinder, steel sphere, steel cube and steel parallelepiped. The 1.1g or 17 grain FSP is the most common and is normally specified at a given velocity in equipment requirements specification. MIL-STD-662 is similar to the actual version of STANAG 2920 but it is intended to be used not only for personal protective equipment but for a wider range of components including: armour for light and heavy vehicles, transparent armour for windows, windshields vision blocks or visors for face and eye protection and other related applications. The fragments configuration as define in MIL-P-46593 are chisel nose cylinders of 17 grain or .22 caliber, 44 grain or .30 caliber, 207 grain or .50 caliber and 830 grain or 20 mm caliber. The standards also provide the velocity of various projectiles at different distances range from the target. Both methodologies mainly require to calculate or measure the velocity up front the target using a chronograph or radar system and use a witness plate behind the test panel to confirm the partial or complete penetration.FS SS SSS nS SSS See Date January 16,1998 Page 11 of 140 An improved test procedure is proposed by Beat P. Kneubueh! [2], which allows to evaluate not only the mean penetration velocity (V50), but also the accompanying standard deviation, This method has the advantage to rank the performance of two armour systems having similar VSO with the one having the lowest standard deviation being superior to the other. The drawback of this method is that it requires more projectiles to be shot at the armour system. 3.4.1.1. Measurement of V50 is as follow: An even number of shots, at least six are used in the calculation. Half of the shots must perforate the target material. Half of the shots must not perforate the target material. The highest recorded velocity of the group (3 perforations and 3 non-perforation) must not be more than 40 m/s higher than the lowest of the group, or, * The highest recorded velocity of the group (5 perforations and 5 non-perforation) must not be more than 50 m/s higher than the lowest of the group, or, © The highest recorded velocity of the group (7 perforations and 7 non-perforation) must not be more than 60 m/s higher than the lowest of the group, or, «The testing shall be repeated on a new sample of material if the highest partial velocity exceeds the lowest complete velocity by more than 60 m/s. © The measurement is the mean of the group velocities, 3.4.1.2 Casualty Reduction Analysis Assessment This technique is used to measure the ballistic response of a complete armour system against a specific fragmentation shell in a real scenario (e.g. mortar shell at 20 meters). The technique consists in measuring the striking and residual velocities of typically four sizes (2, 4, 16, 64 grains) of Right Circular Cylinders (RCC) fragment simulators for a given armour system. The fragments are shot at O*and at 45° [3]. The results of the tests are included in a numerical code that simulates the vulnerability of the soldier and allows the design optimization by trading off coverage and weight to improve mobility and comfort of the armour system which payoff in mission enhancement effectiveness through: * Reduced load and heat stress, «Improved tactical mobility, * Reduced casualties, © Increased survivability.3 =F OFS eae ores SSS eS SSS Document n'_2017-R7-001 Revision’ 8 Date January 16,1998 Pa 12 of 140 3.4.2 Bullets The test method to which every other is compared to, is the National Institute of Justice test method NIJ-0101.03. This method is the most known and used to verify body armour and insert plate and is uses a pass/fail VO criteria. This test method was specifically developed for body armour and includes handgun/pistol and rifle projectiles. The method is briefly presented to understand the testing methodology and explain the elements that need to be improved . 3.4.2.1 NIJ -0101.03 Test Method The terminology in the standard defines a body armour MODEL as manufacturer designation that identifies a unique ballistic panel construction; i.e., a specific number of layers of one or more types of ballistic fabric and or ballistic-resistant material assembled in a specific manner. A body armour STYLE is a manufacturer designation (number, name, or other descriptive caption) used to distinguish between different configurations of a body armour product line each of which includes the same model of ballistic panel. The distinctions between body armour model and style were established to eliminate the necessity of re-testing a given body armour model for compliance with the NIJ Standard each time a manufacturer incorporates the model into different styles of armour. 3.4.2.1.1 Conduct of the Test Armour to be tested is mounted on a flat block of inelastic backing material, typically molding clay, to be shot at. Other types of backing material such as plastilina or gelatin can also be used. The ballistic results may however vary. The impact velocity of each bullet is measured using a ballistic chronograph. If the bullet hits an appropriate point on the panel at an impact velocity within specified limits, the impact is considered a fair hit. The test requires a fair hit in each of six specified areas on each panel in a specified sequence as illustrated in Figure 3. Each shot must impact at least 7.6 cm (3 inches) from the edge of the panel and at least 5 cm (2 inches) from the closest point of impact of any prior shot.ta | | U Document n’ 2017-RT-001 a Revision’ B 0 Date January 16,1998 13 of 140 { | All shots at least 7.6 cm (3 in) from any edge Q and at least 5 cm (2 in) from another shot A. Test ammunition shot series i t 0 All shots at least 7.6 cm (3 in) from any edge and at least 5 cm (2 in) from another shot 0 B. Optional second ammunition shot series Figure 3.1 - Sequence oints on Each Panel, ified in NIJ Std. 010,03 [4]Document n*_2017-AT-001 Revision’ 8 Date January 16,1998 Page 14 of 140 The body armour system is rated per level upon the projectile type and velocity. Table 3.1 illustrates the various projectiles and levels used for the NIJ 0101.03. Tox vais Pelomsace regeenees Reged ‘equed ‘fh ‘chin Mims perume perme Nooisl oma’ pe” Makes moe tx Te fete bale geal ath ot Sect = ee ee 4 1 Sept 1025 23a ‘ 2 ' BN Lad ise Qo) 7 aia 2p Sms 7 2 ta oe anon 1 SMe 02g Ce 7 3 ma i ise a0) oieaom tog Stas + 2 ng ie amon 7 Sige 7 z 7 isp ite __cossai9 rs Oe Stan 7 2 nae bie a 1 Miges ssp «hm 7 z Lad WCGe We CODEN) os Chests 7 Sum ty See ee 2 na ie cans ane "ame 325 Stas ¢ am a m Cm Wedem) Ie OH) any Ao. soe ie a 7 ro ° Ld a ie casei) ane ia : 7 > rs : apron am femay ‘Tieac inne mat be apeciiod by ewe. Allo ie hams me apeclod [Nose Amaoe per coveag the ton fet sed to back wit or witou side coverage atl each be ipa wit the ince smumber of air his. Armor pars cove he goa and cosy all each be impacted wih thre arin a O° glo niece. The ‘efornton de tthe ftir it dallbe mere 9 deczine compliance No hr ir ballet ot oe impacting Ylocy lower ‘han the minim rogured ble loc sal peer te armor ‘Abbreviions AP = Armee Percng Fg Fel Mend Jacket TP — Inch Sof Pol REN — Long Rifle High Velocity ‘RN — Rom Nowe SWC Seat Wadearer = Protection level and ammut ecified in NIJ Standard 0101.03 [4] Table 3.Document a’ 2017-RT-001 nh Revisions” 8 w Date “January 16,1998 Page 15 of 140 i] 1 fl In tests of Type |, I-A, Il, or III-A ballistic resistance, four complete armours, typically including eight armour panels (four each front and back) are usually shot at. Each ballistic element (front or back panel) is sprayed with water and then shot with test bullets of the first type, then another one is sprayed and shot with test bullets of the second type. This is repeated with unsprayed, dry samples. This requires a minimum of 48 shots per test: 2 element types (front and back) x 6 shots each x 2 types of bullets x 2 wetness conditions. Ss =S If the velocity of a shot is too low and it does not penetrate the panel, or if the velocity of a shot is too high and it does penetrate the panel, the shot is repeated, aimed at least 2 inches from the closest point of impact of any prior shot. However, no more than eight shots (of one caliber) may be fired at any panel. The armour cannot be certified if any fair shot penetrates. = After the first fair shot at each panel, the panel is removed from the backing and the depth of the crater (called the backface signature or BFS) is measured. If the BFS exceeds 44 mm or if the armour was penetrated, it fails; if not, the panel is replaced on the backing without filling the crater or otherwise reconditioning the backing material, and testing for penetration is resumed. The standard prohibits adjusting the panel (e.g., patting it down) thereafter, unless it is reused for testing with a second type of bullet. == Nid Standard 0101.03 specifies that body armour has to be tested on a block of backing material at least 4 inches thick and of sufficient length and width to completely back the body armour. The standard does not specify unambiguously that the backing must be flat, and in fact requires it to be built up to achieve contact with the armour when testing female armour with bust cups or when testing rigid armour for Type Ill or IV ballistic resistance. However, in practice, a flat surface is used in other cases. =e aS = 3.4.2.1.2 NIJ Standard 0101.03 Revision The standard is in the process of being revised. It will be revised to reduce the latitude in test procedures permitted by the standard. This would limit lab-to-lab and test-to-test variations in test conditions, which might be partly responsible for variations in test results. Revising the standard to specify a number of specific laboratory procedures already used at H.P. White Laboratory, Inc., would further limit possible lab-to-lab variations in test conditions. SS EMC) €=e Se SSS SS. =e SS A SS Document n*_20 vision a’ B January 16 16 of 140 Since NIJ Standard 0101.03 was issued in 1987, the H.P. White Laboratory, Inc. (HPWL), which currently is the only ballistic test laboratory authorized by NiJ to do testing for certification “by Ni" in compliance with the standard, has adopted particular ways of conducting the test in the interest of reproducibility. NIJ has also issued directives instructing H.P. White Laboratory to perform parts of the test in particular ways that are not the only ways allowed by the standard. Other laboratories attempting to conduct a test in accordance with the standard, e.g., for developmental testing of a new model, might conduct their testing in accordance with the standard but not exactly in accordance with the procedures H.P. White Laboratory would use for certification testing of the model. Sections of the NlJ Standard 0101.03 identified to be revised includes: * Revise the Backface Signature Limit + Require Patting Down of Armour Between Shots + Specify Standard Bullets * Specify Standard Backing Material «Reduce Tolerances on Backing Material Properties Certify Wet and Dry Ballistic Resistance Separately * Rate the Ballistic Resistance of Each Certified Model With a Score The standard could specify a way to rate the ballistic resistance of each certified model with a score, such as the V50 ballistic limit -- the velocity at which test bullets have a 50 percent chance of penetrating. © Use Anthropomorphic Test Fixture © Certify Lots NWJ could certify lots, rather than models, of armour." To exercise this option, NIJ would have to 1. Define a lot. 2. Specify a sampling plan -- ie., the number of samples from each lot to be tested, and criteria for acceptance and rejection based on test results. 3. Ensure the samples to be tested are selected randomly from each lot. * Establish a Voluntary Quality-Control ProgramDocument n’_2017-RT-001 Revisions’ 6 1998 Q f Page 17 of 140 3.4.2.2 Distinction between NIJ and other standards ‘Some European countries and Canada are developing their own standards, finding the’NIJ not adequate for the reasons discussed in Section 3.4.2.1.2. The major elements of difference are the type of projectiles, the hit sequence, and test procedure for subsequent hits, the angle of incidence, the acceptance level of I behind armour defect and the choice of backing material [5]. 3.4.2.2.1 Type of projectiles | European countries generally agree on specifying a bullet type for test, to reduce i the error attributed with the variance in construction and hardness of projectiles between bullet manufacturers as illustrated in Table 3.2. f Projectiles Country Type Mass |] Velocity (9) (m/s) 9mm USA (NU) FMJ-nobrand [8.0 |>332 0 9mm France GecofFiocchi__[8.0 [320 h 9mm Germany Dyanamit Nobel [8.0 [365 #5 4 9mm Great Britain _[Dyanamit Nobel [8.0 [330+ 10 Ql 9mm Belgium FN 8.0 [>420 m/s 1 omm Canada (CGSB) [FMJ-no brand [8.03 |365 7 i 9mm 1sO. Dyanamit Nobel [8.0 [360 = 10 I Table 3.2 l 3.4.2.2.2 Angle of incidence Table 3.3 gives the differences for several countries in the angle of incidence. The 0° as indicated in Table 3.3 is the angle normal to the target. It was reported that it is more difficult to stop the projectile when it hits the target at 60°. Country [Angle of incidence USA (NIJ) (0° and 30° France (OP and 30° 0 [Germany (0° and 60° Great Britain [0° and 65° Belgium (0? and 60° ll Canada (CGSB) [0°, 30° and 60° Iso (0° and 60° 0 Table 3.3,win’ 2017-RT-001 8 January 1 18 of 140 Doct 998 3.4.2.2.3 Hit sequence, and test procedure for subsequent hits Figure 3.2 shows NIJ standard-Hit sequence for hand-gun ammunition. [4] All shots at least 7.6 cm (3 in) from any edge and at least 5 cm (2 in) from another shot Figure 3.2 Figure 3.3 shows PSDB Standard hit sequence for handgun. (6]' , i i ' i | I I } i ; | ! i ! I i I i I | i I {| Document n*_2017-RT-001 Revision’ 8 Date “January 16,1998 Page 19 of 140 Figure 3.4 is illustrating PSDB Standard Positioning of angle shots [6] Line offre ot shots 4 and 5 Figure 3.4 Figure 3.5 shows ISO/CEN Standard hit sequence for handgun [7] 27m x x 275mm x x 260mm =a | = Hits pattern for shots at an impact angle of 0° = 3° for levels 0.4 X = possible impact points Figure3.4.2.2.4 Choice of plastilina Document n’_2017-RT-001 Revision’ B Date [eam | reag 10.00 | 5085 | ase | eso il naman | 0.18% 0.0 | 26a | 1 ais worm |_0.2i%9 10.0) | az | 18) 380 ara | 0.0889 10.00 | 08 | ae | aw oA wean | 270g «02 | 709 | ane | Tee waerave | 0.3%5510.01 |_ae00 | nso | aa 4 a, 2 H 1. aeten munurscruse tren sue tae | 1 Unovess VALUE OF Re 3042 ! 2. AnNsr OMRENION € 10 INE comect ' veroet Figure 4.1- A3/6723 Drawing (STANAG 2920 FSP) [9] 250 *.002. 925.008. (MAX. FLAT 005 NOTE: 1. NO SUBSTITUTES FoR STEEL 2. FINISH 6g/ excert ‘AS NOTED Fragment simul: caliber 4 (armor |_—aowust LENGTH oN BASE SURFACE TO MEET INDICATED WEIGHT 10)Document n* 2017-RT-001 Revision a’ 8 Date “January 16,1998 Pa 28 of 140 250 ——+ aeonox oy 3 toos ADJUST LENGTH ON BASE SURFACE TO MEET INDICATED WEIGHT S t was ‘#1002 +215 0005 FLAT TO BE CENTERED PERMISSIBLE WITHIN.003 TLR, NOTE: 1, NO SuasTiTUTEs FoR STEEL 2. FINISH 125/ EXCEPT AS NOTED 3. TOLERANCES ON ANGLES 1* 2 type 2 (body armour) Fragment si caliber 340 002: 034 4,005 + MAX. FLAT 005 wot, ADJUST LENGTH | “ON BASE SURFACE | ToMEET wioIcATED lis WEIGHT 3g ss 18 [ Nore: LNO SUBSTITUTES FOR STEEL ire, 30 [10) ZFINISH @3/ EXCEPT AS NOTEDSSS SSS SS SS SSS SSS SS 502+ 002 bon -5' pe =c| NOTE: INO SUBSTITUTES FOR STEEL. 2.FINISH §5/ EXCEPT AS NOTED Figure 4.5- Fragment simulator caliber nore: I-NOSUBSTITUTES FOR STEEL 2-FINISH 63 EXCEPT AS NOTED 3124010 ————} 0884.04. MAX FLAT 006 F _[-—AowusT LencTH on BASE SURFACE TO MEET INDICATED WEIGHT WAX FLAT ADJUST LENGTH ON BASE | ihe 10, 008) MEET INOIGATED | weicur 740. nt si for caliber 20 mm [10]SSS SS SS SS eS Document n’_2017-AT-001 8 anuary 1 30 of 140 998 MASS (g) ‘A +0.02 (mm) |B 4.148 £0.02 | 8.740. 9.08 2.828 +0.02 17.493 8.06 1.102 + 0.02 [5.385 6.17 0.486 + 0.02 [4.064 4.78 0.325+0.01 [3.600 4.07 0.237 +0.01 {3.251 3.64 0.162 + 0.01 [2.642 3.77 ‘Steel Cylinder- of diameter A and length B Length B must be adjusted to obtain indicated mass. Note: 1 g (gram) equals 14,15432 gr (grains); 1 gr equals 0.07065 g Table 4.1 - Steel cylinder MASS (g) ‘A = 0.02 (mm) 4.148 + 0.02 |12.890 2.828 0.02 [8.788 4.102 + 0.02 [6.451 0.486 «0.02 [4.910 0.3250.01 [4.294 0.237 + 0.01 [3.865 0.162 +0.01 [3.405 ‘Steel Sphere - of diameter A Note: 1-9 (gram) equals 14.1842 gr (grains); 1 gr equals 0.07065 g Table 4.2 - Steel sphere MASS (9) ‘Az 0.02 (mm) 4.148 + 0.02 10.389 2.828 + 0.02 _|7.083 1.102 0.02 [5.199 0.486 + 0.02 [3.958 0.325 +0.01 [3.461 0.237 + 0.01 [3.115 0.162 20.01 [2.744 ‘Steel Gube - offength A Note: 19 (gram) equals 14.15432 gr (grains); 1 gr equals 0.07065 g Table 4.3 - Steel cubees 20% 8 January 1 31 of 140 001 998 MASS (a) Section (mm?) ]A = 0.02 (mm) +£0.02 x + 0.02) 2852002 (58x58 11.6 1.102 + 0.02 [4x4 89 0.20+0.02 [2x2 67 Steel Parallelopiped - of length A Table 4.4 - Stee! parallelopiped 4.2 Hand Gun And Rifle Bullets (Up To 12.7 mm) The projectiles listed in Table 4.5 represents threats encountered in police and military operations. These threat levels are defined in various standards and vary upon projectile velocity, caliber and mass. Other threats not define in standards are also listed in Table 4.6. These threats are cccasionally call out in user specified requirements as a + or ++ levels. Table 4.7 is providing a list of projectiles illustrated in Figure 4.7. a a a a— Document n’_2017-RT-001 Revisionn’ 8 Date January 16,1998 32 of 140 afalelelela|z|a|aleDocument n’_2017-AT-001 Revision n’ 8 Date “January 16,1998 Page 33. of 140 sla] slelels}e|e)e}s|é a}e]sle|slalale Table 4.5 &== = = ee = Document nt 2017-RT-001 Revision n" 0 January 16,1998 Pe 34 of 140 we | came Rowdee sar =" ae @ | = 7 jane ne juve ze | jr paw a [cso Paes se ze | [rao cin [crea sere Waa Guerin oz | = jane con lawn feuser ree FN -oeccuM = fravo eon leo leuer wee GecomOCoM. FRANCE = [ano aun pom [wera ancxeTED) wo | = Fano aun leon [aL MeTALINCETED) eo | [oo aun = [pumen | joo aun lem Fi a Mera KETO) | pane aun [emmy 9000 nae | etisoleeae 7 oan [ammoriee wo |= | 5 [rane con pon cworecn [a weenie 2 | = Jno un [amatane [then senior ze | [rao oun fpemnoms Forme net 7 | fraxo-cun [ponsne [Sverre Pat | a fran gun aero 0 bs wa | | s z [noaun bao [aes sro 2 | Table 4.6SSeS eS SS SS SS SS ee ee ee ee a SS Document n° 2017-RT-001 Revision’ 8 Date January 16,1998 Page 35. of 140 Weiner caine Rona ype = PE om 5 Fano can [ewan [sever son Po we | fro cum [eto [Serr wasam caso we | Fe axe [po mca ae | Fe [easy 180m ee Fe [ste by amen jeromm = Jere [5569 etme oc jerce [ss6by sme foacnsaess pre ssteyemm [ese = seoyesem [ae o are Issey [saese 3 lane 7 [eens | = lane [senm nn [oenssrine a Jenasinmov 70 [rsteyaeem imo oren Cone Pema WemseeRENOT| ea | FO Jexasinenov axe? [ret by am psisreet cone) 7, jane [rst siem we 3 "p> z jane [savy sim rua aon wnicne Tem) 7 _ |e [sorcos roy bo puaset oeae a0 ve [serous sou sw = [ose [seaeu SPER oA a ve [ose hee ae veDocument n’ 201: Date January 16,1998 Page 36 of 140 001 Position} We Caliber Round type La mis. 7 ZUR Tead 320 2 545x18 [Steel core 300 3 6.35 Browning FM ead core GECO } 4 Machine pistol / 5 | ste uecnPctnuns| 7.2%25Tokarey [FM stet jacketed - lead core ball projectile 427-480 pone ee x25 Tokarev mild steel core project 5 Jc Mane urs] 792X258 Tokarev [FM stool jacketed - mid steel core project 503, 7 om IFA DYNAMIT NOBEL DMT1A1B2 - GERMANYIUK a7 2 Simitar to 21 impacting at an angle of 90° 3 Similar to 21 impacting at an angle of 25° 4 9x19 5 9x19 410 6 9x19 fo mm Para m 39/8 FMJ-lead core ball projectile 7 9x19 ‘9 mm BULLET TYPE GECO/FIOCCH! - FRANCE 320 8 9x18 JFMJ Stee! cove - Makarov a 9x19 Similar to 28 impacting at an angle of 90° 10 9x19 ‘mm 9x 19Para 9x 19Para 9x19 Para 9x19 Para 9x19 Para 7357 Magnum 357 Magnum ‘omm 357 Magnum 38 Special "44 Magnum 44 Magnum 44 Magnum —_|Semi-Wide Cutter SOLIDLEAD SLUG _]FOR 12/70 GAUGE SHOTGUN BRENNEKE. FRAGMENT [STANAG 2920 FRAGMENT — |STANAG 2020 FRAGMENT — |STANAG 2920 5.385 mm FRAGMENT _ |MIL-P-45693 5.46 mm 358 HAND GUN HAND GUN HAND GUN ISHOT GUN, 158 315, 654 0237 0.325 1 14 Table 4.7Document n’_2017-RT-001 sion” 8 Dat January 6 fi A i} 0 Page 37 of 140 1 2 3 4 z Figure 4.7 [11]Revision a’ _@ ‘January 16,1998 38 of 140 4.3 Knives The knives and stab weapons from standards described in Section 3.4.3 are shown in Figure 4.8 to 4.13, [ Figure | Joules (mis) 48 Tee pick 217 49 Stiletto 35 52 Knife No. 1 blade 42 14.5 Knife No. 5 blade 42 14.5 Cutting spike 42 6 BeveliSpike 100 63 Table 4.8 180 SS SSS SS SSS SS o-oo oSDocument n'_2017-RT-001 Revision n’ 8 anvary 16,1998 39 of 140 ——| — a — — = DETAIL A =e Figure 4.9 Stiletto = Measurements of the stiletto test blade (mm) |Depth of penetration 5 40 [Thickness of blade 16 Table 4.9 CEN/TC 162/WG 5/PGS5 N83 Stiletto blade configuration [13] Measurements of the stiletto test blade (mm) [Depth of penetration lickness of blade HOHE: 7.0 | 4.5 17 | 1.3 10_ Swiss Police Techt SSS SS =Document n’_2017-RT-001 Revisionn’ 6 Date “January 16,1998 Page 40of 140 95 | 152.5 LO, Detail A __. | ces) Figure 4.10 Knife No. 1 Blade L113 [15] L 7 = i _. ~ LI in ~ ; wt 115. a} 140 _________ Figure 4.11 Knife No. 5 Blade L104 [15]SS SSS SSS Se = = Document n*_2017-RT-001 nv 8 jocumer Revisior Date Page Figure 4.13 Bevel/Spike [8] January 16,1998 41 of 140Document n’ 2017-AT-001 8 ‘January 16,1998 42 of 140 4.4 Flechettes Flechettes are small steel darts that have good penetration against human targets because their energy is concentrated into a very small cross sectional area. Flechettes are a threat that can easily be acquired and although only included in the latest edition of STANAG 2920, can potentially become a serious threat to military personnel. Flechettes' typical configuration is illustrated in Figure 4.14. Figure 4.14 Artillery Flechette Li (mm) 26.5 L2 (mm), 15.2 D (mm) 5.53 d (mm) 2.26 o 30 mass (g) 1.36 Hardness (Re) 40 Nose Shape nail-type Table 4.11 y 4 t I l f' 0 0 t b 0 b b SSS es Document n’_2017-RT-001 fevsionst 8 Date January 16,1998 Page 43 of 140 The flechettes can be fired from rifles, shotgun, grenade and artillery shell, They are usually packed upside down and required a minimum distances of approximately 25 to 30 meters to become stabilized. to become stabilized. They are effective either day or night on rough terrain, in dense underbrush, jungle and forest for short range combat where conventional rifle grenades can't be used. 4.5 Saboted Light Armour Penetrator (SLAP) The principle of discarding sabot ammunition consists of using a full caliber weapon to maximize internal ballistic and a sub-caliber armour piercing projectile to maximize the extemal ballistic performance and concentrate the target effect ‘over a small cross-sectional area. The plastic sabots used, allow to produce very high velocity bullets, The smaller penetrator projectile is centered in the sabot which fills the bore of the weapon from which the projectile is fired. A typical configuration is a 5.56 projectile fired from a 7.62 rifle. 4.6 Anti-Personnel Mines [17] The anti-personnel mines are designed to be effective on direct contact with the target. It will cause an incapacitating wound to the foot and leg of the soldier. It is not necessary for such mines to produce metal fragments or to have directional effects. The small explosive charges contained in a plastic or metallic cases are initiated by pressure fuses. The charge weight of some anti personnel mines is listed in Table 4.12Document n*_2017-RT-001 Revision n’ 8 Di January 16,1998 44 of 140 Pag Charge Effect Examples weight (0) [Traumatic amputation of foot or __|Czech PP-Mi-Ba lower limb; multiple injuries; death |W German DM11 114 [Traumatic amputation of foot or _ [Hungarian M62 lower limb French MAPDV 64 [Swiss P59 59 Italian TS-50 50 Italian VS-50 43 Italian SB-33 [Soviet PFM-1 Disabling wound to foot Italian MAUS-1 Brithish L10 (ranger) Canadian C3 Table 4.12 46.1 Claymore mines Claymore mines are frequently employed in prepared defensive positions and in ambushes. They are initiated by trip wires or by remote control and are designed to cause casualties within a specified radius or arc. They are of substantial size and include pre-formed fragments. The mine consists of steel balls in a plastic matrix backed by a high explosive charge which propels the fragment in a 60° arc. About 80% of the fragment are confined within that arc. The original M18 mine contains 700 steel balls and a driving charge of 680 g. The effect is lethal at 50 m and potentially incapacitating at up to 100 m. Austrian derivatives mines are the Hirtenberger APM-1 with an explosive of 360 g and 290 fragments and the SMI 21/11C with 11.5 kg of explosive and 1,180 very large (4.5 g) fragments. Such a large mine is designed to dominate a considerable area and cause severe damage to vehicles and helicopters as well as personnel targets. EM)Document n*_2017-RT-001 Revision’ 8 Dat January 45 of 140 5. MATERIAL SYSTEMS IDENTIFICATION AND COMPILATION FOR BALLISTIC PROTECTION APPLICATION ‘The materials that have been reported to be used or that can potentially be used in ballistic protection are reviewed in this section. 5.1 Fiber The critical element of soft body armour system is the fiber type and configuration which dictate the performance and the protection level of the body armour system. Other factors of influence are the weaving style of the fabric and the processing methodology, type of sizing used on the yams, etc. Soft body armour works by catching the bullet in a net-like web of very strong fibers. The projectile stretches not only the few fibers it hits, but also others in contact with them and many more that those pulled. As in any net, the key to success is that many fibers, even those not actually touching the bullet, elongate in response to the collision and so absorb the energy of the projectile. Even so, materials available today do not allow the construction of a vest from a single ply of fabric, a number of layers, often about one or two dozen, are needed to stop a bullet. This section will identify the fiber materials available for body armour system. To better understand the characteristics of each fiber system, the following definitions will be reviewed: «TENSILE STRENGTH OR TENACITY is the tensile stress at rupture of a fiber yarn being expressed in grams force per denier. Tenacity relates to the breaking strength of fibers, and should not be confused with modulus, which relates more directly with a fiber's ability to resist stretch. + DENIER: It is the weight in grams of 9000 meters of a given yam. A higher denier signifies a heavier fiber. * FLEX STRENGTH is the ability of a fiber to retain its strength after being folded back and forth.Document n’_2017-RT-001 Revision’ 6 te ~Janvary 16,1998 Pag 46 of 140 | MODULUS describes a material's inherent ability to resist stretch. The modulus is usually expressed as grams of load per unit of stretch for a certain amount of fiber weight. The higher the initial modulus, the less the fiber will stretch. * UV RESISTANCE measures the effect of sunlight on fabric. UV resistance is usually expressed as the time it would take for a material exposed to sunlight to loose half of its breaking strength. Soft armour has been made from a variety of natural, and more recently, synthetic fibers. For example, silk, was used in American ballistic (bullet-resistant) armour late in the nineteenth century. The tensile-strength-to-weight ratio ("tenacity") of silk, no more than about 5 grams per denier, was surpassed by synthetic fibers such as nylon (8 g/d) and, later, Kevlar? (26 g/d) and Spectra™ (35 g/d). Some spider silks have even greater tenacity, but it cannot be cultivated and collected economically as silkworm silk can. Genetic engineers are striving to develop a way to copy it. During the Second World War and the conflict in Korea, the United States Army developed soft armour made of nylon. These vests provided considerable protection, but were very bulky. The first soft body armour that was produced by police force was made of nylon. Concealable soft body armour as we know it today was made possible in the mid- 1960s, when a solvent for polyaramid plastic was discovered; this allowed the production ("spinning") of polyaramid fiber. Polyaramid fibers have higher tenacity than nylon do, and less elongation before breaking than silk or nylon. Body armour made from aramid became popular during the 70's. This fiber is woven into fabric by weavers, and the fabric is used in the construction of vests by several U.S. and foreign manufacturers. In the late 70’s Ultra High Molecular Weight (UHMW) Polyethylene (PE) fiber was developed using a gel-spinning process and found good usage in body armour application. The synthetic fiber produced from extended chain polyethylene has a lower density than polyaramid and attracted body armour manufacturer that saw weight reduction potential. The limitations for the fiber were that is was more expensive and inherently flammable compared to polyaramid fiber. Other fibers such as glass fiber, PBO, LCP can also be used but are not as popular as the previous ones. asDocument n’_2017-RT-001 Revision’ 6 Date ‘January 16,1998 47 of 140 5.1.1. Aramids (Polyaramids) There are several types of aramid fibers marketed under the names of Kevlar” produced by the E. |. Dupont de Nemours., Inc. and Twaron® produced by the Netherlands company AKZO NOBEL, two major worldwide manufacturers of aramid fibers. Other players not very active on the North American continent include a Japanese company: Teijin Ltd, from Osaka known to produce «Technora » aramid fiber, and a Russian company known to produced "Vnilon". Monsanto has an aramid product named *X-500" not well known on the market for protective armour systems [18]. The Russian high-performance aramid fibers also includes SVM, Terlon and Armos. According to the International Technical Textiles, Conshohoken, Pa., the chemical structure of the SVM fiber contains para-aramid links and heterocycles that induce differences in the production methods, and some physical/mechanical properties. The fiber is said to have less crystalline structure and stronger intermolecular bonds than any other aramids. As a result, it offers good compressive and impact strength properties. ‘As each company produces several grades of aramid fibers, the next sections will discuss the generics of aramid followed by a detail description for the two major ‘suppliers Dupont and AKZO-Nobel of their respective products. The aramid fiber is typically gold colored having a modulus five times greater than polyester. The chemical structure of aramid fiber reveals why it has superior longitudinal strength and weaker transverse strength; this is mainly due to the strong covalent bonds in the fiber direction and weak hydrogen bonds in the transverse direction. Aramid fibers have typically poor UV resistance. The UV resistance can be improved by dyeing the fiber black. 5.1.1.1 Generalities Aramid fiber is a strong fiber made from polymeric aromatic amide (polyaramid) plastic by dissolving it in a special solvent and spraying the solution through a small nozzle called a spinneret. The solvent evaporates, leaving the plastic fiber, which has a strength-to-weight ratio about five times that of steel. The possibility of making polyaramid plastic was hypothesized in 1939. It was synthesized and identified at DuPont in 1960, but polyaramid fiber could not be produced until 1965, when Stephanie Kwolek, a chemist at DuPont, discovered a practical solvent. EMC)Document n° 2017-RT-001 Revision a’ B Date January 161998 48 of 140 At about the same time, a team at Akzo, Inc., a multinational firm headquartered in Holland, independently discovered a practical solvent and applied for a patent for the manufacturing of polyaramid fiber, which DuPont named Kevlar® and Akzo later (1984) named Twaron®. DuPont contested the patent. A consent decree of the International Trade Commission settled the dispute; terms of the settlement included cross-licensing but barred Akzo from marketing Twaron” in the United States until the late 1990. Before aramid fiber was used for body armour, it was used as a substitute for steel in the manufacturing of radial tires, including those. designed for police cars. It does not melt but does pyrolyze (decompose) at very high temperature. It loses some strength as its temperature is increased but remains strong enough to be used for applications requiring high strength-to-weight ratio at high temperatures. The general properties of aramid fibers are described in Table 5.1. Property [Comments [Toughness 22 to 4 times better than carbon composites [Thermal stability [Unchanged properties from -40°F to 266°F. Flammability ICan meet aircraft interior flammability standards ISolvent resistance [Unaffected by organic solvents and bases, attacked by| Istrong acids |Water resistance |Absorbs about 2 to 4% water [Abrasion resistance [Extremely good Cyclic stress|Excellent performance Fiber wet-out [Difficult - use low viscosity resins [Machining / cutting [Difficult- use special tools Tal 5.1.1.2 |. Dupont de Nemours products ‘The aramid product commercialized by E. |. Dupont de Nemours (Dupont) are known by the name of Kevlar®. In 1971 when Kevlar was introduced there were two types. Type 29 & 49 with 49 having a 50% increase in initial Modulus (less stretch) as a result it had lower flex strength. Other Kevlar types 129, 149 & 159 have been developed later. ausSS -S-Ss— SS SSS SSS SSS SS—S Document a’ 2017-RT-001 Revision n’ B Page 49 of 140 DuPont's Kevlar products used in personal protection are 29, 129 or Ht, KM2, Comfort or Lt, Correctional, and introduced late in 1996 was the Kevlar Protera. Table 5.2 lists for the common sizes available, physical and mechanical properties of Kevlar yarns. .3 AKZO products The aramid products commercialized by AKZO NOBEL are known by the name of Twaron®. Twaron is an aramid product very similar to Kevlar. ‘Akzo Nobel's Twaron products used in personal protection are:T-1000, T-2000. AKZO did not introduce new products recently. However the Microfilament technology using T-2000 filament remains and advanced product and consists of a yam of extremely fine filaments. Twaron 2000 Microfilament in 840 denier yarn is composed of 1000 single filaments which is up to 50% more than those contained in traditionally used para-aramid yarns of the same weight. ‘Twaron 2000 Microfilament enables substantial weight reductions to be obtained at equal levels of ballistic protection. This means a lighter and softer garment offering the wearer greater freedom of movement. In comparison with Twaron 1000, panels made from Twaron 2000 Microfilament fabric bring about weight reduction of 41% at an equal level of kinetic energy absorption. The standard material on which this comparison is based on the currently used ballistic Twaron fabric T-713 (1000 denier). Table 5.2 lists for the common sizes available, physical and mechanical properties ‘of Twaron yarns.eee SS a —— — —— — — 50. of 140 KEVLAR 29 [Fer manoay Davia aan} s000 7 «1110 3500 1 (1670) 2570 1 (3300) TOT TH 240 1 (30) 1000 114110) 1420 1 (3500) TOOT TAH 50 1 (045) 500 1 «re70) RT ze 3510 7 (1680 2020 + (3360) ¥-2000 (er) THOT a) ‘40 1 (930 90:1 (1100 1510 1 (8 fFanete seen 2000] — 2500 B74] Tie Zod 235] Za0] NTE] 204 2335] 23.) TeNex ea 233] 239] Tens} 74 235] 234] 23.) Tatton] Zo 235] 7.9 Tara 2530] asia a7] 3310) Tima 739 a5] aaa] 32a] Gamnsisenie} 730 Za] Zea] zs. Nerate mocuv o's aise in 03 1 33] Ta tie] Nien Ea) 723] 35] e25| enn} S678] 20 7564] 7254 TENT 509 aaa] sae] 625] Toray 73 co 7 3q Gane Taeven| or 29] 329] Foel [Fongaton ar orear = 3a EE zy Tal | pectic Gravy ama T ee za Taq Ta Tad Tad ‘Sta. Moisture regain 70°F165% RH) "| x jecompositon Temoerature Ta =szi] sii] =a =a] =| Table 5.2= b b t U SSS SSS iS SS SS SS Document n’_ 2017-RT-001 8 Date January 16,1998 Pag 51 of 140 5.1.2 Ultra High Molecular Weight (UHMW) Polyethylene (PE) There are two major manufacturers of UHMW polyethylene or often described as high performance polyethylene (HPPE) fibers worldwide which are Allied Signal and DSM. Other companies identified producing UHMW polyethylene are Toyobo in Japan which is licensed by DSM on this exclusive market, TENFOR with the product Snia, Mitsui Petro Chemical Tokyo with the product Tekmilon and finally Hoechst Celanese manufacturer's of CERTRAN polyethylene fiber which has a lower modulus than Spectra products. 5.1.2.1 Generalities UHMWPE high-strength synthetic fibers are produced from extended-chain polyethylene (ECPE). Key properties of these include low weight and high strength, as well as resistance to impact, moisture, abrasion, chemicals, and punctures. UHMWPE fibers are made by a process called gel-spinning. Extended-chain polyethylene molecules containing 70,000 to 350,000 carbon atoms are dissolved in a solvent which is heated and forced through tiny nozzles called spinnerets. The resulting jets of solution cool and harden into plastic fibers, which are drawn, dried, and wound onto spools for further steps in manufacturing. This fiber- producing process aligns the extended-chain polyethylene molecules so that the hydrogen atoms of each molecule bonds with those of its neighbors. This gives UHMWPE fibers a tensile strength greater than aramid fibers. UHMWPE fibers. are less dense than other fibers; their specific gravity is only 0.97, so the fibers float. The first successful commercial application for UHMWPE fibers, introduced in 1985, was as a substitute for steel in ropes and cordage. The UHMWPE products other than for advanced ballistic materials are also used in composites for sporting goods such as racing sail, cloth tennis rackets, puncture and cut-resistant safety gloves, ropes, nets for the fishing industry and slings for industrial and other applications.SS 5 SS SSS SS SS Document n*_2017-RT-001 Revision’ B Date January 16,1998 P 52 of 140 The general properties of UHMWPE are summarized in Table 5.3. Property omments, [Toughness IVery good, especially on a weight basis [Thermal stability [Do not use above 200°F Flammability [Burns readily _ Solvent resistance Virtually not affected by organic solvents, acids and bases |Water resistance INo appreciable water absorption [Abrasion resistance [Excellent Cyclic stress|Excellent performance Fiber wet-out [Similar to fiberglass Machining / cutting [Difficult - use special tools Electrical lLow dielectric constant (2.2) over a wide range frequencies Table 5.3 5.1.2.2 Allied Signal products The UHMW PE product commercialized by AlliedSignal is known by the name of Spectra®. Spectra Performance Materials, a business unit of AlliedSignal Inc., has become a global leader in performance materials for the world’s advanced armour systems and for both consumer and industrial products. The company recently announced that it will build a new plant to double its capacity for producing Spectra Fiber and Spectra Shield®. The new $30 million plant will add three million pounds of ultra-high-strength polyethylene fiber, with the capability of converting all or any portion of the output to Spectra Shield®. Spectra Shield is the proprietary technology for making high-strength composite materials from Spectra Fiber. Today, this Shield Technology is being expanded into other synthetic yarns including aramid fibers. Table 5.4 lists for the common sizes available, physical and mechanical properties of Spectra yarns.== ee ee a a 5.1.2.3 DSM products Document n* 201 Revision Date Pag 8 “January 16, 53 of 140 198 The UHMW PE product commercialized by DSM is known by the name of Dyneema®. Dyneema fibers have been in commercial production since 1990 in the Netherlands. Table 5.4 lists for the common sizes available, physical and mechanical properties of Dyneema yams, TYNEENA] OYWEEWA OYNEENA | SPECTRA | SPECTRA | SPECTRA sxes| skeo | skrr_-| ~ so | 1000 | ~ 1000 Hevate sags Testy | sG0TR] aoe] sen] — seanoo] 10000] tate ie) 7 7 8 +5] 204 Gieq| sto] 350] apo} ——r. wae 204] (ene io) s90] —— aao] —— tor] ——— to] 2 eet | 3100] 3300] oof ——7 Teed] 2a ENdiex] 310] ES) a CT ante] —— 0] 330] oo] —— 67] rae} a ‘Meal 3007] ——sz0i| ses] aso] ——zaar| za Tae 07] 397] se] aes] “ne Garscener| | 7 | 2 “aI 3 Gos bsieg mn Baa al ea iss oon] —— 10] 31 71 Tetiex| 919] ——Tor0] tao] ——s| Fe] —T (cNtex 700] ——To%00] ——seo00] ——sore| 7133] es rnNvox | 7000] ——Toro00| ——veonoo| ——~sarar| ——rraso| soos ENae 3a] Toro] 00 soe] ——Fve] 7 (Gra) 3 elt] 73 10] 1 {GE [aero] 1100] | ter] ase] a0 17 [Eonar at bea @ Ta Ex a7 ED x x Soecite ry Gans teo] 097]. 3a 097] a7 fs ss, Moisture regain F165 RH [beconpostion Tenpesture Ta af =o] =e] 09] a] Table 5.4 4 SPECTRA SHIELD AND UD66 / UD77 Unlike other composites ballistic materials, Spectra Shield™ from Allied Signal or UD66 / UD77from DSM are not woven. It consists of two unidirectional layers which are single layers of closely spaced parallel UHMWPE fibers bonded together with Kraton™ resin (produced by Shell Chemical) to form a single ply, arranged to cross each other at 0 to 90 degree angles and held in place by the same flexible resin as illustrated in Figure 5.1. TheDocument n’_2017-AT-001 January 16,1998 54 of 140 surface of the two-ply sheet is sealed between two sheets of polyethylene to reduce friction and abrasion. The result is a strong, thin and lightweight non-woven ballistic material. Spectra-Shield® and UD66 / UD77are used in soft as well as rigid armour. Figure 5.1 This unique design eliminates the gaps inherent in woven fabrics, so there's less chance of projectiles penetrating through the gaps even with angled shots or high velocity metal-jacketed rounds. A ballistic panel for an armour garment could be made by cutting multiple layers of two-ply Spectra Shield™ or UD66 / UD77 into the desired shape, stacking the plies without stitching them together, and enctosing them in a cloth cover. And, because more of the fiber surface engages the bullet, this material has excellent stopping power. For hard ballistic, the polyethylene film layers are not applied and allow the plies to adhere to each other when formed by compression molding into hard panel. ‘As armour manufacturers strive to defeat today's ever increasing high velocity, multi-round threats, UHMWPE composite and other UHMWPE. fiber-based systems are specified more often. UHMWPE composite is the high performance armour material used in many applications from soft concealable body armour to hard armoured limousine doors and panels. Some manufacturers make "hybrid" armour by sandwiching sheets of Spectra Shield” or UD86 / UD77 between layers of UHMWPE or aramid fabric. UaeDocument n’ 2017-RT-001 ona’ 8 Date January 16,1998 Page 55 of 140 5.1.2.5 Wet condition performance Untreated fabric woven from either aramid or UHMWPE fiber loses some ballistic performance when it is wet. Possibly the water lubricates the intersections of the weave, so that stretching fibers slip on their neighbors rather than pulling them into sharing the work of stopping the bullet. There are three options for preventing or reducing this effect * The fiber or fabric may be treated by any of several processes to promote water-repellency. ‘Armour panels of untreated fabric may be encased in waterproof covers. * Armour panels may use enough untreated fabric to provide the ballistic resistance desired even when wet. Upon drying, untreated fabric of either type regains its original ballistic performance. The ballistic resistance of panels of Spectra Shield® and UD66 / UD77 non-woven composite material is unaffected by wetness because the fibers are already encapsulated. Therefore the cover does not need to be waterproof. 5.1.2.6 Energy absorption mechanism The traditional approach to stopping a bullet was to "catch" it with several layers of woven material made from fiber available. As a bullet would pass through a layer of the woven fabric, its tip would engage thousands of individual fibers. These fibers would stretch and break as energy was transferred outward through the fibers into the weave. As it passed through each progressive layer, the bullet would continue to lose energy as it was deformed or flattened, eventually bringing it to a stop. Figure 5.2 illustrates the energy dispersion pattern of traditional woven ballistic material. Figure 5.2Document n’_ 2017-81-01 Notice the star-like shape it forms. As the bullet passes through each layer, fibers are snagged and pulled through the material. The result is seen in the photos above - only a few strands of yarn clung to this bullet as it ripped through each layer. Angle shots have been shown to sometimes "slip" the weave and push aside ballistic yam strands. The only solution is to add more layers of material, or to sew the existing layers of material together, and that often means extra weight and discomfort. National Institute of Justice statistics show that certain styles of aramid fabric can lose up to 20% of their ballistic efficiency when struck at an angle. Spectra Shield™ and UD66 / UD77 materials eliminate gaps between fibers and hold them firmly in place during a ballistic event. Unlike woven ballistic fabrics, unidirectional materials’ fixed fiber orientation keep high velocity metal jacketed bullets from pushing the fibers apart and transfer energy faster away from the Point of impact in all directions and across a wider surface than possible with woven fabric, especially in angle shot situations. Spectra Shield™ and UD86 / UD77 characteristic is the high velocity - 12,300 m/s - at which the stress imparted by a bullet propagates within the armour outward from the point of impact, which allows the bullet's energy to be absorbed by a large area of the armour. In the 1 to 2 milliseconds during which a low-energy bullet is decelerated by armour and backing material, part of its energy would be distributed over and absorbed by the entire ballistic panel The energy dispersion pattern of Spectra Shield™ and UD66 / UD77 covers a wider, more rounded area, flattening the bullet by sending energy across the surface at incredible speed, bringing the bullet to a quick stop. The result is seen in Figure 5.3. Figure 5.3Revisionn’ B De January 16,1998 Pagi 57 of 140 5.1.3 Glass Glass fibers are used in ballistic protection in hard armour configuration. Therefore, it is used in manufacturing trauma panels as the backing material for ceramic face armour type. There are several types of glass: +E glass is the most common glass fiber used in many industrial applications. This fiber is available from a number of manufacturers. SSeS e-— + S2° Glass is a high strength glass from Owens-Coming specified in many armour configuration. * Hollex® glass is a product developed by Owens Coming and is an intermediate between E-Glass and S2 Glass in terms of mechanical properties. Hollex is approximately 30% lighter in weight than E-glass. This fiber was commercialized in 1993 and tested in some ballistic applications. Its high price ($16-$20 US per pound) made it difficult to compete with existing products. Therefore. Owens Coming decided not to commercialize this product anymore, Although upon request, the production could be reinitiated * Zentron® glass is the latest fiber from Owens Coming. This fiber shows properties similar to S2 glass, having a tensile strength 15 % lower but a 5% modulus increase over $2. The price of the fiber is slightly lower (3 to 5%) than $2. This product could eventually replace $2 glass in large quantity because price reduction could be around 10% lower than the actual S2 glass price. Vertex® glass is a new high strength distributed by IVG Composites in United States and North America. The fiber is produced in Russia and showed similar properties as $2 glass except for the strength which is approximately 10% lower. This fiber is approved per MIL-R-60346 Type IV Class | and Class Il. RH glass from Vetrotex is no longer in production. The company decided in 1998 to shut down this operation for a more lucrative market. 2S SS SSS SS SS eS SS SS€ = SSS 5.1.4 Docu Revision n° Date Page Properties of some glass fibers are listed in Table 5.5. a _2017-RT-001 8 January 16,1998 58 of 140 S2Glass Polyamide HT Fiber Avaitbiity 660 Tex} 675 Tex 1980 Tex| [Fensife strengih 680000] 575000] igaa74 1.9] 1.6] 08 EEX 76.1 8.0 189] 164 80, 7890] i612 800 18.9) 16.1 80) 789] 164 80 7688 3064] 312 478 405 33 21 18] 3 [Tensile modulus 12.8) 135] 0 36 38 5 356 378 50 3559 3784] 500 35586] 37837} 5000 356] 378 50 28 93 6 403 423 37 Elongation at break 3a] 20 [Specitic Gravity (grams co) 2.48 ZAG 14 6 Std. Moisture regain (70°F/65% RH.) Ql Decomposition Temperature (a =a Table 5.5 Liquid Crystal Polymer This type of fiber is known by the name of Vectran® and is produced by Hoechst- Celanese. It is a high modulus yarn polyester based liquid crystal fiber. Vectran has a modulus comparable to Kevlar 29 but, due to its molecular composition, it has better flex and abrasion resistance. Vectran is characterized by a combination of beneficial properties: high strength, no creep when tested at 50 percent of breaking load, low moisture absorption, negative coefficient of thermal expansion (CTE), good property retention over a broad temperature range and extraordinary chemical resistance. UBDocument n’_2017-8T-001 Revision’ 6 Date January 16,1998 Page 59 of 140 These characteristics make Vectran an interesting candidate as a performance fiber, although it is more expensive than either Kevlar or Spectra. It is produced in gold standard color but is available in black, with the colors having no effect on the properties of the fiber. Because of its higher price, this fiber product was not used extensively in armour product. 5.1.5 PBO This type of fiber as illustrated in Figure 5.4 is known by the name of Zylon™ and is produced by Toyobo a Japan based company. Formerly the development was done by Dow Chemical igure 5.4 PBO fiber is: Poly(p-phenylene-2,6-benzobisoxazole)(PBO)is a rigid-rod isotropic liquid crystal polymer. PBO fiber is a new high performance fiber using the latest material science and state of the art fiber technology. PBO fiber has superior tensile strength and features modulus numbers that are significantly better than other high modulus yarns modulus such as p-Aramid fibers. It has excellent resistance to stretch after repeated folding.. It also has outstanding high flame resistance and thermal stability among organic fibers. PBO looks in replacing other aramid applications in the future. PBO fiber furthermore shows excellent performance, in such properties as creep, chemical resistance, cut/abrasion resistance, and high temperature abrasion resistance, which far exceeds p-Aramid fibers. PBO fiber's moisture regain is low (0.6%) and it is dimensionally stable against humidity. uoDocument n’_2017-RT-001 Rovisionn” 8 0 January 1 Pag 60 of 140 PBO fiber is quite flexible and is very hand soft in spite of its extremely high mechanical properties. It can be processed into various product forms such as continuous filament, staple fiber, spun yam, woven and knitted fabrics, chopped fiber and pulp. PBO fiber's excellent heat and mechanical resistant properties will enable the design of high strength and light weight fiber reinforced composites and provide flexible fabrics with improved comfort and mobility., useful even where high heat resistance is required. The mechanical properties are listed in Table 5.6. [Tensile modulus [Elongation at break ISpecific Gravity J Std. Moisture regain (70°F/65% RH.) [Decomposition Temperature Table 5.6 The Japanese government restrict the fiber usage for body armour or related ballistic applications outside Japan. A confidentiality agreement needed to be signed to access more technical information disclosure. Lue| | Document a’ 2017-AT-001 Revisions’ B Date January 16,1998 Pe 61 of 140, 5.2 Fabric The fabric style as an important role in the performance of body armour system. The number of yams per centimeter or inch also influences the stiffness of the fabric, the surface treatment or sizing used by the weaver to produce the fabric is an other criteria that can affect the performance. 5.2.1 Weaving styles 5.2.1.1 Plain weaves The most common weaving style used in body armour is the plain weave. In this most simple weave pattern, warp and fill yarns are interlaced over and under each other in an alternating pattern. Plain weaves characteristically have good stability, and the least yam slippage for a given yarn count. Consequently, the lightest weight fabrics with a given yam are made with a plain weave fabric. Plain weave style fabrics are ideal for flat panel, where a high degree of conformability is not required. Plain weave configuration is illustrated in Figure 5.5. SS AY Nas Nias ast J Plain weave confi0 0 0 0 D b b 0 a — oo — od — or — or —— on = Document n’_2017-RT-001 Revisionn’ 8 Date “January 16,1998 Page 62 of 140 5.2.1.2 Basket weaves Basket weaves are a plain weaves variation in which multiple ends "ends" of yarn are woven together as one in each direction of the fabric. Basket weaves are typically used to make heavy fabrics which have a high degree of fiber crimp. 5.2.1.3 Satin weaves With a satin weave construction, the yams in fabric do not interlace at every yarn intersection. Instead, the yarns in both directions will “float” over several intersections and interlace under one. Satin fabrics have a higher degree of drapability than plain weaves. Common satin weaves used in composite applications are four-harness satin (or crowfoot), five-hamess satin as shown in Figure 5.6 and height-harness satin. mA AG I weave configuration se RG 5.2.1.4 Twill weaves ‘Twill weaves are a variation of satin weave. With a twill weave construction the yarns float over several intersections and under one or more intersections. Twill weaves always have a characteristics "twill" or twill lines . These are diagonal parallel lines formed by the interlace points in the fabric. Figure 5.7 illustrates 2/2 Twill UBSSS Document n’_2017-RT-001 Revision’ 8 Date ‘January 16,1998 Pag 63 of 140 = SSC SSrsssv Figure 5,7 - 2/2 Twill weave configuration —— a 5.2.1.5 Aramid weaving process The fiber can be damaged during each operation of the weaving process. It is important to perform QC test on samples at the end of the process to validate the performance of a given fabric. The following steps briefly describe the weaving operation. 1. The yams are beamed from little bobbins to a large beam cylinder to the width of the fabric. This operation needs to be performed under controlled tension. Otherwise, the fabric uniformity will be affected. The yams are already supplied with an amidon base sizing to gather each filament and to act as a lubricant to prevent damage due to friction. SSS 2. The weaving is done preferably on a “rapier” type loom. Other types such as gun type or air pulse can damage the fiber. 3. The fabric is scoured to remove sizing from initial filament and yarn processing. This washing of the fiber consists in rolling and unrolling the fabric into a solution. UhSS SS SS SS SS SS eS Se ee Document n’_ 2017-RT-001 Revision n’ 6 Date January 16,1998 Pag 64 of 140 Quality control of the scouring operation is done using a 10 g specimen of fabric. The specimen is weighed before (W1) and after (W2) being cleaned with a distillate methanol solvent to dissolve oil and other contaminants. To be accepted, the fraction of contaminants must be less than 0.1% otherwise the fabric needs to be rescoured again. W1-W2 < 0.1% wi 4. The fiber is dried at an initial stage of 130°C and a final stage of 150°C. 5. Water repellent treatment (WRT) is applied to the fiber. This is a solution of water, fluorocarbon and alcohol. The alcohol is used to reduced the surface tension of the fiber and improve wetability of the solution, 6. If the scouring operation is not performed adequately the WRT solution will not be efficient. 7. The fabric is re-dried to remove water and alcohol. To be effective the WRT needs to be cured at 170°C. 8. It is possible to add melamine resin simultaneously with the WRT. This as the effect of stiffening the fabric to improve low angle penetration of bullet in soft ballistic application. This also reduces the blunt trauma (by 1 or 2 mm) to some extent. 9. To pass the German wet test, it is mandatory to apply the WRT. Values obtained for untreated fabric could be as low as 360-390 m/s instead of V50>425 m/s for the wet condition. Aramid yarns, as discussed previously, are produced in several denier or Tex. Twaron 2000 Microfilament yarn uses smaller filament in the yarn which pays off by adding flexibility to the fabric. Although more layers may be required the body armour flexibility is improved. Another important aspect is the twisted yam for aramid application. It is normally required to twist the yarn in order to be woven. This is to prevent the small filaments from breaking during the process. However, this produces a stiffer fabric. An altemate method to twisted yarn is entanglement. This consists in pulsing air about every 20 cm on the yam to locally attached together the small filaments. This results in more flexible yarns and fabric improving the comfort of body armour users. LBDoct Revi Dat Page January 16,1998 65 of 140 5.2.1.6 Coated fabric 5.2.2 5.2.3 Some coating can be applied to fabric combined with a particular type of weaving to improve puncture resistance of knives and ice pick. A product called "Turtle Skin” from Warwick mills used this configuration. The coating is also applied to UHMWPE and LCP fibers Non-Woven Fabrics Shield technology developed by AlliedSignal, can produce lighter weight armour system over fabric which regards protection against bullet but it does not perform ‘as good as fabric against fragments. This is true for both aramid or HMWPE. Shield layers can be produced up to ten (10) times faster than woven fabric. Park Technology is also using unidirectional fiber in its fabric. The fibers are encapsulated with individual thermoplastic film carriers The layers are assembled together to form a soft ballistic pack. The layers can also be compacted by compression molding to form a rigid plate for superior ballistic performance. Typical fabric supplied by AKZO Table 5.7 is providing several fabrics construction designated by AKZO. These constructions are typical in the industry.Document n*_2017-RT-001 Revision’ 8 Date January 16,1998 Page 66 of 140 AKZONOBEL = Twaron Ballistic Fabric Styles ‘Solea” Geum [ wate [wow Tari] rnc [ioe eraungteee | eee wariven_| waver warble are er109 930, 5:0} 2040) 2000 an 40s) 105 20 oso | 76007 7000 | scouedyt ane 930; 920 | 2040) 2000 pile yn no 035 | e4ooy 8600 | scowes/t ans 100) 1100 | 2060 2000 en ey as 10 030 | roo 400 | scoueset ane 1100) 1100 | 20601 2000 am eed 280 oxo} 9800/1000, we 1180 ean) 1680 | 10601000 a my 18 260 axa | 93007 9800, wt om ean) 1680 | 206012000 i ou oa 20 ase | asooy asco | scoured ams ean) 1680 | 20402000 ia 19 20 exo | 96007 9600 | scuetye 735 reaor rex | 10407 1000 | oaoeeana 135/138 a8 se | r6000/re000 | scouedye ans ean; 1600 | 20002000 | wwe 202 mya a0 cs | r4000/1s000 | scued one 100 1680 | 2000 2000 | oaser 202 ray 142 a oes | rsrooyste0o | scawea 1750 3e0) 3360 | 1000/1000 ian oo “a oes | 13soo/3s00 | seus 1751 3360) 3360 | 10 1000 ian “6 x00 ass | 9800 9500 | scour 1785 3360) 3350 | 1000) 1000 | mesa x4 ou 95 605 00 | r9so0rssoo | scowe 1760 607 5360} 1000) 1000 | wt oy 2 63s 105} r9s00j19500 | tease Table 5.7=—————— Document n’_2017-AT-001 Revision” 6 0 anvary 1 Page 67 of 140 998 5.2.4 Felts = a = Felts are produced in both aramid and UHMWPE for ballistic applications. They are used specifically for fragment protection. The product commercialized by DSM as illustrated in Figure 5.8 is designated “Fraglight" and performed extremely well against fragments at velocity between 400 m/s and 600 m/s for an areal weight between 0.5 to 2.5 kg/m’. The material is highly flexible and provides vests with a lower weight for a given protection The major inconvenient of UHMWPE felts, is the significant performance reduction when the felt has been soaked in water. A water tight envelope needs to be produced and special care must be taken by the user to prevent any damage of the envelope. Felts do not perform well against even low caliber bullets. The pack thickness is increased by a factor of 3 compared with aramid fabric. The material is available in rolls 160 cm in width by 100 meters long. The nominal weight of the Fraglight is 200 g/m*. Figure 5.8- FRAGLIGHT Dupont reported that felt pack made out of Kevlar felt material was comparable in weight with UHMWPE felt pack as illustrated in Figure 5.9 and Figure 5.10. EMCAlso test data has demonstrated that ballistic performance is significantly reduced Pack areal density (ko/m2) Document n’_2017. Revisionn’ 8 0: ‘Weight comparison of packs meeting 470 m/s V50 STANAG 2920 1.1 g FSP Dry 285 22 7 ww kevlar HT Style ‘02 Kevlar Confort ‘hye 310 (witout waterproofing enveloppe) Kevarfet UHMWPE fet igure 5.9 under wet conditions as shown in Figure 5.10. \V50 wet (nis) g 8 8 8 8 Ballistic V50 of wet packs against 1.1 g FSP Stanag 2920 470 = 40 360 350 Alpacks Kevlar KevlarlHT-—Kevarfet UHMWPE. ay Confort Style 802 fet (conta) Style 310 (without waterproofing enveloppe) Figure 5.10 January 1 68 of 140Document n’_ 2017-81-01 Revision’ 6 Date January 16,1998 Page 69 of 140 As indicated in Figure 5.11, the panel thickness for a given protection level of 470 m/s V50 are 3 to 4 times thicker for felt configuration than for fabric construction. Thickness of 470 mis packs 27 g 1 Bis ] a 5 é Eo 3 | 2 | Bs | 3 28 e | i | | “Kove Kove nae fet over fot Contr Sie 802 rt sie 10 cepa Figure 5.11 Also as a result from stopping the projectile, the deformation behind the armour reported with felt configuration armour system is higher than for fabric construction. However, felt materials have been used successfully as interlayer materials with Goldshield type layers armour system to reduce blunt trauma by assisting in dissipating the transmitted energy. 5.2.5 Cost overview The cost of the raw materials is reported in Table 5.8 for reference only. iy [Fiber type [SCdnikg li K29 67 $ ki29(78$ kao [98 $ IkMi2 78S lub6s [100 $ lup77__ [120 [Fraglight _ |105$ Table 5.8 i ! i I ft t t i iDocument n’_2017-RT-001 vision nt B Date January 16,1998 Pag 70 of 140 5.3 Composites Composite materials by definition are made with a minimum of two elements which are the reinforcing fiber and the resin or matrix which can either be thermoset or thermoplastic materials. The composite materials are used in hard panel either with or without ceramic facing to protect against higher level threats. Because soft body armour performance limitation is up to NWJ level 3A, it is necessary to incorporate insert plates (back and front) in the body armour system to enhance the survivability of the user during various missions and operations. ee ee Most fibers can be integrated in hard panels including glass, aramid, high density polyethylene. The military has defined a number of specifications to insure consistency between manufacturers. ‘Aramid systems are typically pre-impregnated with PVB-phenolic resin system with a resin content between 15% to 18% as specified in military specification MIL-H-44099A. It can be impregnated using two methods: surface coated system or dip coated. The first method consists in applying a precise amount of resin on silicone paper media, the resin is transferred to the fabric by contact on one side only. The second method consists in having the fabric totally impregnated in a resin bath and an amount of resin is squeeze off the fabric using pressure rollers. SS The second method has been used more extensively to produce armour systems. However, it was said that the surface coated method could slightly improve the ballistic performance. Other resin systems than PVB phenolic used with aramid fibers are vynilester resin and black rubber matrix In shield technology the matrix being used is a Kraton matrix. This is a rubber thermoplastic matrix developed by Shell Chemical. 0 0 0 Q )Document n’_2017-AT-001 Revision n’ 8 i January 16,1998 i Page 71 of 140 5.4 Thermoplastics The thermoplastic materials are polymers that can be molten, formed and molten again as opposed to thermoset materials that harden by the chemical reactions which enable the resin and hardener to cross-link. In this case, the thermoset resin produced can not be re-melted and will eventually degrade by carbonization with addition of heat. There are several thermoplastic materials identified that are or could potentially be used in body armour system: polycarbonate, acrylics, polyethylene and polypropylene. Polycarbonate and acrylics are used extensively on transparent armour system. ‘The advantage of thermoplastic material is that they can be molded either by compression, vacuum forming or by injection molding. In this last case significantly reduced cost per unit can be expected. However, the tooling cost is higher. Polyethylene and polypropylene can be manufactured to generate highly oriented polymer. ADOPAC (made from polyethylene) and ARMORDON (made from polypropylene) represent 2 examples of oriented polymers. Limited tests have been performed with these panels but results indicate that for low protection level they could offer an excellent performance at a lower price ratio. Thermoplastic materials identified above are subject to burn when exposed to direct fire. 5.5 Ceramic = el Ceramic materials are used in ballistic protection to defeat high threat level like armour piercing (AP) projectiles. The mechanism used to defeat the projectiles is illustrated in Figure 5.12. SSS"= Document” 2017-RT-001 Revision’ 6 E Date Janvary 16,1998 Page 72 of 140 |______ Batlstic Spall Cover | __Boron Carbide or other Ceramic Facing Fractured * Projectile Fracture Conoid Kevlar", Spectra™. or Fiberglass Laminate Typical Impact Sass es Figure 5.12 The projectile defeat system is a composite consisting of a ballistic spall cover, ceramic tile, and an aramid, UHMWPE or glass reinforced plastic backing material. On impact, the ceramic fractures the projectile core. A major portion of the kinetic energy is absorbed by the ceramic, with residual energy being absorbed by the backing. Selection of the backing material is determined by structural, ballistic and weight requirements, Various compositions of Keviar/Twaron, fiberglass, and Spectra/Dyneema and aluminum have all been used. = Ss The spall cover is applied over the ceramic tiles and is typically a light weight high strength nylon or other material, to prevent loose fragments of ceramic facing from injuring personnel or equipment from impact. There are various types of ceramic material system used in hard panels for body armour system. Ceramics are much harder than the steel and the mass effectiveness is consequently higher and exceeds 2 and even 3 times in some cases when compared with RHA steel. The Vickers hardness number (VHN) of ceramics ranges from 2,000 to 3,000 compared with around 750 VHN of the hardest steels. The most common ceramic materials are alumina-oxide ceramic Al,O,, Silicone Carbide SiC, titanium diboride TiB, and boron carbide B,C. Table 5.9 lists the physical properties of the most common ceramics which have been considered for use in armour system ballistic protection. LB SS"Document n’_2017-RT-001 January 16,1998 73 of 140 Material Density E | Longitudinal] Hardness | Relative (g/cm? (GPa) | wave | Vickers | cost velocity | (Kg/mm’) (r/s) ‘Soda glass 25 | 72 5370 450 = Glass ceramic 2.52 [95 6140 750__| 7-15 Steatite 2:7 ea1A0 6380 600 a 85% Alumina 3.45 [250 9701 970 05 95% Alumina 3.72 | 322 10602 4450 1 99% Alumina 3.92 | 375 11305 1720 2 ZTA 4.15 | 340 10328 1570 ~ ‘Aluminum Nitride 3.3 | 330 1000 1100 2 Sintered Silicone Nitride__[ 3.25 | 290 9450 1600 = Sintered Silicone Carbide | 3.15 | 410 11410 2200 5 HP Silicon Carbide 3.2 | 455 12250 2500 40. Titanium Diboride H.P. 4.48 | 575 11330 2500__| 20 - 25 Boron Carbide H.P. 2.48 | 450 13700 3000 20 Diamond 3.47 | 1035 | 17250 8000 - Table 5.9 5.5.1 Alumina-oxide Al,O, This type of ceramic is available in various alumina purity concentration. The most common grades are 85%, 87%, 90% 95%,96%, 99.5%, Alumina oxide tile have the possibility to be molded in mosaic or monolithic configuration as illustrated in Figure 5.13.Document n° 2017-RT-001 axe uP oF Batuste Pane Revision a’ 8 January 16 1998 Page 74 of 140 305 mm # 254 mm ane uP oF 305 mm 284 com iE of SauusTe PANEL, CE ey SPALL COVER Monolithic configuration has proven to offer good multi-hit capabilities and to reduce the thickness of the ceramic upon the multi-hit pattern requirements. Figure 5.14 shows recommendations for tile arrangement in different multi-hit requirements for the 7.62 NATO Ball caliber. MULTI-HIT CAPABILITY OF ALUMINA MONOLITHIC TILES 7.82 mm CALIBRE BULLETS HIT PATTERN fan esis i win atg ston ad ped nyo pee Figure 5.14 MONOUTHICOR MOSAIC 16% weight saving with sano or sae protection evantagenus to use ‘orl ties| Use optimum size mosaic tileDocument n’_2017-AT-001 Revision’ 8 Date January 16,1998 Page 75 of 140 Figure 5.15 is showing the mean ballistic velocity for centre and comer impacts for the 7.62 NATO Ball caliber. MEAN BALLISTIC LIMIT VELOCITY FOR | CENTRE AND CORNER IMPACTS I Fe | g 880 y i g é Ss wo y 780 | 25 30 35 40 45 50 55 60 65 7.0 75 80 CERAMIC THICKNESS-nm 50mm x S0mm TILES GAP. BACKING NATO BALL Figure 5.15 A special tool design for a specific breast or back plate can cost around 35,000$ ‘to 40,000$ CDN. Drawings of different tile configurations produced by Coors Ceramics and Morgan Matrox can be found in Appendix F. Small ceramic tiles (1" x 1") can also be used to resist puncture from knife or ice pick. a a ee 5.5.2 Silicon Carbide SiC This material is an excellent compromise between the aluminum-oxide and boron carbide ceramic. LueS Document n*_ 2017-AT-001 Revision n’ 8 Di Sanuary 16,1998 Pe 76 of 140 5.5.3 Boron carbide B,C Ss This is the hardest ceramic and provides the lowest weight option to defeat armour piercing threats. This type of ceramic, although it is the hardest, is more brittle and when subjected to multi-hit impact does not perform as well than in single hit firing, 5.5.4 Ceramic configuration pattern Sao a a el — a i The size of the ceramic tile and the configuration of the ceramic array are important factors in the design of ballistic ceramic insert plates. Therefore, the Performance reduction has been attributed to the number of joi staggered arrangement is preferred to minimize the number of j ints Other factors of influence in the ceramic performance are the edges and surface finish. It is important to minimize the gap between each tile. Therefore, the edges of the tile needs to be ground. Also, crack propagations are more likely to happen on tiles that were not surface machined, When using ceramic panels it might be required to use a layer of glass between the composite laminate, especially if it is made of UHMWPE, and the ceramic to provide better adhesion. The ceramic surface shall be properly cleaned. High strength adhesives with high elongation properties have been reported to improve ballistic and multi-hit performance with ceramic materials. The type of backing and its surface condition is also critical in the performance of a given armour system. Urethane adhesives such as the one component Sikaflex or two components Pliogrip, Ethylene vynil acetate or Pro-seal A-10 polysulfide and epoxy adhesives are among the types used in ceramic/composites panel system.Document n’_ 2017-81-01 Revisions’ 6 Date “January 16,1998 Page 7 of 140 Foamed materials Various types of foams are used in ballistic protection mainly for energy dissipation. The most common foam type use is urethane. Densities and hardness can be adjusted for each application. Foamed materials are used in body armour to reduce the blunt trauma and in helmet to absorb shock energy. They can also be used to improve comfort. 5.7 Metals Metals have been used in ballistic protection at its early stage in shields, armour vehicles and other various applications. Its mass effectiveness is generally low compared to non-metallic materials such as ceramics. The most common metals are described below. As for fiber materials, there is a lot of military specifications for steel, aluminum or titanium materials to cover various specifications and applications. These specifications are listed among other military specifications in Appendix A. 5.7.1 Steel and aluminum armour Typical steel and aluminum armour material are listed in Table 5.10 with the areal density required at point blank range and normal impact. . The relative effectiveness or mass effectiveness is best characterized by comparing the areal density, which is the mass per unit of area, of two materials providing the same degrees of protection against a given threat. In this example the mass effectiveness of the materials are normalized to RHA. Material type _| Density | Areal density kg/m? kg/m? Rolled homogeneous | 7830 114 steel armour (RHA) (320-380 BHN) High hardness armour | 7850 98 1.16 (650 BHN) Dual hardness armour | 7850 64 178 (600-440 BHN) '5083 alloy (75 BHN) | 2660 128 108 7039 alloy (150 BHN)_| 2780 106 0.89 2519 alloy 2807 100) 4.14 Table 5.10Document n*_2017-RT-001 Revision a’ 8 al January 16,1998 Page 78 of 140, ‘The effect of increasing the hardness of steel armour is illustrated in Figure 5.16 which shows curves in the thickness of plates required to provide protection against 7.62 mm AP versus obliquity for three different types of armour produced by Svenskt Stal, They are ARMOX 3008 with 280 to 340 BHN, ARMOX 4008 with 380 to 440 BHN and ARMOX 500 with 480 to 540 BHN. jickness, mm Plate Oo 10 20 30 40 so 60 Obliquity, degrees igure 5.16 t i i I 1 1 i il i I I 4 i i 1 hi d i 0 b 0 Q 0 f 0 0 0 0 0 Document n'_2017-RT-001 Revi B Date January 16,1998 Page 79 of 140 High hardness steel would be desirable from the point of view of mass effectiveness but very hard armour tends to be brittle and to shatter when hit.. The desired combination with high hardness and toughness is achieved with dual hardness steel consisting of an outer layer of steel hardened to 600 BHN and roll bonded to a thicker backing of a softer but tougher steel of 400 BHN. This can provide a mass effectiveness of about 1.78 as seen in Table 5.10. 5083 aluminum-magnesium-manganese alloy has proved more effective against shell fragments than RHA. However, the hardness of the 5083 alloy is only in the order of 75BHN, which makes it less effective against high velocity bullets Aluminum alloys are not used in personal protection, but primarily in vehicle armour where they offer also excellent strength to weight ratio. 5.7.2 Titanium Except for titanium, metals are not used often in personal protection because of their low mass effectiveness ratio when compare to non-metallic materials. Titanium is being used in different applications: stab protection, helmet and in insert panels. A development program on helmet conducted by ARL in the Unites States was reported to have a titanium shell made of Ti-6A\-4V alloy backed with Kevlar/PVB composites to defeat Tokarev 7.62 x 25 mm steel jacket, steel core round at 503 m/s Titanium is also used as an interlayer between ceramics and SpectraShield or equivalent material on insert panels to improve the multi-hit performance of such system that can be reduced significantly by the delamination of the composite material. For stab protection, titanium is used in small thin pieces assembled like a fish scale. Steel chain mesh is also used in similar application but is very heavy.sa SS i 0 0 i fl t i 5.8 Transparent mater Document n’_2017-RT-001 Revisionn’ 8 Date ‘anvary 16,1998 Page 80 of 140 Is (face and eye protection) Transparent armour systems are systems used in eye gear protection including face mask, glasses, lens for gas mask . ‘The materials identified to provide such protection include glass, polycarbonate and acrylics thermoplastic material and various kinds of ceramics. Enhanced systems are produced with combinations of transparent ceramics. Two types of transparent ceramic have been produced; glass ceramic produced from LO - SiO, by GEC Alshtom and “sapphire” ceramic by "Céramiques et Composites" in France, With current technology, distortion problems is not completely solve for large surface such as full face visor The glass ceramic has a lower density compared to other ceramics and can be formed. The size of the crystals is smaller than the wavelength of light explaining the transparency. A.V50 ballistic limit over 640 m/s was reported using a hybrid construction made of glass ceramic and polycarbonate against 1.19 FSP. According to the manufacturer 9 mm projectiles can also be stopped. Other development was reported to provide weight saving in the magnitude of 25% compared with traditional glass laminate against 7.62 AP threat round. This material is still produced on a laboratory scale. Therefore, the price to purchase some systems is extremely high.SS SS SS Ss SS SS S--e Document n’_2017-RT-001 Revision’ 8 Date January 16,1998 Page 81 of 140 6. ARMOUR SYSTEM CONFIGURATION Personal protection is provided using various components from helmet, body armour, trauma panel with or without ceramic insert, etc. Each components use materials discussed in the section 5 with a configuration that can either be rigid or flexible. Helmets use a ballistic shell made of hard composite materials. The suspension system may require shock absorbing foam to protect the head and incorporate a visor for eye and face protection against fragments, lasers or other threats. Body armour system includes protection that covers the upper part of the body excluding legs, arms and head protection. Body armour system can be designed for different operations and missions as function of the type of activity and environment. Some activities require the body armour to be resistant to environmental conditions such as: Rain Immersion in water Wear Fire resistance Heat Burning fluids Solvents Etc. Depending upon the mission the body armour system can be : » Concealed to act as undershirt -not seen or felt Uniform smart non aggressive official duties * Aggressive a deterrent * Functional a design not influence by appearance Active or passive roles have an influence on the requirements of body armour system. In an active role, the minimum weight and restriction allow the personnel to carry out with ease physical movements. The requirements include: performance, coverage, weight, comfort, etc. All these factors will influence the cost. UBDocument n*_2017-RT-001 een Dab arany sl IIB Page 82 of 140 6.1 Current US Military Soldier Systems 6.1.1 Individual Body Armour 61.2 The body armour used by Marines protects them from ballistic fragments. It can be vulnerable to bullets and leaves the neck, groin and sides of the torso without protection. The new individual body armour will consist of a camouflage fragment protective vest which protect against small arms high velocity bullet up to 7.62 round, using ceramic plates inserted in the large front pockets. Ranger Body Armour Ranger Body Armour (RBA) is a two part system; a flexible vest and a rigid plate. The flexible vest consists of an Aramid (Kevlar KM2) filler encased in a nylon woodland camouflage printed carrier. The vest protects the front and back torso from most 9 mm and 44 magnum threats up to NIJ level IIIA, as well as fragmentation protection similar to that of the Personnel Armour System for Ground Troops (PASGT) vest. The RBA vest weighs approximately 8 pounds (size Medium). ‘A.3.6 kg (8 pound) ceramic plate inserted into the front pocket is use to upgrade the vest, vital organs in the front torso are protected from both 5.56 mm and 7.62 mm ball projectiles over an area of approximately 25 cm x 30 om (10" X 12"). The plate is made of 5 cm x 5 cm (2" X 2") aluminum oxide ceramic tiles. The vest and plate meet the National Institute of Justice Standards, Ballistic Resistance of Police Body Armour. With the ceramic plate inserted in the vest, the system weighs 7.2 kg (16 pounds). LueDocument a? 2017-RT-001 "8 January 16,1908 Page 83 of 140 6.1.3 Interim Small Arms Protective Overset To keep up with advances in ballistic protective technology, the Interim Small Arms Protective Overset (ISAPO) was developed to provide ballistic protection against selected high velocity 7.62 mm and 5.56 mm rounds. The ISAPO which consists of a carrier made of camouflage, with adjustable straps at the waist provides a modular small arms protection upgrade for the existing Personnel Armour System for Ground Troops (PASGT) fragmentation protective armoured vest. The additional ballistic protection is provided by two Ranger Body Armour (RBA) ceramic plates that are inserted in pockets on the front and back of the carrier. The carrier and plates are worn over the PASGT vest to provide front and back protection against small arms and flechette threats. With ISAPO, an additional ballistic plate can be added to RBA to provide small arms protection to the back. ISAPO provides the same level of small arms protection as RBA, however, the area of fragmentation protection is greater.Document n’ 2017-81-01 Revision’ 8 Date January 16,1998 Page 84 of 140 6.2 Equipment Description and Manufacturer of military, civilian, police equipment This section describes the companies involved in manufacturing either materials or equipment related with personal ballistic protection. It is organized per categories of material or equipment provided. Appendix E provides the complete information about the manufacturers. 6.2.1. CONSULTANTS The consultants identified to provide various services from design, ballistic testing, and other related ballistic protection except for production are identified in Table 6.1. [COMPANY COUNTRY [ARMOUR CONSULTANTS, CANADA IBIOKINETICS CANADA IBOSIK CONSULTANTS LTD. CANADA ICARLETON UNIVERSITY CANADA ICLERMARK INC. CANADA ICMC ST-JEROME CANADA |GAUSERTEC INC. CANADA JGD_ CANADA INORTH GROUP INTERNATIONAL CANADA ISECURESEARCH INC CANADA, [SNC IT CANADA UNIVERSITY OF BRITISH CANADA, ICOLUMBIA, FACKLER CONSULTANTS, USA H.P. WHITE. USASS" oS = Ss Ss er Document n’_2017-RT-001 Revision n’ 8 Date “January 16,1998 Page 65 of 140 6.2.1.1 BIOKINETICS AND ASSOCIATES LTD Biokinetics is establish since 1975 and provides services related with human engineering design factor and main activities are related with: ‘Average Work Force: 20 * Personal Protective Equipment; Helmets; Riot Equipment; Protective Equipment ‘* Design; Headgear Testing; Headgear Evaluation; Helmet Testing; Helmet Evaluation; Protective Equipment Testing; Protective Equipment Evaluation; Prototype * Fabrication; Litigation Consulting; Automotive Research; Crashworthiness; Restraint Design; Restraint Systems; Riot Suit; Construction + Helmet Design and Development. Biokinetics has developed specifications for protective equipment. Consultation to manufacturers and government agencies has resulted in the design of a range of safety equipment. Crash test studies have been conducted to examine the effectiveness of current protective systems and to identify ways of improving protection in accidents. Anthropometric test devices have been redesigned to provide more realistic monitoring techniques for injuries to selected body regions. Biokinetics has evaluated and utilized devices for the spatial quantification of anthropometric and physical landmarks. Biokinetics has conducted field trials of protective equipment. Biokinetics has utilized MADYMO and other simulation programs to study occupant dynamics in crash situations. Biokinetics has in-house test facilities to evaluate helmet performance and establish compliance to national and international standards. Dummy components and human subjects can be evaluated. Access to outside laboratories supports such work as wind tunnel testing, ballistic testing, car crash testing and high-g sled tests.SSS See ee ee SS Se Document nt Revision n* Date Page 6.2.1.2 BOSIK CONSULTANTS LTD. 2017-AT-001 8 January 16,1998 86 of 140 Bosik Consultants is an engineering firm involved in equipment design, special test fixtures and that can’ perform ballistic material evaluation. The laboratory equipment includes: * Shooting range for small calibers handgun/pistols, riffles for ballistic material performance evaluation equipped with light screens velocity measurement system, Large gas canon for shooting heavy projectiles at supersonic velocities, Small machine tools. 6.2.1.3 CARLETON UNIVERSITY Carleton University has developed expertise in numerical code development using hydrocodes for dynamic analysis. Highly specialized test such as dynamic material properties evaluation using Hopkinson bars can be performed. 4 CLERMARK INC. Dyneema fiber from DSM is sold in Canada through their distributor Clermark Inc. This company offers the product support for all the Dyneema family product range. 6.2.1.5 CMC ST-JEROME The Composite Materials Center of Saint-Jéréme (CMC) is a specialized technology application center, and is offering the following products and ser Research and validation of ideas, Product conception, engineering, and 3D CAD, Selection of raw materials and production processes, Fabrication of prototype tooling, Fabrication and testing of prototypes, Implementation and optimization of production processes, In-house training programs, Technology transfer service, Information services.SS SS SSS See eee ee ee Document n’_2017-AT-001 “anvary 16,1998 87 of 140 CMC employs a specialized team of 17 engineers and technologists, with ‘expertise and know-how in the following technological areas: Computer-aided design (CAD) and computer-aided manufacturing (CAM), Matrices (or resins), Additives and fillers, Reinforcements (or high-performance fibers) in various formats such as yarn, roving, textile, prepreg, etc. Core and combination materials, Production processes, Fabrication of prototype tooling, Fabrication of prototypes, Bonding adhesives, Testing methods, Environment and recycling, Market sectors of the composite materials industry for products or parts for the following sectors: ‘Aerospace, Construction, Consumer, Corrosion, Defense and ballistic protection, Electrical, Marine, Transportation. 6.2.1.6 GAUSERTEC INC. This service firm owned by Mr. Alain G. Gauthier, represents several composites manufacturers that are involved in ballistic protection system. 6.2.1.7 JGD This service firm owned by Mr. Jean-Guy Dion, works closely with Clermark Inc. and provide Dyneema fiber product support. LuDocument n’_2017-RT-001 Revision’ 8 Dat January 16,1998 Page 88 of 140 6.2.1.8 SNC IT Primarily devoted for ammunition manufacturing, SNC IT has an engineering team specialized in vulnerability study and armour system development. SNC IT is the prime contractor for the MASTD tech-demo and is also involved in the IPCE program with CDC as a supplier for the gas mask. ‘SNC IT does not produce anymore body armour system. 6.2.1.9 UNIVERSITY OF BRITISH COLUMBIA The University of British Columbia (UBC) can perform experimental high strain rate composite materials characterization. These results are used as input for numerical code modeling and analysis, also performed by the engineering team of UBC. 6.2.1.10 FACKLER CONSULTANTS Doctor Martin Fackler, is a well known surgeon expert in wound ballistic. The type of services offered by Dr. Fackler includes: «Test method development to simulate body injuries caused by projectiles * Standards and material specification write up. 6.2.1.11 HP, WHITE This establishment is a testing laboratory for various ballistic protection system from personal armour to vehicle armour. This laboratory is recognized by the National Institute of Justice (NIJ) and offers a complete range of ammunition for test purposes including Armour Piercing (AP) round and FSP's.| i 6.2.2 FIBER PRODUCERS Document n’_2017-RT-001 Revision’ 8 Date January 89 of 140 1998 The fiber producers identified to provide related material for ballistic protection are listed in Table 6.2. [COMPANY COUNTRY. ICLERMARK INC. CANADA, IDUPONT CANADA INC. CANADA, \VETROTEX-CERTAINTEED CANADA. [AKZO NOBEL FASER AG GERMANY, INITTO BOSEKI. JAPAN ITOYOBO CO.,LTD. JAPAN. [DUPONT DE NEMOURS INT. ‘SWITZERLAND IDSM_—-HIGH = PERFORMANCE| FIBERS THE NETHERLANDS [AKZO NOBEL FIBERS INC. USA’ JALLIED SIGNAL INC. USA’ IDUPONT ADVANCED FIBERS| USA SYSTEMS, HOECHST CELANESE USA’ VG COMPOSITES USA’ JOWENS-CORNING USA’ Table 6.2 6.2.2.1 CLERMARK INC. Clermark distributes DSM Dyneema High Performance UHMWPE Fiber products in 6.2.2.2 DUPONT CANADA INC. © Dupont Canada distributes the complete range of Kevlar aramids product line including Kevlar 29, Kevlar 129 (Ht), Kevlar KM2, Kevlar LT (Comfort), Kevlar Correctional and Kevlar Protera. 6.2.2.3 VETROTEX-CERTAINTEED © Twintex E- glass thermoplastic material is produced by Vetrotex Certainteed. Vetrotex used to produce the RH Glass equivalent to the S2 Glass and approved to Luems Document n’_2017-RT-001 Revisionn” 8 Date anvary 16,1998 Page 90 of 140 the Mil Specifications. The demand for this type of glass was not sufficient and the company decided to stop this product line to other type of products such as E-Glass or Twintex. The thermoplastic used for the Twintex product can either be polypropylene (PP) or PET material . The material is available in pre-consolidated sheet form or in roving for further transformation in textile form or directly in the molding process. 6.2.2.4 AKZO NOBEL FASER AG ‘© Akzo Nobel produces Twaron aramids product line including T-1000, T-2000 and T-2000 Microfilament yarns. 6.2.2.5 NITTO-BOSEKI This company produces high strength glass fibers and E glass fibers but is not well known in North America. The market for this fiber is more in China and Asia countries. 6.2.2.6 TOYOBO CO.,LTD. * Toyobo produces Zylon PBO fibers. 6.2.2.7 DSM HIGH PERFORMANCE FIBERS * DSM manufactures Dyneema High Performance UHMWPE Fiber products. 6.2.2.8 AKZO NOBEL FIBERS INC. «Akzo Nobel distributes Twaron aramids product line in USA and North America 6.2.2.9 ALLIED SIGNAL INC. * AlliedSignal manufactures Spectra and SpectraShield UHMWPE Fiber products. 6.2.2.10 HOECHST CELANESE Hoechst Celanese manufactures the Vectran Liquid Crystal Polymer (LCP) fibers. 6.2.2.11 IVG COMPOSITES ‘* High strength glass fibers are distributed by IVG Composites in North America. 6.2.2.12 OWENS-CORNING * $2 Glass high strength glass fibers and E glass fibers are produced by Owens Coming. Uae= a — ee es a — or — = Document n° 2017-RT-001 vision B Date January Page 91 of 140 6.2.3 PREPREG PRODUCERS The companies listed in Table 6.3 are either prepreger or resin producer. They are categorized per country. [COMPANY COUNTRY. ICIBA-GEIGY CANADA LTD. CANADA [CMC CANADA [TEN CATE NETHERLANDS ICYTEC AEROSPACE UK IFOTHERGILLS ENGINEERED] UK IFABRICS LTD IBEDFORD USA’ BORDEN USA IGEORGIA-PACIFIC RESINS, INC. USA, ICI FIBERITE USA’ LEWCOTT USA’ IPARK TECHNOLOGY, INC USA’ [SIOUX MANUFACTURING CORP. USA’ Table 6.3 6.2.3.1 CIBA-GEIGY CANADA LTD Ciba-Geigy Canada is mainly an epoxy resin producer and distributor. Other division of Ciba-Geigy in the United States and Europe are producing prepreg material which can be acquire through Ciba-Geigy Canada. 6.2.3.2 CMC CMC is mainly an engineering firm as discussed earlier in 6.2.1.5. CMC also has prepregging capabilities for polyester, vynilester and phenolic resins. 6.2.3.3 TEN CATE Ten-Cate can prepreg a wide range of fabrics and materials within military specifications. 6.2.3.4 CYTEC AEROSPACE Cytec Aerospace can prepreg a wide range of fabrics and materials within military specifications. LB92 of 140 6.2.3.5 FOTHERGILLS ENGINEERED FABRICS LTD Fothergills Engineered Fabrics can prepreg a wide range of fabrics and materials within military specifications 6.2.3.6 BEDFORD Bedford can prepreg a wide range of fabrics and materials within military specifications, Bedford has special abilities to produce prepreg material in either small or large quantities in a cost effective way. 6.2.3.7 BORDEN Borden is a resin manufacturer producing phenolic resins to meet military specifications. 6.2.3.8 GEORGIA-PACIFIC RESINS, INC. Georgia-Pacific Resins is a resin manufacturer producing phenolic resins to meet military specifications. 6.2.3.9 ICI FIBERITE ICI Fiberite is a prepreger that can prepreg a wide range of fabrics and materials within military specifications with production adapted for high volumes. 6.2.3.10 LEWCOTT Lewcott can prepreg a wide range of fabrics and materials within military specifications. Lewcott has special abilities to produce prepreg material in either ‘small or large quantities in a cost effective way. 6.2.3.11 PARK TECHNOLOGY, INC Park Technology used thermoplastic film materials in is and manufacturer thermoplastic prepreg ready for compression molding without any shelf life. 6.2.3.12 SIOUX MANUFACTURING CORP. ioux is a prepreger that can prepreg a wide range of fabrics and materials within military specifications.Document n'_ 2017-RT-001 Revision’ 6 0: January 16,1998 93 of 140 6.2.4 BODY-ARMOUR MANUFACTURERS The design of body armour system varies upon the requirements of military organization, the type of mission (special purpose/tactical armour), the protection level (fragmentation vests, bullets, knives and other ballistics protection), as a function of the threat likely to face in theater, etc. Tactical Vest Main Features The common items often incorporated on body armour systems include: * Modular pouch attachment system * Full front, rear, and side protection «Integral front and rear plate pockets * Reinforced "Rescue Strap" on back + Removable identification labels, front and back + Engineered “Front Closure" design + Removable ballistic panels * Rifle retention bars standard + Water-resistant nylon outershell The body armour system can be specifically designed to include some or all of the following features: Ballistic groin protector Ballistic collar protection Fire-retardant outershell Tactical plate Carry case It is also possible to convert concealable vest to light-weight tactical use with the addition of modular tactical outershell. Most tactical vests are available in NIJ Level II and IIIA ballistic packages. The companies listed in Table 6.4 are body armour manufacturers. They are categorized per country. Most of these companies offer a wide range of standard products that will meet NIJ requirements at different level with different area of coverage and in various sizes from small, medium, large and extra-large. Several companies are tailoring their body armour to fit each individual user by measuring the size of each person.Document n°_2017-RT-001 Revision’ B Date January 16,1998 Page 94 of 140 ‘COMPANY COUNTRY, ‘SIGNAL ONE INTERNATIONAL PLY LTD AUSTRALIA BROWNING SA BELGIUM BARRDAY INC. ‘CANADA, CANADIAN BODY ARMOUR LIMITED CANADA, GALLET SECURITE INT. CANADA LES DISTRIBUTEURS R. NICHOLLS ‘CANADA, NORTH GROUP INTERNATIONAL CANADA, OPTIMA CANADA, PACIFIC BODY ARMOUR CANADA PRO SAFETY ACCESSORIES INC. CANADA PSP INC. CANADA SNC CANADA T. K. GROVES ENGINEERING CONSULTANTS LTD. CANADA TERRA AEROSPACE CORPORATION CANADA VALLEY ASSOCIATES INC. CANADA INTERNATIONAL BALLISTIC PROTECTION FRANCE MANDEFENCE FRANCE SOCIETE D'EQUIPEMENT MILITAIRE ET ADMINISTRATIF FRANCE (SEMA) MEHLER VARIO SYSTEM GMBH GERMANY PLASAN-SASA CPMPOSITE MATERIALS ISRAEL RABINTEX INDUSTRIES LTO. ISRAEL ITAAS ISRAEL INDUSTRY LTD. ISRAEL URDAN INDUSTRIES LIMITED ISRAEL KIRASA CORPORATE COMPANY RUSSIA REASEARCH INSTITUTE OF SPECIAL TECHNICS RUSSIA ‘YUGOIMPORT-SDPR SERBIA CLANSMAN ARMOUR SYSTEM SOUTH AFRICA INDUYCO SPAIN [AKERS KRUTBRUK PROTECTION AB ‘SWEEDEN [ARMOUR TECHNOLOGY LTD UK ARMOURSHIELD LTD. UK COURTAULDS AEROSPACE UK DOWTY ARMOURSHIELD UK EUROCOURT DEVELOPMENTS LTD UK ICL TECHNICAL PLASTICS LTD. | waeJanuary 16,1998 95 of 140 ‘COMPANY. COUNTRY LIGHTWEIGHT BODY ARMOUR LTD UK MEGGITT COMPOSITES. UK ML LIFEGUARD EQUIPMENT LTD. UK RBR. UK TBA INDUSTRIAL PRODUCTS LTD, BALLISTIC ARMOUR UK BUSINESS TETRANIKE ARMOUR SYSTEMS LIGHTWEIGHT BODY UK ARMOUR LTD 21ST CENTURY HARD ARMOUR USA ADVANCED COMPOSITE MATERIALS CORP. USA AMERICAN BODY ARMOUR & EQUIPMENT INC. (ABA) USA AMERICAN PROTECTION CORPORATION USA ARMOUR HOLDINGS: USA ARMOUR OF AMERICA USA CCS INTERNATIONAL LTD USA FIRST DEFENCE INTERNATIONAL USA GENTEX CORPORATION USA GUARDIAN TECHNOLOGIES INTERNATIONAL, USA KERAMONT CORPORATION USA MACOISA INTERNACIONAL CO. USA MISTRAL SECURITY INC. USA PARK TECHNOLOGY, INC USA POINT BLANK BODY ARMOUR INC. USA PROGRESSIVE TECHNOLOGY OF AMERICA INC. USA PROTECH ARMOURED PRODUCTS. USA PROTECTIVE APPAREL CORP. OF AMERICA (PACA) USA PROTECTIVE MATERIALS CO., INC. USA RBR ARMOUR INC. USA ‘SAFARILAND USA SECOND CHANCE. USA SECURITY UNLIMITED INC. USA SILENT PARTNER BODY ARMOUR INC. (SPBA) USA SPECIALTY PLASTIC PRODUCTS INC. USA T & RARMOUR SYSTEMS: USA TOP-LINE USA USA U.S. ARMOUR CORPORATION USA Table 6.4