end-user marketing geosynthetics / advanced composites - TenCate

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Safety / Protection TENCATE ADVANCED ARMOUR PRESENTS 3D MOULDING PROCESS Lighter and improved In mid-September TenCate Advanced Armour will present an advanced technology for three-dimensional moulding of armour solutions based on TenCate Liba ® . Hinged steel components for armoured vehicles can thus be replaced by parts consisting entirely of composite material. This will ultimately lead to the production of lighter and better protected vehicles. Traditionally, armoured vehicles consist of steel or aluminium armour, and composite material is used for the add-on armour layer and the vehicle’s spall-liners. A spall-liner is a soft material that is fitted into the cabin to protect the crew against shrapnel (spall) upon impact. This new technology will enable the key components of armoured vehicles that were originally made of steel, such as hatches, doors, panels and bulkheads, to be replaced by components consisting entirely of composite. This means improved protection for less weight. Impediments During the development of the technology a number of impediments were overcome. The new materials were for example required to have the same stiffness as steel. To achieve this, the fibres have to be meticulously fitted in the right direction. The design may not display a single ballistic weakness. This required finding the right weaving architecture and ensuring that no cuts are made. Typically, a 3D shape needs to be constructed of a complex ‘mesh’ of pieces of material. Each one of these cuts reduces performance and adds weight to the solution, as extra reinforcement has to be added. For the new technology it was decided to use 3D TenCate Liba ® ceramic and a no-cut aramid backing. ‘No other ceramic system is capable of being formed into a 3D shape’, explains Paul Bourke (research, technical & development director, TenCate Advanced 38 txtures | number 3 | autumn 2011 Armour). ‘Its sophisticated nature lies not only in the ceramic systems but also in the backing, which has been formed in a single piece. This is an exceptionally difficult task.’ Practical tests The design and testing of the structural armouring were supervised by the project team, headed by lead engineers Dylan Cawthorne and Maxime Dartois from TenCate Advanced Armour. During the mechanical design stage the TenCate Advanced Armour R&D team had to tackle aspects such as structural analysis, the shape of the insert, fitting, testing and environmental characteristics. The ballistic solution was then subjected to a number of
protection practical tests. Paul Bourke expects these to show that only minor adjustments will prove necessary to ensure that the systems are fully ready for use. ‘Thorough and ongoing research has been conducted and exhaustively tested. There was also close cooperation with the vehicle manufacturer, which formed the basis of the project.’ Matrix TenCate Liba ® is a patented lightweight protection solution based on ceramic pellets in a matrix of elastic polymer. From this mater ial the inserts are made. TenCate Liba ® has excellent characteristics as regards flexibility and multi-hit capability. The latter ensures a high degree of protection if the vehicle is hit by MARKET – antiballistics (personal and vehicle protection) PRODUCT – TenCate Liba ® TECHNOLOGY – ceramic and polymer technology PROCESS – inserts are fitted into bulletproof vests and vehicle armouring. various projectiles or shrapnel. For this reason TenCate Liba ® was the obvious choice for the project. Moreover, TenCate Liba ® makes a flexible and cost-effective production process possible. As a result of this development in armour technology the vehicle manufacturer can achieve considerable savings on the overall weight of the vehicle. All in all, a major step can thus be taken to reduce the costs of the product life cycle and increase the service life of the vehicle. Presentation The 3D technology will be presented at the Defence Security and Equipment International Exhibition (DSEi) in London in September. This is the ideal venue for the presentation of such a development in structural armouring. The exhibition is visited by large numbers of vehicle manufacturers, military officials and representatives of defence forces. They will all benefit from the advantages that the technology offers. ‘Ultimately, this will make it possible to replace a number of heavy steel vehicle parts with lighter and stronger solutions consisting entirely of composite’, says Paul Bourke. ‘It will lead to lighter and better protected vehicles.’ www.tencateadvancedarmour.com advancedarmour.europe@tencate.com 39
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