RECENT ADVANCES IN ALUMINUM OxYNITRIDE

(ALONTM) OPTICAL CERAMIC

Lee M. Goldman, Thomas M. Hartnett, Joseph M. Wahi
Raytheon Electronic Systems, Lexington Laboratories,
1 3 1 Spring St. Lexington MA 02421
and
Robert J. Ondercin, and Karen Olson
Materials Directorate, AFRL, WPAFB OH

Abstract
Aluminum Oxynitride or ALONTM optical ceramic is transparent material, developed and
patented by Raytheon, which is very similar to sapphire, being comprised mostly of A12O3
with a small amount of additional nitrogen. This nitrogen addition has the effect of
producing a cubic material whose optical and mechanical properties are isotropic.
Importantly, this means that it can be produced by powder processing methods, which are
scalable to larger sizes, and at lower prices than can be achieved by the single crystal
growth techniques that are used to grow sapphire. Furthermore, its isotropic properties
make it much easier to grind and polish than sapphire.

Recently, the interest in ALONTM optical ceramic has grown substantially following
impressive results in ballistic testing. Ballistic laminates, containing ALONTM layers,
have demonstrated protection against armor piercing rounds, at halfthe areal density and
thickness of conventional ballistic laminates.

ALONTM plates as large as 14x20-in are being produced, under Air Force funding, for
evaluation as JR windows and transparent armor, using conventional powder processing
techniques. The production processes themselves are now being scaled to produce large
pieces and large quantities of ALONTM optical ceramic.

Introduction
ALONTM optical ceramic was developed at Raytheon in the 1980's for use as an JR
window and dome material. It was one ofa number ofMWJR transparent window and
dome materials (primarily oxides) that were evaluated for these applications. Other
materials that were evaluated at that time included yttrium oxide and spinel.

Because it has a cubic structure, its optical and mechanical properties are isotropic,
making it transparent in polycrystalline form. In turn, this means that it can be fabricated
by powder processing techniques, which allow it to be scaled to larger sizes and at lower
costs than can be achieved by single crystal growth techniques. It is the combination of
excellent mechanical, optical, high temperature and chemical resistant properties and its
1
E-mail address thomasmhartnettraytheon.com

Window and Dome Technologies and Materials VII, Randal W. Tustison, Editor,
Proceedings of SPIE Vol. 4375 (2001) © 2001 SPIE · 0277-786X/01/$15.00 71

Downloaded From: http://proceedings.spiedigitallibrary.org/ on 07/18/2015 Terms of Use: http://spiedl.org/terms

 ability to be fabricated by established powder processing methods, which make of
ALONTM optical ceramic attractive.

Like sapphire, ALONTM optical ceramic has also benefited from applications that are not
related to infrared imaging. Ballistic testing over the past several years has demonstrated
that ALONTM optical ceramic is the leading transparent ceramic armor material. It is
very effective against small arms fire as well as armor piercing projectiles. In the latter
case, a reduction of over 50 % in areal density and physical thickness, compared with the
existing glass laminate structure is achieved. This ballistic ALONTM Optical Ceramic-
laminate design was demonstrated in a 1 Oxi 0-in transparent armor window having a
single axis of curvature, much the same type of window which would be found in a small
aircraft. Processes have been identified which are capable ofproducing windows like this
up to 30 inches in diameter. Work is continuing on ballistic window demonstrations as
well as JR window and dome process development. Work is also continuing to bring
ALONTM Optical Ceramic to the commercial market place, as well as into major
Raytheon programs and platforms.

Preparation of ALONTM Ceramics

Transparent ALONTM Optical Ceramics are made by conventional powder processing and
heat treatment methods. 10,1 1 Powder compacts of near net shape and size are made by dry
pressing, injection molding or casting and subsequently heat treating to transparency.
This process is summarized schematically in Figure 1 . The size of components that can
be manufactured is limited only by the capacity of the processing equipment. This
limitation is being relieved as new equipment comes on line that ultimately will be
capable ofproducing windows up to 30 inches in diameter. Processes similar to the one
used to produce ALONTM material are being used routinely within the ceramics industry,
producing tons of ceramic product per year.
"
:

7dI*I, 4jirt.:

Figure 1: Flow Diagram 0IALONTM Processing Steps

72 Proc. SPIE Vol. 4375

Downloaded From: http://proceedings.spiedigitallibrary.org/ on 07/18/2015 Terms of Use: http://spiedl.org/terms

 Properties of ALONTM Optical Ceramic

Transparency from ultraviolet wavelengths (UV) 0.2 tm to mid-infrared

wavelengths (MID-IR) 6.0 urn and low levels of optical scatter have been achieved in
polycrystalline ALONTM Optical Ceramic.4 The only transparent engineering materials
that have strength and hardness greater than ALONTM are single crystal sapphire and
diamond. ALONTM Optical Ceramic has demonstrated higher resistance to sand erosion
and rain erosion than the other glass and polycrystalline ceramic materials of interest.567
ALONTM also has the potential for the lowest fabrication costs when compared to the
polycrystalline ceramics and to sapphire.

Table 1 : Physical Properties of Some Transparent Ceramics

Property ALONTM Fused Sapphire Spinel Magnesia Zinc Yttria

Optical Silica Sulfide
CeramicA SiO2 Al203 MgA12O4 MgO ZnS Y203
l23O27N5
Density 3.7 2.5 3.98 3.59 3.58 4.08 5.03
(Grams/cm3)
Areal 19.23 11.44 20.68 18.61 18.55 21.20 26.14
Density
1" thickness
(lb/ft2)
Young's 317 73 420 268 245 74 179
Modulus
(GPa)
Poisson's 0.24 0.17 0.22 0.26 0.18 0.3 0.23
Ratio
Flexural 300 110 400 184 132 103 150
Strength
(MPa)
Hardness 1850 460 2200 1520 640 250 720
(kg/mm2)
Reference [8] [8] [8] [8], [9] [8] [8] [8]

Ballistic Testing of ALONTM Optical Ceramic

Extensive ballistic testing has been performed on ALONTM tiles. Excellent performance
against armor piercing ammunition has been demonstrated. ALONTM laminates have been
shown to provide comparable performance to conventional glass/polycarbonate laminates
at half the areal density and half the thickness. For a standard ground vehicle, this
translates into hundreds of pounds of weight savings per vehicle.

Proc. SPIE Vol. 4375 73

Downloaded From: http://proceedings.spiedigitallibrary.org/ on 07/18/2015 Terms of Use: http://spiedl.org/terms

 V
nn BAL 38 Plus"
5
0
Areal Density 41 .45 lb/ft2
BAL38+/SLAP 3.62-inch thick
B 45n
A
L • .5OALON/SLAP I
L BAL 38
4nn .
. BAL38/SLAP
I
S U .44ALON/SLAP Areal Density 34.68 lb/ft2
T 3.07-inch thick
5n . .
BAL31(97)/SLAP

/
C
• BAL3I(84)/SLAP BAL3I
L .38ALON/.3OM2AP
nn i- a BAL23/.3OM2AP Areal Density 2
M U • .
.38ALON/.3OM2AP
S .
2 4R-inr.h thir.k
T 20 L!BAL36/.3OM2AP I I
I

10 15 20 25 30 35 40 45 ALON (.3 ... ,.

Polycarbonate(0.375")
Areal Density (psi) Areal Density 16.7 lb/ft2
• RAl V5fl RIIistir I imit I .33-inch thick
ALON (.375")/ Polycarbonate
. ALON V50 Ballistic Limit (0.5")
Velocity (fps) Areal Density 10.5 lb/ft2
0.921-inch thick

Figure 2: Comparison of V50 ballistic limitfor ALON and conventional ballistic

laminates. Also shown is a photograph ofboth conventional and ALON laminates,
demonstrating the substantial difference in physical thickness required to stop a
particular threat

A summary of single impact testing, conducted at the University of Dayton Research

Institute (UDRI) is shown in the figure above. Recently, a number of 12x12-in ALONTM
tiles were fabricated for multi-hit testing. Figure 3 below is a photograph of one such tile
following 4 impacts from armor piercing rounds (30 cal M2 AP).

74 Proc. SPIE Vol. 4375

Downloaded From: http://proceedings.spiedigitallibrary.org/ on 07/18/2015 Terms of Use: http://spiedl.org/terms

 Figure 3: Photograph ofl2xl2-in ALONTM laminatefollowing 4 impacts by 30 cal
M2 AP rounds

ALONTM Scale up
The ALONTM process is currently being scaled to produce prototype 14x20-in
panels, under Air Force funding. At the present time, over a dozen 12x12-in tiles have
been fabricated, and the first 14x20-in panels are nearly complete. The 1 2x12-in tiles
have been used primarily for ballistic testing. The large panels will be used for both JR
(i.e., Recce windows) and ballistic laminates.
Process scale up has involved all of the process steps detailed in figure 1.
Initially, large quantities of ALONTM powder were produced. Next, a number of forming
techniques were evaluated to determine the best way ofproducing large greeen ALONTM
parts, figure 4. The green parts were then consolidated through heat treatment, and
subsequently optically finished, figure 5. Several ALONTM blanks, sufficiently large to
yield 14x20-in windows, figure 6, have been formed and are currently in process.
Raytheon is in the process of creating a separate ALONTM business, which will be
capable of supplying large quantities of ALONTM materials for both commercial and
military applications.

Proc. SPIE Vol. 4375 75

Downloaded From: http://proceedings.spiedigitallibrary.org/ on 07/18/2015 Terms of Use: http://spiedl.org/terms

 . TM
Figure 4: Photograph oflarge, green ALON parts

Figure 5: 3 12x12-in ALu.. . tilesfoiowing optical fabrication

76 Proc. SPIE Vol. 4375

Downloaded From: http://proceedings.spiedigitallibrary.org/ on 07/18/2015 Terms of Use: http://spiedl.org/terms

 Figure 6:Photograph oflarge green ALONTM blank that willyield 14x20-in finished part

Applications
ALONTM windows and domes have been inserted into a number of Raytheon and
non-Raytheon applications. These applications include JR missile domes, missile warning
windows, underwater applications and commercial applications. Raython is working with
a number of outside companies to insert ALONTM windows and domes into many
commercial and military applications.

Conclusions
ALONTM Optical Ceramic is a promising material for both JR window/dome and
transparent armor applications. Jt has already been inserted into a number of Raytheon
applications and is under evaluation for a number of additional programs.
ALONTM Optical Ceramic has demonstrated superior performance in both single
and multiple hit ballistic tests and is currently under evaluation for insertion into ground
based transparent armor applications.
Over 1 dozen 12x1 2-in samples have been fabricated to date, and the process is
currently being scaled to produce 14x20-in windows. A number of 14x20-in prototypes
are currently being fabricated.

Proc. SPIE Vol. 4375 77

Downloaded From: http://proceedings.spiedigitallibrary.org/ on 07/18/2015 Terms of Use: http://spiedl.org/terms

 References
1. Product Literature, PPG SecuriTect Products, Huntsville, Alabama (1997).
2. F.S. Lyons, R. Huyett, D. Hardtmann, "Helicopter Advanced Armor Concepts (HAAC)", Final Report
USAATCOM TR 94-D-16, Prepared for The Aviation Applied Technology Directorate, U.S. Aviation
and Troop Command, Ft. Eustis, VA (1995).

3. AK. Wong and I. Berman, Lightweight Ceramic Armor — A Review, DIA Project 1T062105A330,
AMCMS Code 502E.11.296, Army Materials and Mechanics Research Center. (1971)

4. TM. Hartnett, S.D. Bernstein, E.A. Maguire and R.W. Tustison, "Optical properties of ALON
(aluminum oxynitride)", Proceedings of SPIE, Vol. 3060, 284 (1997).

5. D.C. Harris, "Comparative Sand and Rain Erosion Resistance of Spinel, Aluminum Oxynitride
(AEON), Magnesium Fluoride, and Germanate Glass", Report No. NAWCWPNS TP 8147, Naval Air
Warfare Center Weapons Division, China Lake, CA (1993)

6. D.C. Harris, "Rain Erosion Studies of Sapphire, Aluminum Oxynitride (AEON), Spinel, Lanthana
Doped Yttria, and TAF Glass", Report No. NWC TP 7098, Naval Air Warfare Center Weapons
Division, China Lake, CA (1990).

7. E.A. Maguire, J.K. Rawson, R.W. Tustison, "Aluminum Oxynitride's Resistance to Impact and
Erosion", Published in window and Dome Technologies IV, P. Klocek, Editor, SPIE Proceedings 2286
p26-32 (1994).

8. D.C. Harris, Infrared Window and Dome Materials, SPIE Optical Engineering Press, Bellingham
(1992)

9. D.W. Roy, "Hot Pressed MgA12O3 for ultraviolet (UV), visible, and infrared (IR) optical
requirements", SPIE Proceedings Vol. 297 (1981).

10. T. M. Hartnett, R.L. Gentilman, and E.A. Maguire, "Aluminum Oxynitride Having Improved Optical
Characteristics and Method ofManufacture", U.S. Patent 4,481,300 (1984).

11. F.F.Y. Wang, Treatise on Materials Science and Technology Vol. 9 Ceramic Fabrication Processes,
Academic Press, New York (1976).

12. S.J. Hanchak, " The Evaluation ofALON Ceramic For Use as a Transparent Vehicle Armor Against
Advanced Small Arms Ammunition", Final Report UDR-TR-97-129 for Subcontract No. R-10694
(N39998-96-C-5005), sponsored by the Office ofSpecial Technologies (OST) (1997)

78 Proc. SPIE Vol. 4375

Downloaded From: http://proceedings.spiedigitallibrary.org/ on 07/18/2015 Terms of Use: http://spiedl.org/terms