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Composite armour is a type of
vehicle armour Military vehicles are commonly armoured (or armored; see spelling differences) to withstand the impact of shrapnel, bullets, shells, rockets, and missiles, protecting the personnel inside from enemy fire. Such vehicles include armoured fi ...
consisting of layers of different material such as
metal A metal (from ancient Greek, Greek μέταλλον ''métallon'', "mine, quarry, metal") is a material that, when freshly prepared, polished, or fractured, shows a lustrous appearance, and conducts electrical resistivity and conductivity, e ...
s,
plastics Plastics are a wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. Their plasticity makes it possible for plastics to be moulded, extruded or pressed into solid objects of various shapes. This adaptabi ...
,
ceramic A ceramic is any of the various hard, brittle, heat-resistant and corrosion-resistant materials made by shaping and then firing an inorganic, nonmetallic material, such as clay, at a high temperature. Common examples are earthenware, porcelain, ...
s or
air The atmosphere of Earth is the layer of gases, known collectively as air, retained by Earth's gravity that surrounds the planet and forms its planetary atmosphere. The atmosphere of Earth protects life on Earth by creating pressure allowing f ...
. Most composite armours are lighter than their all-metal equivalent, but instead occupy a larger volume for the same resistance to penetration. It is possible to design composite armour stronger, lighter and less voluminous than traditional armour, but the cost is often prohibitively high, restricting its use to especially vulnerable parts of a vehicle. Its primary purpose is to help defeat
high-explosive anti-tank High-explosive anti-tank (HEAT) is the effect of a shaped charge explosive that uses the Munroe effect to penetrate heavy armor. The warhead functions by having an explosive charge collapse a metal liner inside the warhead into a high-velocity ...
(HEAT) projectiles. HEAT had posed a serious threat to armoured vehicles since its introduction in
World War II World War II or the Second World War, often abbreviated as WWII or WW2, was a world war that lasted from 1939 to 1945. It involved the World War II by country, vast majority of the world's countries—including all of the great power ...
. Lightweight and small, HEAT projectiles could nevertheless penetrate hundreds of millimetres of the most resistant steel armours. The capability of most materials for defeating HEAT follows the "density law", which states that the penetration of
shaped charge A shaped charge is an explosive charge shaped to form an explosively formed penetrator (EFP) to focus the effect of the explosive's energy. Different types of shaped charges are used for various purposes such as cutting and forming metal, ini ...
jets is proportional to the square root of the shaped charge liner
density Density (volumetric mass density or specific mass) is the substance's mass per unit of volume. The symbol most often used for density is ''ρ'' (the lower case Greek letter rho), although the Latin letter ''D'' can also be used. Mathematicall ...
(typically
copper Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pink ...
) divided by the square root of the target density. On a weight basis, lighter targets are more advantageous than heavier targets, but using large quantities of lightweight materials has obvious disadvantages in terms of mechanical layout. Certain materials have an optimal compromise in terms of density that makes them particularly useful in this role.Evaluation of Siliceous Cored Armor for the XM60 Tank


History

The earliest known composite armour for armoured vehicles was developed as part of the
US Army The United States Army (USA) is the land service branch of the United States Armed Forces. It is one of the eight U.S. uniformed services, and is designated as the Army of the United States in the U.S. Constitution.Article II, section 2, cla ...
's T95 experimental series from the mid-1950s. The T95 featured ''siliceous-cored armour'' which contained a plate of
fused silica Fused quartz, fused silica or quartz glass is a glass consisting of almost pure silica (silicon dioxide, SiO2) in amorphous (non- crystalline) form. This differs from all other commercial glasses in which other ingredients are added which ch ...
glass between rolled
steel Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistan ...
plates. The stopping power of glass exceeds that of steel armour on a thickness basis and in many cases glass is more than twice as effective as steel on a thickness basis. Although the T95 never entered production, a number of its concepts were used on the
M60 Patton The M60 is an American second-generation main battle tank (MBT). It was officially standardized as the Tank, Combat, Full Tracked: 105-mm Gun, M60 in March 1959. Although developed from the M48 Patton, the M60 tank series was never officially ...
, and during the development stage (as the XM60) the siliceous-cored armour was at least considered for use, although it was not a feature of the production vehicles. The first widespread use of a composite armour appears to have been on the
Soviet The Soviet Union,. officially the Union of Soviet Socialist Republics. (USSR),. was a List of former transcontinental countries#Since 1700, transcontinental country that spanned much of Eurasia from 1922 to 1991. A flagship communist state, ...
T-64 The T-64 is a Soviet tank manufactured in Kharkiv, and designed by Kharkiv Morozov Machine Building Design Bureau. The tank was introduced in the early 1960s. It was a more advanced counterpart to the T-62: the T-64 served in tank divisions, whil ...
. It used an armour known as '' combination K'', which apparently is
glass-reinforced plastic Fiberglass (American English) or fibreglass (Commonwealth English) is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass clo ...
sandwiched between inner and outer steel layers. Through a mechanism called
thixotropy Thixotropy is a time-dependent shear thinning property. Certain gels or fluids that are thick or viscous under static conditions will flow (become thinner, less viscous) over time when shaken, agitated, shear-stressed, or otherwise stressed ( ...
, the
resin In polymer chemistry and materials science, resin is a solid or highly viscous substance of plant or synthetic origin that is typically convertible into polymers. Resins are usually mixtures of organic compounds. This article focuses on nat ...
changes to a fluid under constant pressure, allowing the armour to be moulded into curved shapes. Later models of the T-64, along with newer designs, use a
boron carbide Boron carbide (chemical formula approximately B4C) is an extremely hard boron–carbon ceramic, a covalent material used in tank armor, bulletproof vests, engine sabotage powders, as well as numerous industrial applications. With a Vickers hard ...
-filled resin
aggregate Aggregate or aggregates may refer to: Computing and mathematics * collection of objects that are bound together by a root entity, otherwise known as an aggregate root. The aggregate root guarantees the consistency of changes being made within the ...
for greatly improved protection . The Soviets also invested heavily in
reactive armour Reactive armour is a type of vehicle armour that reacts in some way to the impact of a weapon to reduce the damage done to the vehicle being protected. It is most effective in protecting against shaped charges and specially hardened kinetic ener ...
, which allowed them some ability to control quality, even after production. Among NATO nations and allies, the most common type of
composite Composite or compositing may refer to: Materials * Composite material, a material that is made from several different substances ** Metal matrix composite, composed of metal and other parts ** Cermet, a composite of ceramic and metallic materials ...
armour today is
Chobham armour Chobham armour is the informal name of a composite armour developed in the 1960s at the British tank research centre on Chobham Common, Surrey. The name has since become the common generic term for composite ceramic vehicle armour. Other name ...
, first developed and used by the British in the experimental FV 4211 tank, which was based on
Chieftain tank The FV4201 Chieftain was the main battle tank of the United Kingdom during the 1960s–1990s. A development of the Centurion, the Chieftain introduced the supine (reclining) driver position to British design allowing a heavily sloped hull with r ...
components. Chobham uses multiple non-explosive reactive armour plates (NERA), which sandwich a layer of elastomer (like rubber) between two plates of steel armour. This was shown to dramatically increase the resistance to HEAT projectiles, even in comparison to other composite armour designs. Chobham was such an improvement that it was soon used on the new U.S.
M1 Abrams The M1 Abrams is a third-generation American main battle tank designed by Chrysler Defense (now General Dynamics Land Systems) and named for General Creighton Abrams. Conceived for modern armored ground warfare and now one of the heaviest t ...
main battle tank A main battle tank (MBT), also known as a battle tank or universal tank, is a tank that fills the role of armor-protected direct fire and maneuver in many modern armies. Cold War-era development of more powerful engines, better suspension sys ...
(MBT) as well. The need to mount multiple angles plates, along with an outer steel layer to protect the armour array, gives the
Challenger Challenger, Challengers, or The Challengers may refer to: Entertainment Comics and manga * Challenger (character), comic book character * ''Challengers'' (manga), manga by Hinako Takanaga Film and TV * ''The Challengers'' (TV series), a 1979 ...
and Abrams their "slab sided" look. The Soviets/Russians had a similar composite armour to the West's own "NERA", with rubber sandwiches between plates of steel. This armour was confirmed to be inside the T-72B's "Super Dolly Parton" armour, but is suspected to be inside the T-80A as well, since it is unlikely the Soviets would put worse armour in their "premier" tank.


Design

Chobham armour defeats HEAT warheads by disrupting the high speed jet generated by the warhead. The outer steel "burster" plate detonates the shell and protects the composite array from the blast, increasing the armour's multi hit abilities. After making it through the burster plate, the jet penetrates into the first NERA plate, and begins to compress the elastomer. The elastomer quickly reaches maximum compression and rapidly expands, pushing the two steel plates in opposite directions. It is the movement of the steel plates that disrupts the jet, both by feeding more material into the jet's path, and introducing lateral forces to break the jet apart. The effectiveness of the system was amply demonstrated in
Desert Storm The Gulf War was a 1990–1991 armed campaign waged by a 35-country military coalition in response to the Iraqi invasion of Kuwait. Spearheaded by the United States, the coalition's efforts against Iraq were carried out in two key phases ...
, where not a single
British Army The British Army is the principal land warfare force of the United Kingdom, a part of the British Armed Forces along with the Royal Navy and the Royal Air Force. , the British Army comprises 79,380 regular full-time personnel, 4,090 Gurkha ...
Challenger tank was lost to enemy tank fire. (However, one was destroyed by friendly fire on March 25, 2003, killing two crew members after a HESH projectile detonated on the commander's hatch causing high-velocity fragments to enter the
turret Turret may refer to: * Turret (architecture), a small tower that projects above the wall of a building * Gun turret, a mechanism of a projectile-firing weapon * Objective turret, an indexable holder of multiple lenses in an optical microscope * M ...
.) Chobham-type armour is currently in its third generation and is used on modern western tanks such as the British Challenger 2 and the American
M1 Abrams The M1 Abrams is a third-generation American main battle tank designed by Chrysler Defense (now General Dynamics Land Systems) and named for General Creighton Abrams. Conceived for modern armored ground warfare and now one of the heaviest t ...
. The Abrams is also unique in its usage of depleted uranium armour plates in conjunction with composite armour, increasing overall vehicle protection. The Leopard 2A4 is similar in its use of tungsten inserts.


Use

All modern third-generation main battle tanks use composite armour arrays in their construction. While many of these vehicles feature the composite armour permanently integrated with the vehicle, the Japanese
Type 10 The is a fourth generation main battle tank of JSDF produced by Mitsubishi Heavy Industries for the Japanese Ground Self Defense Force, entering service in 2012. Compared with other currently-serving main battle tanks in the JGSDF, the Type ...
and
Type 90 Kyū-maru The is a main battle tank (MBT) of the Japan Ground Self-Defense Force (JGSDF). It was designed and built by Mitsubishi Heavy Industries as a replacement for the Type 61 and to supplement the then current fleet of Type 74 tanks, and entered s ...
MBTs, French Leclerc, Iranian Karrar, Turkish Altay, Indian Arjun, Italian
Ariete The C1 Ariete ( en, battering ram) is the main battle tank of the Italian Army, developed by Consorzio Iveco Oto Melara (CIO), a consortium formed by IVECO and OTO Melara. The chassis and engine were produced by Iveco, while the turret and fire- ...
and Chinese Type 96/98 and Type 99 tanks use a modular composite armour, where sections of the composite armour can be easily and quickly switched out or upgraded with armour modules. The adoption of modular composite armour design facilitates far more efficient and easier upgrades and exchanges of the armour. Soviet/Russian main battle tanks such as
T-90 The T-90 is a third-generation Russian main battle tank. It uses a 125mm 2A46 smoothbore main gun, the 1A45T fire-control system, an upgraded engine, and gunner's thermal sight. Standard protective measures include a blend of steel and comp ...
s
T-80 The T-80 is a main battle tank (MBT) that was designed and manufactured in the former Soviet Union and manufactured in Russia. The T-80 is based on the T-64, while incorporating features from the later T-72. The chief designer of the T-80 was S ...
Us and the Chinese Type 96/99s use composite armour in tandem with
explosive reactive armour Reactive armour is a type of vehicle armour that reacts in some way to the impact of a weapon to reduce the damage done to the vehicle being protected. It is most effective in protecting against shaped charges and specially hardened kinetic ener ...
(ERA), making it hard for shaped charge munitions such as HEAT projectiles and missile warheads to penetrate the frontal and a portion of their side armour. The most advanced versions of these armours such as the Relikt and
Kontakt-5 Kontakt-5 is a type of second-generation explosive reactive armour (ERA) originating in the Soviet Union. It is the first type of ERA that is able to significantly decrease the penetration of armour-piercing fin-stabilized discarding sabot (APFS ...
armour provide protection not only against shaped charges but also
kinetic energy penetrator A kinetic energy penetrator (KEP), also known as long-rod penetrator (LRP), is a type of ammunition designed to penetrate vehicle armour using a flechette-like, high- sectional density projectile. Like a bullet or kinetic energy weapon, thi ...
s by using the explosive force to shear the projectile apart. Applique armour has also been used in conjunction with composite armour to provide increased amounts of protection and to supplant existing composite arrays on a vehicle. The German Leopard 2A5 featured distinctive arrowhead laminated armour modules that was mounted directly onto the turret composite arrays, increasing protection markedly above the previous 2A4 model. Composite armour has since been applied to smaller vehicles, right down to
jeep Jeep is an American automobile marque, now owned by multi-national corporation Stellantis. Jeep has been part of Chrysler since 1987, when Chrysler acquired the Jeep brand, along with remaining assets, from its previous owner American Motors ...
-sized automobiles. Many of these systems are applied as upgrades to existing armour, which makes them difficult to place around the entire vehicle. Nevertheless, they are often surprisingly effective; upgrades with
MEXAS The Modular Expandable Armor System (MEXAS) is a composite armour system developed by the German company IBD Deisenroth Engineering. MEXAS was introduced in 1994 and has been applied on over 20,000 combat vehicles worldwide. The successor of MEXAS ...
ceramic armour to Canadian M113s were carried out in the 1990s, after it was realized that it would offer more protection than newly built IFVs like the
M2 Bradley The M2 Bradley, or Bradley IFV, is an American infantry fighting vehicle that is a member of the Bradley Fighting Vehicle family. It is manufactured by BAE Systems Land & Armaments, which was formerly United Defense. The Bradley is designed ...
.


Improvised

In 2004, American
Marvin Heemeyer Marvin John Heemeyer (October 28, 1951 – June 4, 2004) was an American automobile muffler repair shop owner who, following a dispute with town officials, demolished numerous buildings with a modified bulldozer in Granby, Colorado, on June 4, ...
used an ''ad hoc'' composite armour on his Komatsu D355A
bulldozer A bulldozer or dozer (also called a crawler) is a large, motorized machine equipped with a metal blade to the front for pushing material: soil, sand, snow, rubble, or rock during construction work. It travels most commonly on continuous track ...
("Killdozer") used in a rampage in response to a dispute with the city he lived in over a zoning issue. The armour, at some places a foot thick, consisted of a layer of
concrete Concrete is a composite material composed of fine and coarse aggregate bonded together with a fluid cement (cement paste) that hardens (cures) over time. Concrete is the second-most-used substance in the world after water, and is the most wid ...
sandwiched between layers of
steel Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistan ...
, successfully rendering the vehicle impervious to
small arms A firearm is any type of gun designed to be readily carried and used by an individual. The term is legally defined further in different countries (see Legal definitions). The first firearms originated in 10th-century China, when bamboo tubes ...
fire and small explosives used by law enforcement in an attempt to stop the vehicle.


See also

*
AMAP AMAP is a multiple sequence alignment program based on sequence annealing. This approach consists of building up the multiple alignment one match at a time, thereby circumventing many of the problems of progressive alignment. The AMAP parameters ...
*
Chobham armour Chobham armour is the informal name of a composite armour developed in the 1960s at the British tank research centre on Chobham Common, Surrey. The name has since become the common generic term for composite ceramic vehicle armour. Other name ...
* Combination K *
Compound armour Compound armour was a type of armour used on warships in the 1880s, developed in response to the emergence of armor-piercing shells and the continual need for reliable protection with the increasing size in naval ordnance. Compound armour was a no ...
*
Kanchan armour The Kanchan Armour is the name informally given to a modular composite armour developed by India. The armour got its name from Kanchan Bagh, Hyderabad, Telangana, where the Defence Metallurgical Research Laboratory (DMRL) is located. Although the ...
*
MEXAS The Modular Expandable Armor System (MEXAS) is a composite armour system developed by the German company IBD Deisenroth Engineering. MEXAS was introduced in 1994 and has been applied on over 20,000 combat vehicles worldwide. The successor of MEXAS ...
* Plastic composite (disambiguation) *
Pykrete Pykrete is a frozen ice composite, originally made of approximately 14% sawdust or some other form of wood pulp (such as paper) and 86% ice by weight (6 to 1 by weight). During World War II, Geoffrey Pyke proposed it as a candidate material ...


References

{{DEFAULTSORT:Composite Armour Vehicle armour Armour, Composite