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Experimental study on spall behavior of single and multi-plate composites

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DOI: 10.1177/0021998320916229

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 JOURNAL OF
COMPOSITE
Article M AT E R I A L S
Journal of Composite Materials
2020, Vol. 54(24) 3491–3499
! The Author(s) 2020
Experimental study on spall behavior Article reuse guidelines:
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of single and multi-plate composites DOI: 10.1177/0021998320916229
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behind armor subjected to shaped charge

A Kaan Toksoy1, Volkan Arıkan2 , Ramazan Karakuzu3,

Yusuf Arman3 and Aytaç Gören3

Abstract
Spall behavior of single and multi-layered hybrid composite structures behind armor was investigated by using shaped
charge. Firstly, spall cone angles of Aluminum 5083-H116 and rolled homogeneous armor (RHA) steel as base armor
materials were determined without any composite to select base armor. The single and multi-plates composite samples
were produced by using S2 glass plain fabric, Kevlar plain fabric and hybrid Carbon-Kevlar twill fabric and epoxy resin
system. After that, composite samples were placed behind the selected base armor plates with different distance in
between them. The changes of spall cone angle, spall diameter, and penetrated area after shaped charge penetration were
determined and analyzed in terms of both material configuration and distance behind the armor plates. As a result,
increasing the behind armor distance reduces the jetting area and thus spall distribution decreases. In addition, it can be
recommended to use hybrid 1 and 50 mm behind armor distance by evaluating both spall distribution and in-vehicle
volume restriction.

Keywords
Single and multi-plate composite, ballistic impact, S2 glass, Kevlar, hybrid carbon-Kevlar fiber, spall, shaped charge

The researchers mainly focus on the following con-

Introduction
During the ballistic attack, armor materials such as
aluminum and steel of the vehicle chassis cause severe
fragmentation or spallation, which cause heavy injuries
to the crewmember. The secondary damage can occur
with and without perforation of the armor plate by
induced shock by impact of projectile. In order to pro-
tect the crew from fragments, a composite stack/plate,
which is commonly called as spall liner, is generally
mounted in the compartment of vehicles. Such an add-
itional protection serves to minimize the area of effect
of fragments of penetration (by reducing spall angle)
and prevents fragments (perforating spall liner) from
being accelerated towards the occupants of the vehicle.
Therefore, extensive researches on spall behavior of
armor-piercing or shaped charge (SC) ammunition
have been made by using different materials and con-
figurations. Experimental studies are mostly focused on
V50 testing of different composite structures made of
E-glass/epoxy, S2 glass/epoxy, Kevlar/epoxy, Carbon/
epoxy, and so on.1–6
cerns (i) to develop material or to make lighter struc-
ture, which occupies less space but provides more
protection,7 (ii) to develop features for reducing the
cone angle of scattering particles which occurs behind
the armor,8 or (iii) to comparatively study the experi-
mental and numerical models.9,10 However, performing
ballistic tests, determining the standards and producing
a liner to limit the spall distribution are over costing
researches. Therefore, some of the researches that are
conducted on this issue have focused on the production
of more economic structures i.e. Fink and Jr.
Gillespie.11 To the best of author’s knowledge, there
1
Department of Ballistic Protection, Roketsan Missiles Inc., Turkey
2
Department of Mechanical Engineering, Osmaniye Korkut Ata
University, Turkey
3
Department of Mechanical Engineering, Dokuz Eylül University, Turkey
Corresponding author:
A Kaan Toksoy, Roketsan Missiles Inc., Kemalpas¸a Mahallesi Şehit Yüzbas¸ı
Adem Kutlu Sokak No: 21 Elmadağ, Ankara 06780, Turkey.
Email: ktoksoy@roketsan.com.tr
3492
is not much work associated with structures to prevent
the effects of fragmentation. Despite this, the previous
studies related to ballistic impact might shed light on
efforts to reduce the effect mentioned above. Park and
Jang12 studied the effect of hybrid structure on mech-
anical performance of the Kevlar-polyethylene hybrid
composites against ballistic impact. They considered
fiber volume fraction and fiber orientation as a param-
eter. They used two different stacking sequences of
[0/0]4 and [0/90]4 and four different fiber volume frac-
tions of 0%, 50%, 75%, and 100%. It was observed
that with increasing volumetric percentage of fibers,
bending strength and flexural modulus have increased.
Silva et al.13 experimentally and numerically investi-
gated the ballistic impact of thin composite plates rein-
forced with Kevlar 29. They performed ballistic tests
on the plates, which was designed in accordance
with STANAG 2910, having different thicknesses.
Impact response of the Kevlar 29 and E-glass fiber
reinforced hybrid composite has been studied both
numerically and experimentally by Muhi et al.14 They
used four different stacking sequences and three differ-
ent impactor geometries on impact tests. Experimental
tests showed that hybridization increases the impact
performance of the composite plates against the
penetration.
Gillespie et al.15 studied the failure strength of S2
glass fiber reinforced polyester, vinyl ester, and epoxy
matrix composite plates under ballistic impact loading.
Damaged and undamaged areas were identified by
using ultrasonic methods. It is concluded that compos-
ites with vinyl acetate and epoxy matrix showed small
damaged areas. Ballistic damage and penetration mech-
anics for thick composite plates have been studied by
conducting quasi-static punch shear tests by Gama and
Gillespie.16 Experiments with the same boundary con-
ditions have been made in order to establish similarities
between quasi-static penetration and ballistic
Figure 1. Production of composite material by VARIM.
Journal of Composite Materials 54(24)
penetration of S2 glass/SC15 epoxy. Nunes et al.17 con-
ducted a study on ballistic impact response of the bul-
letproof glass/epoxy composite plates. The stacking
sequences and the components of the composite
plates were changed for analyzing the effect on ballistic
damage. Finally, it is shown that both the delamination
area of the composite and the isotropy of the ballistic
response are important features to determine the ballis-
tic performance.
The main objective of this work is to investigate the
spall distribution of single and multi-plate composite
structures behind armor after SC penetration.
Therefore, different types of fabrics made from S2-
Glass, Kevlar, and Carbon-Kevlar were used to pro-
duce test samples. SC with 66 mm diameter was used
to create spall particles to evaluate both the perform-
ance of base armor and the composite structure against
ballistic impact. Initially, selection of base armor has
been made by using rolled homogeneous armor (RHA)
steel and Grade 5083 aluminum alloy for representative
vehicle chassis. After completing the selection of base
armor, serial ballistic tests on single and multi-plate
samples behind armor have been conducted to deter-
mine the spall distribution. Damaged sample and
behind armor damage packages were further analyzed
by using the mechanisms that are affecting damage and
distribution of spall.
Materials and method
Production of single and multi-plate composite
samples
Kevlar, S2 glass, and Carbon-Kevlar hybrid fabrics
were used to produce composite plates by using the
vacuum-assisted resin infusion molding method
(VARIM) (Figure 1). In production, epoxy system
was obtained by mixture of HEXION LR160 resin
Toksoy et al. 3493

Table 1. Single and multi-plate composites.

Dry fabric areal Number Thickness Areal density

Test sample type Fabric type density (g/m2) of layers (mm) (kg/m2)

Single plate S2 glass (plain) 190 56 9.0 15.8

Hybrid carbon-Kevlar (twill) 210 36 9.0 12.3
Kevlar 300 (plain) 300 18 7.8 8.1
Kevlar 410 (plain) 410 15 7.7 9.3
Multi-plates S2 glass/epoxy 190 52 (13  4) 9.1 16.8
Hybrid carbon-Kevlar/epoxy 210 32 (8  4) 9.0 12.1
Kevlar 300/epoxy 300 16 (4  4) 7.7 10.9
Kevlar 410/epoxy 410 16 (4  4) 8.0 11.1

Table 2. Multi-hybrid composite plates. performed according to ITOP (International Test

Test sample Thickness
name Configuration (mm)
Hybrid 1 S2 þ S2 þ K þ S2 þ S2 13.7
Hybrid 2 S2 þ S2 þ S2 þ K þ S2
K: Kevlar 300 plain fabric; S2: S2 glass/epoxy.
and LH260S hardener in the weight ratio of 100:25.
The reinforced material was completely filled with the
epoxy system by using a leakage controlled vacuum bag
under one bar vacuum pressure. After completely filling
with the epoxy resin system, inlet and vacuum valves
were closed, and the test sample was cured at 80 C for
8 h and then was allowed to cool to room temperature.
Cured composite plates were then cut into pieces
with dimensions of 450  450 mm2. Fabric type,
number of layers, thickness, mass and areal density of
the produced single and multi-plate composites are
given in Table 1. Each multi-plate test sample was
assembled from the four single thin plates with the
same thickness and fiber type by fastening them mech-
anically with bolts and nuts from four corners.
Moreover, two different multi-hybrid composite
plates were produced by changing material types of
layers and locations. S2 glass/epoxy and Kevlar 300
plain fabric with two different layer arrangements
were used to design hybrid composite plates. S2 glass/
epoxy plates with each thickness of 2 mm were used in
hybrid configuration besides 12-layer Kevlar 300 plain
fabric was placed under dry conditions. Related proper-
ties are given Table 2.
Ballistic test setup
The SC having 60 degree of conic cupper liner with
66 mm diameter and Octol explosive (TNT 30%,
HMX 70%) was used in the ballistic tests. Tests were
Operations Procedure) standards. Behind armor
Areal
debris pack (BAD pack) with dimensions of 1500 
density
(kg/m2) 1500 mm2 was used to obtain the spall angle and col-
lecting residual fragments after each ballistic testing.
17.0 From the top to the down, BAD pack consists of two
aluminum plates with each thickness of 1 mm, one alu-
minum plate with thickness of 3 mm, and four steel
plates with each thickness of 1.5 mm. Foams with thick-
ness of 25 mm were also used between plates. The dis-
tance between test sample and the BAD pack was
selected as 600 mm and was kept constant during all
the experimental programs. Related ballistic test setup
is given in Figure 2.
Preliminary ballistic tests were carried out for two
different armor materials in order to obtain more suit-
able armor material considering the number of frag-
ments and the spall angle. Grade Al5083 H116
aluminum and RHA (HB 330-380) steel armor plates
with dimensions of 450  450 mm2 and thicknesses of
38 mm and 12.7 mm, respectively, were used for prelim-
inary ballistic test.
Single and multi-plate composite samples were placed
behind the armor material with a fixed distance of
30 mm. However, for the multi-hybrid composite
sample the distance behind the armor plate was varied
to evaluate the influence of spall angle of the tested sam-
ples. The test matrix is given in Table 3.
Image analysis of witness plates for damaged
area determination
After ballistic testing, each BAD plate was photographed
with high definition and converted to grayscale images.
Each pixel in grayscale image contains intensity informa-
tion between 0 and 255.18,19 These deformed BAD Plate
pictures then transformed to binary image and analyzed
by using bwarea command in MATLAB Image analysis
toolbox.20 Pixel of binary images has only two informa-
tion, 0 (Black) or 1 (White). Black and white pixels
3494 Journal of Composite Materials 54(24)

Figure 2. General view of ballistic test setup.

Table 3. Experimental ballistic test matrix.

Distance behind
No Sample type Layer configuration armor (mm)

1 Single plate S2 glass 30

2 Single plate Kevlar 300 30
3 Single plate Kevlar 410 30
4 Single plate Carbon-Kevlar 300 hybrid 30
5 Multi-plate S2 glass 30
6 Multi-plate Kevlar 300 30
7 Multi-plate Kevlar 410 30
8 Multi-plate Carbon-Kevlar 300 hybrid 30
9 Hybrid 1 S2 þ S2 þ K þ S2 þ S2 0
10 50
11 100
12 Hybrid 2 S2 þ S2 þ S2 þ K þ S2 0
13 50
14 100
K: Kevlar 300 plain fabric; S2: S2 glass/epoxy.

represent the undeformed and deformed areas, respect-

ively. During the deformation analysis, total white pixel
area was divided by total pixel area of the binary image,
which represents BAD plate surface area. This analysis
has been done for each test scenario and used for com-
parison purposes.
Results and discussions
Al5083 and RHA armor plates are subjected to 66 mm
SC to choose suitable armor material. After tests, pene-
tration diameter is measured as 58 mm and 33 mm,
respectively, for Al5083 and RHA armor materials,
Toksoy et al. 3495

B
Back face (Figure 3). Post-test investigation of the BAD package
of ttest sample showed that ballistic test on Al5083 armor material
resulted with higher spall diameter as 1300 mm with
respect to RHA spall diameter, 1200 mm as shown in
Figure 3. However, it was observed that the spall distri-
bution behavior was different for further layers of the
BA AD pack BAD package. Spall diameters of Al5083 and RHA
froont surface steel materials were found as 600 mm and 900 mm at
second layers of BAD packages, respectively. Moreover,
less number of penetration holes has been observed on
further BAD package plates of Al583 armor plates. This
can be explained by large spall particles with less kinetic
energy at Al 5083 armor plates. Fourth BAD plate pene-
5thh BAD trated by these particles and stopped by the fifth layer of
P
Plate BAD Package, showed with by red arrows at Figure 3.
4th
4 BAD
Plate In contrast, the test results of the RHA armor plate
indicated that small particles cause more penetration
inside the BAD package, fifth BAD plate. Therefore,
the RHA plate has been selected as the base armor
For AL50
083 For RHA
plate for the rest of the study.
Figure 3. Spall distributions of Al5083 and RHA. Single and multi-plate samples were tested against
BAD: behind armor debris; RHA: rolled homogeneous armor. 66 mm SC for determination of spall behavior.

(a) Back facce

of test

samplee

BAD pacck

front

surfacee

S2--Glass Carbon-K
Kevlar Kevlar 300 Kevlar 4110

(b)

Back facce of

test sam
mple

BAD paack

front surrface

S
S2-Glass Carbon-Kevlar Kevlaar 300 Kevlarr 410

Figure 4. (a) Single and (b) multi-plate composite samples and BAD pack after ballistic test.
BAD: behind armor debris.
3496
Composite plates and BAD pack after ballistic test are
shown in Figure 4. In this figure, spall diameters of
single and multi-plate composites are given. It is seen
from Figure 5 that similar spall distributions occur for
S2 glass samples with single plate and multi-plate. The
spall diameter of 66 cm is obtained for S2 glass samples
and is the best result for all single plate and multi-plate
tests. However, Single plate with Carbon-Kevlar that
has the same thickness as S2 glass showed a better spall
diameter than that of multi-plate with Carbon-Kevlar.
A similar finding was also observed when S2 Glass and
Kevlar fabric were tested as spall liner with 5083 alu-
minum armor with a thickness of 44.45 mm
(1.75 inch).21 In that study, S2 glass and Kevlar spall
liners were subjected to TOW (5-1/4 inch diameter),
VIPER (2–1/2 inch diameter) SC, and 30 mm APDS
ammunition. S2 glass had the smaller average fragment
cone angle behind the liner compared with Kevlar
fabric except for VIPER SC in which both S2 and
Kevlar Spall liner application resulted with same
angle in fragment distribution.
Kevlar with two different areal densities of 300 g/m2
and 410 g/m2 were also tested for spall distribution with
the same thickness. Kevlar 410 single plate showed a
better spall distribution than that of Kevlar 300 for
single plate (Figure 5). On contrary, for the multi-
plate configuration opposite characteristics were
observed. Spall diameter for Kevlar 410 was higher
than the one for Kevlar 300; 99 cm and 76 cm for
multi-plate configurations, respectively.
Furthermore, hybrid plates with four layers of S2
glass/epoxy and one layer of dry Kevlar 300 fabric
were tested in order to see the benefits of hybrid layer
usage on spall behavior. Deformations after-test of
hybrid samples are illustrated in Figure 6. One can
120
Single
Mul
100
90
85
80
76
Spall Diameter (cm)
80
66 66
60
40
20
0
S2-Glass Carbon- Kevlar Kevlar-300
Figure 5. Spall diameters on BAD plate for single and multi-
plate composite samples.
Journal of Composite Materials 54(24)
infer that deformations of samples after penetration
of SC increase by increasing of the distance behind
armor. In the visual inspection, it was seen from
Figure 6 that hybrid 1 configuration had only one ver-
tical and horizontal crack while hybrid 2 had several
cracks propagated in both directions even in zero dis-
tance behind armor. Deformation area increases by the
increase of distance behind armor for both multi-hybrid
composites. This situation shows that more secondary
particles hit the test samples and kinetic energies of
these particles were absorbed by hybrid composites as
deformation energy. In addition to these, more failure
exists in hybrid plates compared with single and multi-
plates. This situation can be explained by the fact that
hybrid composites absorb more spall.
Spall diameter distribution of hybrid samples are
given in Figure 7. Spall diameters of single and multi-
plate composites are also shown in Figure 7 for behind
armor distance of 30 mm. It was seen from Figure 7
that in hybrid composites spall diameter reduced
50% at zero distance behind armor compared to no
composite plate configuration in which resulted spall
diameter of 120 cm was evaluated with 12.7 mm thick-
ness of RHA (Figure 7). Hybrid 1 configuration
Hybrid 1 Hybrid 2
0mm
m
99 50mm
84
100mm
m
Kevlar 410
Figure 6. Deformation of hybrid samples after 66 mm SC
penetration.
Toksoy et al.
showed the best spall distribution at 50 mm distance
behind armor. Spall diameter increased for 100 mm dis-
tance behind armor. However, this value is smaller
than that of zero distance behind armor. Spall diameter
decreases with increasing the distance behind armor
for hybrid 2. Spall angle was calculated by using the
spall diameter and the distance between the rear surface
of the test sample and the first BAD package for
all cases. When the curves are fitted to hybrid 1 and
hybrid 2 data, hybrid 1 and hybrid 2 configurations
have very smaller spall diameter compared with the
other composite configurations for behind armor dis-
tance of 30 mm.
For further discussion, the results of relative spall
angle reduction, which is the ratio of the spall angle
of armor plate to the spall angle of the tested plate,
Figure 7. Spall diameter vs behind armor distance.
Figure 8. Relative spall angle reduction vs behind armor
distance.
3497
are used. It was seen from Figure 8 that both hybrid
configurations have a better spall reduction capability
than S2 glass and Kevlar 300 single and multi-plate
composite samples for each behind armor distance.
The spall behavior of hybrid plates was also com-
pared with E-glass single plate results. Horsfall et al.22
studied the spall behavior of 25 mm thick E-glass/poly-
ester composite for different distance behind armor
subjected to 32 mm SC. In their study, the adverse
effect on spall angle reduction was seen at higher dis-
tance behind armor. Figure 8 reveals that relative spall
angle reduction of 25 mm thick E-glass polyester com-
posite is similar to the result of hybrid 1. This might be
explained by excessive deformation of last layer of S2
glass/epoxy plate of hybrid 1 configuration by splitting
into several pieces and this cause less kinetic energy
absorption of spall fragment for behind armor distance
of 100 mm as seen in Figure 7.
Last analysis is on determination of the ratios of
deformed area over the total area of BAD plates.
Binary image of the BAD plates for hybrid plates was
created and analysis was done for the ratio of the
deformed area over the total area as illustrated in
Figure 9. Image analysis of the penetrated area shows
that the penetrated area tends to decrease with increas-
ing the distance behind armor (Figure 10). Despite the
different spall angle changes behavior between both
hybrid composite samples, penetration area reduction
HYBRID 1 HYBRID 2
0mm
50mm
100mm
Figure 9. Binary images of BAD plate for hybrid samples used
for penetration analysis.
3498
Figure 10. Percentage of penetrated area over total area dis-
tribution vs behind armor distance.
seems much more dependent on distance between
armor and composite structure. However, hybrid 2 con-
figuration resulted in a less penetrated area at behind
armor distance of 100 mm.
Moreover, penetrated areas of the BAD plate for
single and multi-plate composite were analyzed to
compare with the ones for hybrid plates (Figure 10).
Single Carbon-Kevlar and Kevlar 410 samples have
the highest and the lowest penetrated areas, respectively
among all the single and multi-plate composite samples.
Multi-plates have higher penetration ratio than single
plate except for Carbon-Kevlar.
It was observed that the penetrated area on the BAD
package was decreased when the distance between armor
and spall liner increased. This might be explained with
the oblique impact of the distributed particles on the
composite plates. Distance provides enough time for
momentum transfer in oblique impact. Lopez-Puente
et al.23 pointed out similar behavior of the oblique
impact with 45 resulted with less damaged area respect
to 0 normal impact at low velocity impact of sphere on
carbon/epoxy laminates.
Conclusions
Single plate, multi-plate, and hybrid-plate composite
structures behind armor were subjected to SC with
diameter of 66 mm to analyze the spall behavior.
Initially, RHA steel and Al5083 were tested to obtain
suitable armor material. RHA steel was selected as base
armor structure with composite structures; single,
multi, and multi-hybrid plates. Results of S2 single
and multi-plates shows the lowest spall distribution in
terms of the spall angle compared with the other single
and multi-composites for behind armor distance of
30 mm. Increasing the behind armor distance reduces
the jetting area and thus spall distribution decreases.
Journal of Composite Materials 54(24)
Hybrid 2 gave the most successful spall result in
behind armor distance of 100 mm tests. For behind
armor distance of 50 mm, hybrid 1 gives better spall
distribution than hybrid 2 and the results show a
good correlation with the previous studies in the litera-
ture.22 Therefore, it can be recommended to use hybrid
1 and 50 mm behind armor distance by evaluating both
spall distribution and in-vehicle volume restriction.
Declaration of Conflicting Interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of this
article.
Funding
The author(s) disclosed receipt of the following financial sup-
port for the research, authorship, and/or publication of this
article: This work is supported by the Ministry of Science,
Industry and Technology (Project Number: 01421.STZ-
2012-1) and Roketsan Missiles Inc.
ORCID iD
Volkan Arıkan https://orcid.org/0000-0002-6102-6584
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