Body Armour and Food Container Plastic for Defence Applications

S.B.Yadaw Defence Materials and Stores Research & Development Establishment, G.T. Road, Kanpur -208013

Sr. No. 1.

Items

Utility

Body Armour

For protection of soldiers from bullets and fragments during combat conditions.

2.

Food Container Plastic

For facilitating soldiers to have hygienic and warm food during patrolling and combat duties.

Personnel Protective Systems Against Ballistic and Blast Threats for Infantry Soldier  Bullet Proof Jacket Ballistic - Provides protection to Heart, Lungs and other important organs Ballistic Helmet Ballistic - Provides protection to Head Boot Antimine Infantry- Blast - Provides Protection to Foot/Leg

 

"Our Real Strength is Our Soldiers"

"Compared to other countries, our soldiers are much more dedicated. They can go to any extent to protect their motherland,"

Opines the former Chief of the Army Staff, Gen VN Sharma (Retd) in an interview to VK Joshi on the occasion of Armoured Corps Day.

In complex terrain, it is vital that the infantryman is provided with     Adequate protection, Good intelligence, Clear communications and Rapid information flow.

Requirements of Protective Systems of Infantry Soldier

 Protection from threats  Light weight and comfortable  To enhance operational capabilities by incorporating advanced communication technologies

TYPES OF PROTECTION
BALLISTIC -From Trauma -From Penetration BLAST -From Shock Waves -From Splinters and Fragments

BODY ARMOUR
Modern body armor is divided into two main categories: Hard body armor and Soft body armor. Soft body armor is not made out of soft materials; it is formed from advanced fibers that can be sewn into vests. Hard body armor, made out of thick composite, ceramic or metal plates, defeats high energy bullets. It is hard enough that a bullet or other weapon is deflected. That is, the armor material pushes out on the bullet with the same force (or nearly the same force) with which the bullet pushes in, so the armor is not penetrated.

REQUIREMENTS FOR BODY ARMOUR

Following features in body armour are essential  Provide adequate protection to wearer from bullets  Trauma should be minimum Less than 25mm/44mm  Comfortable and light weight  Easy to wear and take off  Fabric should not be irritant to skin  Added features like camouflage, water proof, pockets to store essential items, computer, GPS, batteries etc.

THREAT PERCEPTIONS
Ammunitions Bullet Mass (gram) 5.65 7.40 7.65 7.85 9.65 Velocity (m/s) 400 730 835 850 854 Energy (KJ) 0.6 2.4 3.25 3.5 3.52

9 mm SMC AK-47 7.62 SLR Dragnov 7.62mm AP

CURRENT STATUS OF BODY ARMOUR

- As defined in NIJ 0101.03 and 0101.04 (USA).

- As defined in GSQR (Indian Army).

Ballistic Weight of Weight of Jacket level HAP (kg) (kg)

III A III IV III A IV 1.5 1.8 2.7- 3.5 1.5 2.5 2.5 -3.5 5.5 6.6 8.5 - 10 5.5 7.5

Remark

Dyneema/ Spectra Two HAPs HAP With ceramic plate DMSRDE DMSRDE

AREAL DENSITY
The areal density of a particular armour is defined as the mass of a 1 metre square Plate of the armour.
AREAL DENSITY=BULK DENSITY X THICKNESS To stop a 7.62 mm AP round you need:

1m

28mm 1m

Al RHA
14mm

Thickness(mm) Density(Kg/m) Areal Density(Kg/m)

14 7830 110

28 2807 79

MASS EFFECTIVENESS
Of a particular armour for a specific threat: Areal density of RHA Mass Effectiveness= Areal density of Armour The mass effectiveness provides a direct indication of the weight saving achieved in applying the armour in comparison to RHA. The mass effectiveness of Aluminum that is required to stop a 7.62 mm AP round: Areal Density of RHA = 110 Kg/m Areal Density of Al = 79 Kg/m 110 = 79 1.39

ROLLED HOMOGENEOUS ARMOUR

Widely used in the 50s-80s. Fe,C(0.25-0.35), Ni(0.01-1.0), Cr(1.25- 1.75), Mo(0.3- 0.6), AlSl 4340 Composition. Rolled from ingots, quenched and tempered. Typical UTS=772-926 MPa, elongation 14-18% Hardness 300-550 BHN. Rolling offers- 5% ballistic performance advantage over similar cast steels.

PROTECTION (7.62 MM AP)

Armour Type Density (kg/m) Areal Density (kg/m) 114 98 79-128 35-50 Mass Effectiveness

RHA (380 BHN) High Hardness Steel (550 BHN) Aluminum Armour Ceramic-faced Armour

7830 7850 2660-2807 2000-4450

1.0 1.16 0.89-1.44 2.28-3.26

SMALL ARMS ATTACK

Ductile backing aluminium, GRP) (Steel,

Ceramic face

SMALL ARMS ATTACK

Projectile fractures or deforms Load spread onto backing

Ballistic Composite Fibres

Material E-glass S-glass Aramid (Kevlar) Carbon (HS) PE (Dyneema Spectra) PBO (Zylon) Density 2.6 2.5 1.45 1.78 0.97 Strength (MPa) 3500 4600 2900 3400 3200 Modulus Strain (%) (GPa) 72 86 120 390 99 4.8 5.2 1.9 1.4 3.7

1.4

5800

365

1.6

Polymeric Ballistic materials

Manufacturer Twaron Dupont DSM Honeywell Twaron Toyobo Type Aramid Aramid Polyethylene Aramid PBO Trade Name Twaron Kevlar Dyneema Goldflex Zylon Construction Woven Woven Uni-directional Uni-directional Woven

Polyethylene Spectra shield Uni directional

Ballistic materials for Hard armour

TYPE Ceramic Steel UHMWPE Glass Ceramic WEIGHT** 2.6 kgs 3.5 kgs 1.4 kgs 1.9 kgs CONSTRUCTION Ceramic (alumina oxide) with aramid backing Tempered steel/specialised metals Pressed polyethylene Dyneema or Spectrashield Glass ceramic with aramid or UHMWPE backing

** 25cm x 30 cm combination plate to defeat NIJ level III ammunition

Dyneemas Ballistic Performance

Threat DyneemaTM Armour (Kg/m2) 3.2 23.0 8.0 8.0 5.0 Strike Face (Kg/m2) None None Alumina tile 26.0 Alumina tile 30.0 Boron carbide 21.0 Total Areal Density (Kg/m2) 3.2 23.0 34.0 38.0 26.0

9 mm 7.62 mm Ball 5.56 mm AP 7.62 mm AP 7.62 mm AP

PRODUCERS OF BODY ARMOUR

SALIENT FEATURES OF GSQR

Sr No 1 2 Features Cover Material Ammunitions GSQR 1095 Nylon 9 mm SMC SAP 7.62 Dragunov, 7.62 SLR, AK 47- HAP 44 mm 25 mm 5000 cm2 1500 cm2 5.5 kg Small, Medium, Large GSQR 1293 Nylon 6,6 9 mm SMC SAP AK 47- HAP 25 mm 50 mm 5500 cm2 3395 cm2 11 kg (Medium Size) Small, Medium, Large and Extra Large

3 4 5 6 7 8

Trauma Inter shot Distance Area (Medium) HAP Area (Medium) Weight Sizes

BULLET PROOF JACKET -III

To Defeat NIJ Level III Ammunitions Light Weight Bullet Proof Jacket (BPJ) has been developed meeting the requirements of GSQR 1095. Main features of the jacket are: Soft Armour Panel defeats 9 mm KF bullet from a distance of 5 m.  Hard Armour Panel defeats 7.62 mm Ball ammunition and AK47 rifle from 10 m distance.  Total weight of jacket (including two Hard Armour Plates) is 5.5 Kg.

BULLET PROOF JACKET -IIIS

To Defeat NIJ Level III Steel Core Ammunitions Light Weight Bullet Proof Jacket (BPJ) has been developed to defeat NIJ level III steel core ammunitions. Main features of the jacket are:  Soft Armour Panel defeats 9 mm KF bullet from a distance of 5 m.  Hard Armour Panel defeats 7.62 mm Dragunov Dual core and 5.56 mm INSAS ammunitions from 10 m distance.  Total weight of jacket (including two Hard Armour Plates) is 6.3 Kg.

BULLET PROOF JACKET -IV

To Defeat NIJ Level IV Ammunitions Light Weight Bullet Proof Jacket (BPJ) has been developed to defeat NIJ level IV ammunitions. Main features of the jacket are: Soft Armour Panel defeats 9 mm KF bullet from a distance of 5 m. Hard Armour Panel defeats 7.62 mm hard steel core ammunition from 25 m distance.  Total weight of jacket (including two Hard Armour Plates) is 7.5 Kg.

FEATURES OF GSQR 1293

Sr No 1 2 Features
Design Cover Material

GSQR 1293 Requirements

Modular Nylon 6,6 Closely Woven rip stop Nylon 6.6 Mass/m2 Breaking strength Tearing Strength Elongation at break :140 gram : 1150 N min. (Warp) : 900 N min. (Weft) : 200 N min. (Warp) :180 N min.(Weft) : 27% Max. (Warp) : 27% Max. (Weft) Etc.

FEATURES OF GSQR 1293 AND STATUS

Sr No 3
SAP

Features

GSQR 1293 Requirements

Front and Rear, Groin , Collar, Upper Arms with Trauma Pads Groin 500 cm2 Collar 500 cm2 Arms - 350 cm2 Total - 5500-cm2

Area of components SAP

each

Pockets with Flaps

LMG Magazine Two Grenade Two Rifle Magazine Three Radio - One

FEATURES OF GSQR 1293 AND STATUS

Sr No 6. 7. 8. Features
Velcro Fastener HAP Area (Medium) Size of HAP

GSQR 1293 Requirements

Peel Strength 125 N/cm (min) Shear Strength 750 N/cm sq (min) 3395 cm2 Front : 1750 cm2 Back : 1000 cm2 Throat: 270 cm2 Groin: 375 cm2 9 mm SMC and MP5 from 5 m SAP AK 47 from 10 m HAP Trauma 25 mm Inter Shot Distance 51 mm

9.

Ammunitions to be Defeated

FEATURES OF GSQR 1293 AND STATUS

Sr No 10
Weight

Features

GSQR 1293 Requirements

Small: 10.5 kg Medium: 11 kg Large: 11.5 kg Ex Large: 12 kg Camouflage Jungle, Desert Small, Medium, Large and Extra Large Basic + 3 Upgrades -20 to 45 oC Hum 95%, 40 oC GSQR-1293

11 12 13 14 15

Colour Sizes Configuration Environment Governing Specifications

VARIENTS OF BULLET PROOF JACKETS DEVELOPED BY DMSRDE

Sr. No.
1. 2. 3. 4. 5. 6. 7

Threat
9 mm SMC 7.62 mm SLR & AK-47 7.62 mm SLR, AK-47 & 5.56 mm INSAS 7.62 mm SLR & AK-47 7.62 mm SLR, AK-47 & 5.56 mm 7.62 mm AP MP5 & AK-47

Protection
5000 cm2 Front 25x30 cm2 Front 25x30 cm2 Front & Back Front & Back Front & Back All around

Weight of Jacket
2.25 kg 3.75 kg 4.0 kg 5.3 kg 5.80 kg 7.5 kg 11 kg

Ballistic Trials of HAP

Ammunition: AK-47 Firing Distance: 10 m S.No. Material Condition of Test Back Face Signature (mm) Remarks

1.

Spectra

Dry Trauma not more (18 Shots) than 20 mm. Dry Trauma not more (14 Shots) than 18 mm.

All bullets stopped . All bullets stopped .

2.

Dyneema

The polymer fiber advantage

FRACTURE MECHANISM ON FRP

Fibre breakage, Matrix cracking, Fibre matrix debonding, Fibre pullout, Delamination

FAILURE MODE DICTATED BY :

Strength of fibre, Strength of matrix resin, Strength of interphase, Weave of fabric, Resin content in Composite, Angle of attack and calibre of the projectile.

COMPARISON OF MATERIAL STRENGTHS

0.8 0.7

SPECIFIC STRENGTH

0.6

Unidirectional
0.5 0.4 0.3 0.2 0.1 0

Quasi-isotropic
Carbon Steel Aluminium 7039 Titanium GRP CRP

MATERIALS

E GLASS

Ballistic Perfornmance

Mechanical Properties

Fire Resistance

Cost - Low Weight - High

Poor

Moderate

Good

Excellent

ARAMID

Ballistic Perfornmance

Mechanical Properties

Fire Resistance

Poor

Moderate

Good

Excellent

Cost - Moderate/ High Weight - Low

UHMWPE

Ballistic Perfornmance

Mechanical Properties

Fire Resistance

Cost - High Weight - Lowest

Poor

Moderate

Good

Excellent

ENERGY DISSIPATION

TRADITIONAL WOVEN MATERIALS

UNIDIRECTIONAL CROSSPLIED MATERIALS

Food Container Plastic

 Food Container Plastic has been design to keep food fresh and hot in cold climatic conditions.  5.5 liters is its capacity and stored quantity of food in a food container is sufficient for approximately six people.  The Food Container Plastic can retain food to edible condition in cold climate of -250C for approximately 5 to 6 hours.  Filled food container has been tested for drop weight test and concluded that it can be drop by Helicopter in case where road transport is tedious such as in high altitude region.

Characteristic Features
Strength:  The main (outer) body of Food Container Plastic 5.5 Liters is made up of (HDPE) plastic.  Katordan and lid katordan made up of stainless steel.  The food container is strong enough and food can be supplied by dropping filled food container in high altitude areas.  Its strength is enough so that one can use it as a stool and sit over it.

Storage Capacity:  The storage volume of Food Container Plastic is 5.5 liters.  It has four katordan and lid katordans.  Food can be stored in this Food Container Plastic for approximately six person of normal diet.  Stainless steel casing can be used as a big glass of water for storage of water.  The quantity of water can be stored in the stainless steel casing is about 6 liters.

Thermal Insulation:
 Rigid polyurethane foam is filled between inner and outer wall of the main plastic (HDPE) body of Food Container Plastic.  This provides higher level thermal insulation to Food Container Plastic.  This thermal insulation checks the heat out flow from the stored food in cold climatic condition.

Corrosion Resistant:
 Stainless steel katordan and lid katordan of Food Container Plastic has been tested for corrosion resistance.  The Food Container Plastic is very good against corrosion even in adverse environmental conditions.

Cryogenic Resistant:
The main body, stainless steel katordan and lid katordanof Food Container Plastic shows excellent behaviour at lower temperature of -250C. the Food Container Plastic have not shown any contraction, cracking etc. at this lower temperature.

Light Weight:
The weight of he total assembly of Food Container Plastic is 4.5 kg. this is very less as compared to excellent strength and thermal insulation provided by the Food Container Plastic.

Material features
Sr. No.
1.

Component
Outer container

Material
High density polyethylene Polypropylene Stainless steel

Feature
Drop/ impact resistant material Heat resistant Staining/ corrosion resistant Good insulating properties and compressive strength

2. 3.

Inner container Clamp casing, katordan etc Insulation Material

4.

Rigid Polyurethane foam

FOOD CONTAINER PLASTIC 5.5 LTRS FOR ECW  The outer body is hard and tough and inner body has good insulation resistance.  Insulation by rigid Polyurethane Foam in-situ.  Stainless steel Katordan & lids used with sturdy lamps.  Inner casing specially designed stainless steel body.  Keeps food warm for 4-6 hrs at 20oC ambient temperature. STATUS Recommended its introduction in Services. Indent has been raised for supply. Technology transferred to trade for production and supply.

FOOD CONTAINER PLASTIC 5.5 LTRS FOR ECW