FIELD OF THE INVENTION
[0001] This invention relates to armor panels, in particularly composite armor panels comprising
one or more protective layers.
BACKGROUND OF THE INVENTION
[0002] A standard armor panel of the kind to which the present invention particularly refers,
comprises a multitude of layers, designed to gradually absorb the kinetic energy of
the impact, delivered to the panel by an incoming projectile and finally to completely
avoid penetration of the projectile or its fragments to the body to be protected.
[0003] The layers used in such armor panels may be divided into two groups: hard layers,
e.g. steel or ceramic, and soft layers, e.g. Aramid or UHMW HDPE (Ultra High Molecular
Weight High Density PolyEthylene). The harder layers are usually positioned facing
the expected threat and absorb most of its kinetic energy thereof, thereby slowing
it down and shattering and/or deforming it substantially. The softer layers absorb
the remains of the kinetic energy of the projectile, stopping it and its fragments,
thereby preventing them from deforming/coming in contact with the body to be protected
or at least from penetrating it.
[0004] It is known in the art to use armor panels having several hard layers of different
materials in order to better absorb the kinetic energy of the incoming projectile.
[0005] The choice between various materials that may constitute the hard and/or soft layers
of the armor panel is affected by the required end properties of the panel, such as
ballistic properties, weight, etc. Thus, for example, a hard ceramic layer may be
light-weight, yet brittle, while a hard steel layer having similar ballistic properties,
may be very heavy, though easy to work with.
SUMMARY OF THE INVENTION
[0006] According to the present invention, there is provided an armor panel for protecting
a body from an incoming projectile having an expected impact direction, said armor
panel comprising at least an armor layer made of cemented carbide in the form of metal-carbide
aggregate embedded within a metal binder matrix.
[0007] The armor panel may be adapted to protect the human body, i.e. be in the form of
personal armor such as a vest, or alternatively, be designed to protect a structure,
mobile or immobile, adapted to house individuals to be protected, e.g. a vehicle.
[0008] The 'metal-carbide aggregate' should be understood as being in the form of granular/powder
material, and 'embedded within a metal binder matrix' should be understood as being
homogenously spread throughout the metal binder matrix.
[0009] It should be noted that cemented carbide may be divided into two major groups, a
first group in which the cemented carbide comprises a carbide aggregate embedded within
a binder matrix, and a second group in which the cemented carbide comprises an aggregate
without a binder.
[0010] For the purpose of simplicity, the metal of said metal-carbide will be referred herein
as
'carbide metal' and the metal used for said metal binder matrix will be referred herein as
'binder metal'.
[0011] Said carbide metal and said binder metal may differ in their inherent characteristics.
More particularly, the properties of said carbide and said binder metal may differ
from one another. The metal of said carbide metal may be chosen from a group of refractory
metals, in order to provide said cemented carbide with high hardness, high fracture
toughness and a high melting point. The metal of the binder metal may be a metal having
a lower hardness than that of the metal of the metal-carbide, in order to reduce the
brittleness of the cemented carbide and provide it with high fracture toughness.
[0012] Cemented carbide may be manufactured by a variety of processes in solid, liquid and
vapor phases as known
per se, for example hot isostatic pressing (HIP) or sintering. During manufacture, binder
metal and carbide are heated up until the binder metal is melted down while the aggregate
remains in solid phase, thereby providing the cemented carbide with its desired morphology.
This is due to the carbide having a higher melting point than that of the binder metal.
[0013] The carbide metals are so chosen as to provide the metal-carbide with relatively
high density, high toughness and hardness. Thus, the metal-carbides described above
may have a density ranging from 4.93ö15.8 gr/cc, a toughness ranging from 240ö550
MPa, hardness ranging from 1400ö3000 HV50and a melting point ranging from 1800ö3990°C.
Fracture toughness of the above metal-carbides is relatively not high, e.g. up to
about 12 Mpa*(m
1/2). Some examples of such metal-carbides may be WC, TiC, TaC, NbC, ZrC, HfC, VC, Cr3C2,
Mo2C etc. The cemented carbide may comprise several carbide metals forming several
kinds of aggregates while using the same metal binder. Some examples of such cemented
carbides may be WC-Co, WC-TiC-TaC-NbC-Co, WC-Cr3C2-Co, WC-TiC-TaC-NbC-Cr3C2-Co, TiCN-WC-TiC-TaC-NbC-Ni-Co-Mo2C-VC.
[0014] Said binder metal may have a density ranging from 7.8ö8.9 gr/cc, fracture toughness
ranging up to 400 Mpa*(m
1/2) which is considerably higher than that of the metal-carbides, and a melting point
ranging from 1450ö1536°C. Some examples of such binder metals may be Co, Ni, Fe etc.
[0015] The binder metals listed above have an atomic weight essentially lower than that
of the carbide metals, providing the cemented carbide used for the armor panel with
an essentially lower overall density than a similar cemented carbide in which the
metal (such as W, Ti, Nb etc.) is of an atomic weight close to that of the carbide
metals.
[0016] In the cemented carbide layer, the metal-carbide aggregate may be in the form of
grains homogenously spread throughout the binder. The grain size of the metal-carbide
aggregate may be such that it does not exceed 20µm per grain. For example, for grains
of tungsten carbide (WC), the grain size may range between about 0.5µmö2.3µm, more
particularly between 0.7µmö2.1µm, and still more particularly between 0.9µmö1.9µm,
and having an average grain size of about 1.3µm. For grains of titanium carbide (TiC),
the grain size may range between about 2.5µmö6.2µm, more particularly between 2.7µmö6µm,
and still more particularly between 2.9µmö5.8µm, and having an average grain size
of about 2.7µm.
[0017] The composition of the cemented carbide may be such that, by weight percentage, the
metal carbide aggregate does not exceed 80%. The metal carbide aggregate may constitute
between about 80ö96%, more particularly between about 85ö94%, and still more particularly
between about 90ö92%. The metal binder matrix may be such that, by weight, does not
exceed 80%. The metal binder matrix may constitute between about 4%ö20%, more particularly
between about 6%ö15%, and still more particularly between about 8%ö10%.
[0018] The composition of the cemented carbide may also be such that, by volume percentage,
the metal carbide aggregate does not exceed 70%. The metal carbide aggregate may constitute
between about 82ö96%, more particularly between about 86ö92%, and still more particularly
between about 88ö90%. The metal binder matrix may be such that, by volume, does not
exceed 30%. The metal binder matrix may constitute between about 4%ö18%, more particularly
between about 8%ö14%, and still more particularly between about 10%ö12%.
[0019] It should be appreciated that the cemented carbide may comprise metal carbide aggregates
of various metal, for example both titanium carbide (TiC) aggregates and tungsten
carbide (WC) aggregates. In this case, the composition of the cemented carbide may
be such that, by weight, WC ranges between 70%ö85%, more particularly between 74%ö80%,
and still more particularly between 76%ö79%. The weight percentage of the titanium
carbide (TiC) may range between 10%ö20%, more particularly between 12%ö18%, and still
more particularly between 14%ö16%. The weight percentage of the binder may range between
4%ö20%, more particularly between 6%ö15%, and still more particularly between 8%ö10%.
[0020] In the above case, the composition of the cemented carbide may be such that, by volume,
WC may range between 50%ö65%, more particularly between 53%ö62%, and still more particularly
between 56%ö60%. The volume percentage of the titanium carbide (TiC) may range between
24%ö40%, more particularly between 27%ö36%, and still more particularly between 30%ö33%.
The volume percentage of the binder may range between 4%ö16%, more particularly between
6%ö14%, and still more particularly between 9%ö12%.
[0021] The said cemented carbide may have an overall density ranging from 5.5ö15.5 gr/cc,
a toughness ranging from 1.7-4.1 GPa, hardness ranging from 87ö93 HRa, and fracture
toughness up to 20 Mpa*(m
1/2), i.e. lower than that of the binder metal yet higher that of the metal-carbide.
[0022] It should also be understood that the above compositions are chosen specifically
in order to provide the cemented carbide, on the one hand, with high hardness due
to the metal-carbide aggregate, and on the other hand, high fracture toughness due
to the metal-binder matrix. In particular, since the cemented carbide is used in an
armor panel, the composition is chosen such that it may be adapted to withstand a
high impact during a short time interval.
[0023] It should be noted that the armor panel may also comprise a layer which is partially
made of cemented carbide, for example, containing cemented carbide pellets and/or
tiles. The term
pellets' should be understood to refer to armor elements adapted to be incorporated within
the armor panel, and usually having a polygonal/cylindrical shape extending along
a central axis. The design of the armor panel may be such that the pellets/tiles are
incorporated within a matrix which is of different characteristics than that of the
metal-binder matrix, for example, made of a light weight metal (e.g. aluminum) or
a thermoplastic/thermosetic polymer (e.g. resin).
[0024] One of surprising properties that may be obtained in the cemented carbide armor layer
as defined above, is that this layer, on the one hand, exhibits uniform mechanical
properties as in known, and widely used in the field of armor, ceramic tiles, and
on the other hand, may be essentially less brittle then these tiles (due to the inherent
ductile properties of the binder metal), due to which the armor layer may have a high
multi-hit capability compatible to that of an armor layer made of metal carbide pellets
or armor elements within a matrix, and the ability to be processed, in particular
cut, without causing its fracture, e.g. using CNC tools, to have a desired design.
[0025] Tests carried out on an armor panel having an armor layer of cemented carbide as
described above, in comparison with a reference armor panel having a steel armor layer
of a greater thickness than that of the cemented carbide layer and otherwise being
of a design similar to that of the cemented carbide panel, exhibits penetration resistance
properties similar to that of the reference panel, though at an essentially lower
weight. The armor panel may comprise two or more layers which may be made of the same
or different cemented carbides.
[0026] Said armor panel may comprise in addition to the at least one layer of cemented carbide,
a complementary armor layer positioned in front or behind said cemented carbide layer,
and/or an optional a backing layer. The additional layers may be made of any appropriate
ballistic materials, such as steel, metal, ceramic or any other ballistic material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In order to understand the invention and to see how it may be carried out in practice,
embodiments will now be described, by way of non-limiting examples only, with reference
to the accompanying drawings, in which:
Fig. 1 is a schematic cross-sectional view of a conventional, reference armor panel;
Fig. 2A is a schematic cross-sectional view of an armor panel according to one embodiment
of the present invention;
Fig. 2B and 2C are respective schematic morphological representations of a cemented carbide according
to the present invention and a hard metal according to the prior art;
Fig. 3 is a schematic cross-sectional view of an armor panel according to another embodiment
of the present invention;
Fig. 4 is a schematic cross-sectional view of an armor panel according to yet another embodiment
of the present invention;
Fig. 5 is a schematic cross-sectional view of an armor panel according to still a further
embodiment of the present invention; and
DETAILED DESCRIPTION OF EMBODIMENTS
[0028] In embodiments described below, examples of different designs of an armor panel according
to the present invention are presented, including a cemented carbide layer either
alone or with additional layers. Examples of materials and processes that may be used
for the manufacture of the cemented carbide layer are generally presented in the Summary
of Invention, whilst for the purpose of the present detailed description, one specific
non-limiting example of the cemented carbide will be referred to, which is a cemented
carbide produced from tungsten carbide as a metal-carbide aggregate with cobalt as
a binder metal, by a process including heating up both the binder metal and the carbide
to high temperatures of about 1600 °C. Since the melting point of the carbide, in
this case tungsten-carbide (≅1800 °C), is higher than that of the cobalt binder (≅1550
°C), the cobalt binder is melted to assume a liquid phase while the tungsten-carbide
aggregate remains in solid state. This manufacturing process provides even dispersion
of the aggregate within the binder and causes the resulting cemented carbide to have
extremely low porosity, e.g. about 2%.
[0029] Figs. 2B shows morphological representation of a cemented carbide of the kind used
in armor panels according to the present invention, in particular such as in the specific
example described above. As seen in Fig. 2B, the carbide metal aggregate 42 is formed
in clusters (shown in gray) and is bound by a binder 44 (shown in white). The clusters
42 are immersed in the binder 44, i.e. the connection of the clusters 42 to the binder
44 is achieved by the clusters 42 being a kind of dissolved in, and homogenously spread
throughout, the metal binder 44.
[0030] Fig. 2C shows a cemented carbide of a different kind where no metal binder matrix
is used. Thus, the cemented carbide shown in Fig. 2C comprises WC clusters 52 (gray),
TiC clusters 54 (dark gray), and TaC clusters 56 (light gray). In the present example,
there is no binder between the clusters, and they are attached directly to one another
in solid phase.
[0031] In the example shown in Fig. 2B, the presence of the binder provides the material
with fracture toughness of up to 20 Mpa*(m
1/2), as opposed to about 12 Mpa*(m
1/2) of the material shown in Fig. 2C. Increased fracture toughness may allow for a higher
multi-hit capability of the armor panel.
[0032] For the purpose of illustrating the performance of armor panels described below,
they will be compared with that of a reference armor panel RP (shown Fig. 1), made
of steel and having a thickness T, and a weight W, as summarized in the table below:
Sample No. |
Properties |
Areal Weight [Kg/m2] |
Thickness [mm] |
1 |
172.5 |
22 |
[0033] With reference to Fig. 2, first example of an armor panel according to the present
invention, generally designated as 1, is shown, made of a monolith layer 10 of the
cemented carbide, constituted by a metal binder matrix 12 and a carbide aggregate
14.
[0034] To compare the ballistic performance of the armor panel 1 with that of the above
reference panel RP, the armor panel 1 has been produced with a thickness t of 10mm
and an areal weight w approx. 69 Kg/m
2. Namely, the armor panel 1 is essentially lighter and thinner than the reference
armor panel RP, the respective weight and thickness ratios
m and
d between the armor panels 2 and 1 being

, and

[0035] Surprisingly, despite the above essential thickness and weight ratios d and m, respectively,
the armor panel 1 has appeared to provide the same level of protection (level 3 threats
according to STANAG 4569), as that of the armor panel 1 and withstand AP rounds and
FSP. It should also be appreciated that the armor panel 1 may provide protection against
hollow charges as well.
[0036] Turning now to Fig. 3, another example of an armor panel is shown, generally designated
as 1'. The armor panel 1' comprises a first layer 10 of the cemented carbide and a
second layer 20 of steel, and such combination appears to improve anti-penetration
ability of the entire armor panel.
[0037] It should be noted that the terms
'first' and
'second' are used with reference to an expected impact direction of incoming projectiles,
i.e. among the two layer the
'first' layer meets an incoming projectile before the
'second' layer. Hereinafter, arrow
100 denotes the expected impact direction.
[0038] The panel 1' may for example, be produced with a thickness t' of the first, cemented
carbide layer 10 being 4mm and a thickness T' of the second, steel layer 20 being
5mm. Such an armor panel 1' has appeared to withstand the same threats as those withstood
by the reference armor panel 1, whilst being essentially thinner and lighter.
[0039] With reference to Fig. 4, a further example of an armor panel is shown generally
designated as 1". The armor panel 1" comprises a first layer 10 of the cemented carbide
and a second layer 30 made of a plurality of HDPE sheets. The panel 1" may, for example,
be produced with a thickness t" of the first, cemented carbide layer 10 being 4mm,
and a thickness T' of the second, HDPE layer 30 being 23mm. Such an armor panel 1"
has also been shown to withstand the same threats as those withstood by the reference
armor panel 1, though being essentially lighter.
[0040] Turning now to Fig. 5, a still further example of an armor panel is shown, generally
designated as
1'''. The armor panel
1'' comprises a first layer
10 of cemented carbide, a second layer
20 of steel, and a third, backing layer
30 made of a plurality of Kevlar® sheets. Several tests have been performed on panels
having this design, though different thicknesses and different weights, and their
results are presented below:
Sample No. |
Properties |
Areal Weight [Kg/m2] |
Thickness [mm] |
1 |
86.3 |
18.5 |
Exp. No. |
Bullet Type |
Velocity [m/s] |
Penetration |
1 |
7.62*51 AP (WC core) |
952 |
No |
2 |
7.62*51 AP (WC core) |
933 |
No |
3 |
7.62*51 AP (WC core) |
949 |
No |
4 |
7.62*51 AP (WC core) |
950 |
No |
5 |
7.62*51 AP (WC core) |
948 |
No |
6 |
7.62*51 AP (WC core) |
942 |
No |
7 |
7.62*51 AP (WC core) |
950 |
No |
8 |
7.62*51 AP (WC core) |
945 |
No |
Sample No. |
Properties |
Areal Weight [Kg/m2] |
Thickness [mm] |
2 |
98.74 |
22.8 |
Exp. No. |
Bullet Type |
Velocity [m/s] |
Penetration |
1 |
20mm FSP |
788 |
No |
2 |
20mm FSP |
774 |
No |
3 |
20mm FSP |
815 |
No |
Sample No. |
Properties |
Areal Weight [Kg/m2] |
Thickness [mm] |
3 |
90.2 |
19.1 |
Exp. No. |
Bullet Type |
Velocity [m/s] |
Penetration |
1 |
20mm FSP |
789 |
No |
2 |
20mm FSP |
795 |
No |
Sample No. |
Properties |
Areal Weight [Kg/m2] |
Thickness [mm] |
4 |
94.8 |
18.2 |
Exp. No. |
Bullet Type |
Velocity [m/s] |
Penetration |
1 |
20mm FSP |
845 |
No |
2 |
20mm FSP |
794 |
No |
Sample No. |
Properties |
Areal Weight [Kg/m2] |
Thickness [mm] |
5 |
90.2 |
19.1 |
Exp. No. |
Bullet Type |
Velocity [m/s] |
Penetration |
1 |
7.62 x 54 AP B32 |
862 |
No |
2 |
7.62 x 54 AP B32 |
850 |
No |
3 |
7.62 x 54 AP B32 |
847 |
No |
4 |
7.62 x 54 AP B32 |
734 |
No |
5 |
7.62 x 54 AP B32 |
738 |
No |
6 |
7.62 x 54 AP B32 |
735 |
No |
7 |
7.62 x 54 AP B32 |
864 |
No |
8 |
7.62 x 54 AP B32 |
860 |
No |
[0041] It should be obvious from the above test tables that the armor panel according to
the present invention is capable to provide at least the same ballistic protection
as the reference armor panel RP, however, with reduced overall weight and thickness.
[0042] Those skilled in the art to which this invention pertains will readily appreciate
that numerous changes, variations, and modifications can be made without departing
from the scope of the invention.
1. An armor panel for ballistic protection, comprising at least an armor layer which
is at least partially made of cemented carbide in the form of metal-carbide aggregate
embedded within a metal binder matrix.
2. An armor panel according to Claim 1, wherein the metal-carbide aggregate is in the
form of grains having a grain size not exceeding 20µm.
3. An armor panel according to Claim 1 or 2, wherein the composition is such that said
metal-carbide aggregate constitutes at least one of the following:
(i) at least 70% by volume; and
(ii) at least 80% by weight.
4. An armor panel according to Claim 1, 2 or 3, wherein the composition is such that
said metal binder matrix constitutes at least one of the following:
(i) No more than 30% by volume; and
(ii) No more than 80% by weight.
5. An armor panel according to any one of Claims 1 to 4, wherein said carbide aggregate
has a melting point ranging from 1800ö3990 °C.
6. An armor panel according to any one of Claims 1 to 5, wherein the metal of said metal
binder has a melting point ranging between 1450ö1536 °C.
7. An armor panel according to any one of Claims 1 to 6, wherein said cemented carbide
has a fracture toughness ranging from 7ö20 Mpa*(m1/2).
8. An armor panel according to any one of Claims 1 to 7, wherein said cemented carbide
has a hardness ranging from 87ö93 HRa.
9. An armor panel according to any one of Claims 1 to 8, wherein said cemented carbide
has a density ranging from 5.5ö15.5 gr/cc.
10. An armor panel according to any one of Claims 1 to 9, wherein said cemented carbide
has a porosity ranging from 0ö2%.
11. An armor layer according to any one of Claims 1 to 10, wherein said metal-carbide
aggregate has a higher melting point than that of said metal binder.
12. An armor layer according to any one of Claims 1 to 11, wherein said metal-carbide
aggregate has a lower fracture toughness than that of said metal binder.
13. An armor panel according to any one of Claims 1 to 12, wherein said armor layer is
a single cemented carbide monolith.
14. An armor panel according to any one of Claims 1 to 13, wherein said armor layer comprises
a plurality of cemented carbide pellets.
15. An armor layer for use in ballistic armor made of cemented carbide in the form of
a metal-carbide aggregate embedded within a metal matrix, wherein the metal of said
metal-carbide is a refractory metal.
A method of manufacture of an armor panel, including manufacture of an armor layer
at least partially made of cemented carbide in the form of a metal-carbide aggregate
embedded within a metal matrix, and incorporating said armor layer within said armor
panel.