TEXTILE INSTITUTE OF PAKISTAN

LITERATURE REVIEW
BULLET PROOF JACKET
FARHAN AHMED SIDDIQUI MUHAMMAD ALI TS-4

SUPERVISOR: SIR NOAMAN JAMIL

BULLET PROOF JACKETS

INTRODUCTION
A ballistic vest, bulletproof vest or bullet-resistant vest is an item of personal armor that helps absorb the impact from firearm-fired projectiles and shrapnel from explosions, and is worn on the torso. Soft vests are made from many layers of woven or laminated fibers and can be capable of protecting the wearer from small-caliber handgun and shotgun projectiles, and small fragments from explosives such as hand grenades. Metal or ceramic plates can be used with a soft vest, providing additional protection from rifle rounds, and metallic components or tightly woven fiber layers can give soft armor resistance to stab and slash attacks from knives and similar close-quarter weapons. Soft vests are commonly worn by police forces, private citizens, security guards, and bodyguards, whereas hard-plate reinforced vests are mainly worn by combat soldiers, police tactical units, and hostage rescue teams. Modern body armor may combine a ballistic vest with other items of protective clothing, such as a combat helmet. Vests intended for police and military use may also include ballistic shoulder and side protection armor components, and bomb disposal officers wear heavy armor and helmets with face visors and spine protection.

OVER VIEW
Ballistic vests use layers of very strong fiber to "catch" and deform a bullet, mushrooming it into a dish shape, and spreading its force over a larger portion of the vest fiber. The vest absorbs the energy from the deforming bullet, bringing it to a stop before it can completely penetrate the textile matrix. Some layers may be penetrated but as the bullet deforms, the energy is absorbed by a larger and larger fiber area. While a vest can prevent bullet penetration, the vest and wearer still absorb the bullet's energy. Even without penetration, modern pistol bullets contain enough energy to cause blunt force trauma under the impact point. Vest specifications will typically include both penetration resistance requirements and limits on the amount of impact energy that is delivered to the body. Vests designed for bullets offer little protection against blows from sharp implements, such as knives, arrows or ice picks, or from bullets manufactured of non-deformable materials, i.e., those containing a steel core instead of lead. This is because the impact force of these objects stays concentrated in a relatively small area, allowing them to puncture the fiber layers of most bullet-resistant fabrics Textile vests may be augmented with metal (steel or titanium), ceramic or polyethylene plates that provide extra protection to vital areas. These hard armor plates have proven effective against all handgun bullets and a range of rifles. These upgraded ballistic vests have become standard in military use, as soft body armor vests are ineffective against military rifle rounds. Corrections officers and other law enforcement officers often wear vests which are designed specifically against bladed weapons and sharp objects. These vests may incorporate coated and laminated para-aramid textiles or metallic components.

1950s1970s
In 1969, American Body Armor was founded and began to produce a patented combination of quilted nylon faced with multiple steel plates. This armor configuration was marketed to American law enforcement agencies by Smith & Wesson under the trade name "Barrier Vest." The Barrier Vest was the first police vest to gain wide use during high threat police operations. In the mid-1970s, DuPont introduced Kevlar synthetic fiber, which was woven into a fabric and layered. Immediately Kevlar was incorporated into a National Institute of Justice (NIJ) evaluation program to provide lightweight, concealable body armor to a test pool of American law enforcement officers to ascertain if everyday concealable wearing was possible. In 1975 Richard A. Armellino, the founder of American Body Armor, marketed an all Kevlar vest called the K-15, consisting of 15 layers of Kevlar that also included a 5" 8" ballistic steel "Shok Plate" positioned vertically over the heart and was issued US Patent #3,971,072 for this innovation. Similarly sized and positioned "trauma plates" are still used today on the

front ballistic panels of most concealable vests, reducing blunt trauma and increasing ballistic protection in the center-mass heart/sternum area. Since the 1970s, several new fibers and construction methods for bulletproof fabric have been developed besides woven Kevlar, such as DSM's Dyneema, Honeywell's Gold Flex and Spectra, Teijin Twaron's Twaron, Pinnacle Armor's Dragon Skin, and Toyobo's Zylon. These newer materials are advertised as being lighter, thinner and more resistant than Kevlar, although they are much more expensive.

PERFOMANCE STANDARDS
Due to the various different types of projectile, it is often inaccurate to refer to a particular product as "bulletproof" because this implies that it will protect against any and all threats. Instead, the term bullet resistant is generally preferred. Body armor standards are regional. Around the world ammunition varies and as a result the armor testing must reflect the threats found locally. many standards exist, a few standards are widely used as models. The US National Institute of Justice ballistic and stab documents are examples of broadly accepted standards. In addition to the NIJ, the UK Home Office Scientific Development Branch (HOSDB formerly the Police Scientific Development Branch (PSDB)) standards are used by a number of other countries and organizations. These "model" standards are usually adapted by other counties by incorporation of the basic test methodologies with modification of the bullets that are required for test. NIJ Standard-0101.06 has specific performance standards for bullet resistant vests used by law enforcement. This rates vests on the following scale against penetration and also blunt trauma protection (deformation):

Armor Level Protection

This armor would protect against 2.6 g (40 gr) .22 Long Rifle Lead Round Type I Nose (LR LRN) bullets at a velocity of 329 m/s (1080 ft/s 30 ft/s) and 6.2 g (.22 LR;.380 (95 gr) .380 ACP Full Metal Jacketed Round Nose (FMJ RN) bullets at a ACP) velocity of 322 m/s (1055 ft/s 30 ft/s). It is no longer part of the standard.

New armor protects against 8 g (124 gr) 9x19mm Parabellum Full Metal Type IIA Jacketed Round Nose (FMJ RN) bullets at a velocity of 373 m/s 9.1 m/s (9 mm;.40 (1225 ft/s 30 ft/s); 11.7 g (180 gr) .40 S&W Full Metal Jacketed (FMJ) S&W;.45 bullets at a velocity of 352 m/s 9.1 m/s (1155 ft/s 30 ft/s) and 14.9 g (230 ACP) gr) .45 ACP Full Metal Jacketed (FMJ) bullets at a velocity of 275 m/s 9.1 m/s (900 ft/s 30 ft/s). Conditioned armor protects against 8 g (124 gr)

9 mm FMJ RN bullets at a velocity of 355 m/s 9.1 m/s (1165 ft/s 30 ft/s); 11.7 g (180 gr) .40 S&W FMJ bullets at a velocity of 325 m/s 9.1 m/s (1065 ft/s 30 ft/s) and 14.9 g (230 gr) .45 ACP Full Metal Jacketed (FMJ) bullets at a velocity of 259 m/s 9.1 m/s (850 ft/s 30 ft/s). It also provides protection against the threats mentioned in [Type I].

New armor protects against 8 g (124 gr) 9 mm FMJ RN bullets at a velocity of 398 m/s 9.1 m/s (1305 ft/s 30 ft/s) and 10.2 g (158 gr) .357 Magnum Jacketed Soft Point bullets at a velocity of 436 m/s 9.1 m/s (1430 ft/s Type II 30 ft/s). Conditioned armor protects against 8 g (124 gr) 9 mm FMJ RN (9 mm;.357 bullets at a velocity of 379 m/s 9.1 m/s (1245 ft/s 30 ft/s) and 10.2 g (158 Magnum) gr) .357 Magnum Jacketed Soft Point bullets at a velocity of 408 m/s 9.1 m/s (1340 ft/s 30 ft/s). It also provides protection against the threats mentioned in [Types I and IIA].

New armor protects against 8.1 g (125 gr) .357 SIG FMJ Flat Nose (FN) bullets at a velocity of 448 m/s 9.1 m/s (1470 ft/s 30 ft/s) and 15.6 g (240 gr) .44 Magnum Semi Jacketed Hollow Point (SJHP) bullets at a velocity of Type IIIA 436 m/s (1430 ft/s 30 ft/s). Conditioned armor protects against 8.1 g (125 (.357 SIG; .44 gr) .357 SIG FMJ Flat Nose (FN) bullets at a velocity of 430 m/s 9.1 m/s Magnum) (1410 ft/s 30 ft/s) and 15.6 g (240 gr) .44 Magnum Semi Jacketed Hollow Point (SJHP) bullets at a velocity of 408 m/s 9.1 m/s (1340 ft/s 30 ft/s). It also provides protection against most handgun threats, as well as the threats mentioned in [Types I, IIA, and II].

Type (Rifles)

Conditioned armor protects against 9.6 g (148 gr) 7.62x51mm NATO M80 III ball bullets at a velocity of 847 m/s 9.1 m/s (2780 ft/s 30 ft/s). It also provides protection against the threats mentioned in [Types I, IIA, II, and IIIA].

Type (Armor Piercing Rifle)

IV Conditioned armor protects against 10.8 g (166 gr) .30-06 Springfield M2 armor-piercing (AP) bullets at a velocity of 878 m/s 9.1 m/s (2880 ft/s 30 ft/s). It also provides at least single hit protection against the threats mentioned in [Types I, IIA, II, IIIA, and III].

Textile armor is tested for both penetration resistance by bullets and for the impact energy transmitted to the wearer. The "backface signature," or transmitted impact energy, is measured by shooting armor mounted in front of a backing material, typically oilbased modeling clay. The clay is used at a controlled temperature and verified for impact flow before testing. After the armor is impacted with the test bullet, the vest is removed from the clay and the depth of the indentation in the clay is measured. The backface signature allowed by different test standards can be difficult to compare. Both the clay materials and the bullets used for the test are not common. In general the British, German and other European standards allow 2025 mm of backface signature, while the USNIJ standards allow for 44 mm, which can potentially cause internal injury. The allowable backface signature for body armor has been controversial from its introduction in the first NIJ test standard and the debate as to the relative importance of penetration-resistance vs. backface signature continues in the medical and testing communities. In general a vest's textile material temporarily degrades when wet. Neutral water at room temp does not affect para-aramid or UHMWPE but acidic, basic and some other solutions can permanently reduce para-aramid fiber tensile strength. (As a result of this, the major test standards call for wet testing of textile armor.) Mechanisms for this wet loss of performance are not known. Vests that will be tested after ISO type water immersion tend to have heat sealed enclosures and those that are tested under NIJ type water spray methods tend to have water resistant enclosures.

Backing materials for ballistic testing

One of the critical requirements in soft ballistic testing is measurement of "back side signature" (i.e. energy delivered to tissue by a non-penetrating projectile) in a deformable backing material placed behind the targeted vest. The majority of military and law enforcement standards have settled on an oil/clay mixture for the backing material, known as Roma Plastilena. Although harder and less deformable than human tissue, Roma represents a worst case backing material when plastic deformations in the oil/clay are low (less than 20 mm). (Armor placed over a harder surface is more easily penetrated.) The oil/clay mixture of "Roma" is roughly twice the density of human tissue and therefore does not match its specific gravity, however "Roma" is a plastic material that will not recover its shape elastically, which is important for accurately measuring potential trauma through back side signature. The selection of test backing is significant because in flexible armor, the body tissue of a wearer plays an integral part in absorbing the high energy impact of ballistic and stab events. However the human torso has a very complex mechanical behavior. Away from the rib cage and spine, the soft tissue behavior is soft and compliant. In the tissue over the sternum bone region, the compliance of the torso is significantly lower. This complexity requires very elaborate bio-morphic backing material systems for accurate ballistic and stab armor testing. A number of materials have been used to simulate human tissue in addition to Roma.

In all cases, these materials are placed behind the armor during test impacts and are designed to simulate various aspects of human tissue impact behavior. One important factor in test backing for armor is its hardness. Armor is more easily penetrated in testing when backed by harder materials, and therefore harder materials, such as Roma clay, represent more conservative test methods.

Backer type

Materials

Elastic/plastic Test type

Relative Specific hardness vs Application gravity gelatin

Roma Oil/Clay Plastilena mixture Clay #1

Plastic

Ballistic and Stab

>2

Back face signature Moderately measurement. hard Used for most standard testing Good simulant for human tissue, hard to use, expensive. Required for FBI test methods

10% gelatin

Animal Visco-elastic protein gel

Ballistic

~1 (90% Baseline water)

Neoprene HOSDB- foam, EVA Elastic NIJ Foam foam, sheet rubber

Stab

~1

Moderate agreement with Slightly tissue, easy to harder than use, low in cost. gelatin Used in stab testing Biomedical testing for blunt to force testing, very good tissue match

Silicone gel

Long chain silicone Visco-elastic polymer

Biomedical ~1.2

Similar gelatin

Pig or Sheep Live tissue Various animal testing

Research

~1

Very complex, Real tissue requires ethical is variable review for approval

Backing materials for stab armor testing

Stab and spike armor standards have been developed using 3 different backing materials. The Draft EU norm calls out Roma clay, The California DOC called out 10% ballistic gelatin and the current standard for NIJ and HOSDB calls out a multi-part foam and rubber backing material.

Using Roma clay backing, only metallic stab solutions met the 109 joule Calif. DOC ice pick requirement Using 10% Gelatin backing, all fabric stab solutions were able to meet the 109 joule Calif. DOC ice pick requirement. Most recently the Draft ISO prEN ISO 14876 norm selected Roma as the backing for both ballistics and stab testing.

This history helps explain an important factor in Ballistics and Stab armor testing, backing stiffness affects armor penetration resistance. The energy dissipation of the armor-tissue system is Energy = Force x Displacement when testing on backings that are softer and more deformable the total impact energy is absorbed at lower force. When the force is reduced by a softer more compliant backing the armor is less likely to be penetrated. The use of harder Roma materials in the ISO draft norm makes this the most rigorous of the stab standards in use today.

PROGRESS IN FIBER SCIENCE

In recent years, advances in material science have opened the door to the idea of a literal "bulletproof vest" able to stop handgun and rifle bullets with a soft textile vest, without the assistance of additional metal or ceramic plating. However, progress is moving at a slower rate compared to other technical disciplines. The most recent offering from Kevlar, Protegra, was released in 1996. Current soft body armor can stop most handgun rounds (which has been the case for roughly 15 years, but armor plates are needed to stop rifle rounds and steel core handgun rounds such as 7.62x25. The para-aramids have not progressed beyond the limit of 23 grams per denier in fiber tenacity. Modest ballistic performance improvements have been made by new producers of this fiber type. Much the same can be said for the UHMWPE material; the basic fiber properties have only advanced to the 3035 g/d range. Improvements in this material have been seen in the development of cross-plied non-woven laminate, e.g. Spectra Shield. The major ballistic performance advance of fiber PBO is known as a "cautionary tale" in materials science. This fiber permitted the design of handgun soft armor that was 3050% lower in mass as compared to the aramid and UHMWPE materials. However this higher tenacity was delivered with a well-publicized weakness in environmental durability.

Akzo-Magellan (now DuPont) teams have been working on fiber called M5 fiber; however, its announced startup of its pilot plant has been delayed more than 2 years. Data suggests if the M5 material can be brought to market, its performance will be roughly equivalent to PBO.In May 2008, the Teijin Aramid group announced a super-fibers development program. The Teijin emphasis appears to be on computational chemistry to define a solution to high tenacity without environmental weakness. The materials science of second generation super fibers is complex, requires large investments, and represent significant technical challenges. Research aims to develop artificial spider silk which could be super strong, yet light and flexible. Other research has been done to harness nanotechnology to help create super-strong fibers that could be used in future bulletproof vests.

TEXTILE WOVENS AND LAMINATES RESEARCH

Finer yarns and lighter woven fabrics have been a key factor in improved ballistic results. The cost of ballistic fiber goes up dramatically as yarn size goes down, so it is unclear how long this trend can continue. The current practical limit of fiber size is 200 denier with most wovens limited at the 400 denier level. Three-dimensional weaving with fibers connecting flat wovens together into a 3D system are being considered for both hard and soft ballistics. Team Engineering Inc is designing and weaving these multi layer materials. Dyneema DSM has developed higher performance laminates using a new, higher strength fiber designated SB61, and HB51. DSM feels this advanced material provides some improved performance, however the SB61 soft ballistic version has been recalled. At the Shot Show in 2008, a unique composite of interlocking steel plates and soft UHWMPE plate was exhibited by TurtleSkin. In combination with more traditional woven fabrics and laminates a number of research efforts are working with ballistic felts. Tex Tech has been working on these materials. Like the 3D weaving, Tex Tech sees the advantage in the 3-axis fiber orientation.

Developments in ceramic armor Ceramic materials, materials processing and progress in ceramic penetration mechanics are significant areas of academic and industrial activity. This combined field of ceramics armor research is broad and is perhaps summarized best by The American Ceramics Society. ACerS has run an annual armor conference for a number of years and compiled a proceedings 2004 2007. An area of special activity pertaining to vests is the emerging use of small ceramic components. Large torso sized ceramic plates are complex to manufacture and are subject to cracking in use. Monolithic plates also have limited multi hit capacity as a result of their large impact fracture zone These are the motivations for new types of armor plate. These new designs use 2 and 3 dimensional arrays of ceramic elements that can be rigid, flexible or semi-flexible. Dragon Skin body armor is one these systems. European developments in spherical and hexagonal arrays have resulted in products that have some flex and multi hit performance. The manufacture of array type systems with flex, consistent ballistic performance at edges of ceramic elements is an active area of research. In addition advanced

ceramic processing techniques arrays require adhesive assembly methods. One novel approach is use of hook and loop fasteners to assemble the ceramic arrays.

Dragon Skin
Dragon Skin is a type of ballistic vest made by Pinnacle Armor. It is currently produced inFresno, California. Its characteristic two-inch-wide circular discs overlap like scale armor, creating a flexible vest that allows a good range of motion and can allegedly absorb a high number of hits compared with other military body armor. The discs are composed of silicon carbide ceramic matrices and laminates, much like the larger ceramic plates in other types of bullet resistant vests. This armor has been known to withstand grenade blasts and up to 40 rounds of ammo. The armor is available in three basic protection levels: SOV-2000, which has previously had certification to Level III protection. SOV-3000, which is rated as Level IV by the manufacturer, but has not officially certified as such; and a rating-unspecified "Level V" variant not available to the general public. Dragon Skin has been worn by some civilian contractors in Iraq, some special operations forces in Iraq and Afghanistan, some SWAT teams, nine generals in Afghanistan, bodyguards tasked with protecting generals, and U.S. Secret Service personnel The Central Intelligence Agency (CIA) has also purchased Dragon Skin.

X-ray of Dragon Skin Body Armor

Structure
SOV-2000 armor is made of an imprecated overlapping configuration of high tensile ceramic discs encased in an aramid textile cover. Different layout configurations with variations in coverage are available. AMI level III plates are fabricated using an outer 3 millimeters (0.12 in) MARS steel layer bonded to a compressed Dyneema backing, with a linex coating for spall reduction, resulting in a total plate thickness of approximately 1 inch (25 mm). AMI level III 12 inches (300 mm) 14.5 inches (370 mm) plates weigh about 10 lb (4.5 kg) and 10 inches (250 mm) 12 inches (300 mm) plates are about 9 lb (4.1 kg). SOV-2000 is made of overlapping approximately 0.25 inches (6.4 mm) 2 inches (51 mm) ceramic discs encased in a fabric cover. In evaluating the Dragon Skin system, it is important to note that while the external measurements of the Dragon Skin panel are 11.5 inches (290 mm) 13.5 inches (340 mm), the area of level III coverage provided by the encased ceramic discs is 10 inches (250 mm) 12 inches (300 mm); the fabric edges are not intended to provide ballistic protection. Weight of the SOV-2000 armor providing 10 inches (250 mm) 12 inches (300 mm) of level III protection was approximately 5.5 lb (2.5 kg).

TESTING
Television In a test for the History Channel's military show, Mail Call, the vest repelled nine rounds of steel-core ammunition from a WASR-10 (7.6239 mm) and 35 rounds of 9x19mm from a Heckler & Koch MP5A3, all fired into a 10-by-12-inch area on the vest. On Test Lab, also on the History Channel, the vest withstood 120 rounds fired from a Type 56 (7.6239 mm) rifle and Heckler & Koch MP5 (919 mm). In another demonstration on the Discovery Channel series Future Weapons, a Dragon Skin vest withstood numerous rounds (including steel core rounds) from an AK-47, an Heckler & Koch MP5SD, an M4 carbine (5.5645 mm), and a point-blank detonation of an M67 grenade. While the vest was heavily damaged (mainly by the grenade), there was no penetration of the armor. In 2007, NBC News had independent ballistics testing conducted of Dragon Skin versus Interceptor body armor. Retired four-star general Wayne A. Downing observed the tests and concluded that although the number of trials performed was limited, the Dragon Skin armor performed significantly better In light of the May 2007 media investigations, senators Hillary Clinton and Jim Webb requested that Comptroller General of the United StatesDavid M. Walker initiate a Government Accountability Office investigation into the army's body armor systems. After being confronted with conflicting information by lawmakers who questioned the NBC test results and provided Army-supplied data of vest failures from a May 2006 test, the

technical expert solicited by NBC to certify its test backed away from his staunch defense of Dragon Skin and stated that the vests "weren't ready for prime time." It was also featured on Time Warp on the Discovery Channel.

Law enforcement
In Fresno, California, a police department commissioned the purchase of Dragon Skin for its officers after a vest stopped all the bullets fired during a test, including .308 rounds from a sniper rifle and 30 rounds from a 9mm MP5 fired from five feet away. Ninety-eight federal, state, and local law enforcement officers witnessed the SWAT test. The armor also stopped 40 rounds of PS-M1943 mild steel-core bullets from an AK-47 along with 200 9 mm FMJ military ball bullets fired from a submachine gun.

Academic
Dragon Skin SOV-2000 level III armor was also tested the week of October 2, 2006 by Dr. Gary Roberts, LCDR, USNR, Stanford University Medical Center. These tests were conducted for a local law enforcement agency, as a control sample a stand-alone Armored Mobility Incorporated (AMI) level III steel composite plate armor was used for comparison. Both types of armor were conditioned for 12 hours at 170 F(77 C), then moved to ambient air for approximately 90 minutes prior to being shot. The problems associated with the use of inelastic clay backing material have been well documented; as such, the armor was secured to a life-size curvilinear torso replica made of Perma-Gel. Each armor system was shot a minimum of 20 times with five rounds of each ammunition type fired against each armor systemone 90 degree perpendicular shot, two shots at 60 degrees obliquity, and two shots at 30 degrees obliquity, using each of the following loads fired at a distance of 10 feet (3.0 m):

5.56 mm 40 gr LeMas Urban Warfare (using a moly coated Nosler Ballistic Tip bullet) with a 3,718 feet (1,133 m) per second average velocity. 5.56 mm M855 62 gr FMJ with a 3,054 feet (931 m) per second average velocity. 7.62x39 mm M43 123 gr steel-core FMJ with 2,307 feet (703 m) per second average velocity. .30-06 M2 150 gr FMJ with a 2,736 feet (834 m) per second average velocity.

All of the above ammo was successfully stopped by both armor systems in this testing, with no armor failures or penetrations, even after receiving multiple hits.

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22. ^ Getting America's Best?