66 · MT 11 /2016 The Security Compendium 5th Edition

Marty Kauchak and Brian Kindamo

Combining Lightweight and High Performance Materiel for Starters The armour protection sector is undergoing a rapid evolution. New materiel is expanding the technology baseline for protective products for personnel and weapons platforms. At the same time, business models are moving beyond exclusive suppliers and other traditional ways of doing business common in adjacent defence and security sectors.

Industry continues to respond to the military customers' expanding re­quirements to "lighten the load" and provide other attributes in new ar­mour protection equipment and systems.

In one instance, Marcio Manique, Global Business Director for Life Protection, at DSM Dyneema, matter-of-factly told MT in an interview: "We produce the strongest man-made fibre - that is DYNEEMA."

The industry expert placed DSM's armour solutions in the category of a "new wave" or generation of ballistic protection. As such, the company's, "non-compromised type of offering," is said to combine lightweight and high performance materiel, provide comfort and deliver other attributes to supply the customer with, "everything they need without doing as we did in the past."

Manique specifically called out DYNEEMA grade HB fibre-based com­posite laminate as one instance of riding the bow wave of new ballistic protection armour. Indeed, "DYNEEMA HB fibre is 15 times stronger than steel but still has a wide-range of other properties [into which] we are delv­ing more and more," he emphasised.

Asked which customer demand is prevailing in this sector, the official responded: "They want a lighter version of the product."

Similarly, Cheryl lngstad, Business Manager for Advanced Ceramics Platform - Defense at 3M, told MT: "We have seen a strong demand both in the US and internationally for lighter-weight armour systems, and that 's where our efforts are concentrated today. We are utilising every aspect of our operations - from our proprietary material technology and R&D resources to our people and processes - to deliver lightweight systems that reduce the strain on troops while delivering the required level of protection."

lngstad spoke from the authority of Ceradyne, a 3M company, fielding more than two million body armour inserts and more than 100,000 en­hanced combat helmets (ECH) with the US Armed Forces to date.

Beyond weight, the ECH, "provides greater ballistic and fragmentation protection than any fielded helmet in history, " declared lngstad. "The ECH improves ballistic fragmentation protection by over 35% compared to other currently fielded helmets, while maintaining an equivalent weight. "

The helmet was first fielded to US military forces in 2014.

In another part of the Ceradyne personal protection portfolio, the com­pany's lightweight enhanced small arms protective inserts (ESAPI) pro­vide torso protection against small-arms fire. The inserts are available in multiple sizes and worn inside service men and -womens' tactical vests. "We supply the body armour inserts to the US Defense Logistics Agency, which then manages orders with each individual service," the community expert noted.

One data point on the state-of-the-art in armour inserts can be gained from these ESAPls which vary in weight. The current US DoD contract calls for extra-small, small and medium inserts, which range in weight from less than 2kg (4.41bs) to almost 2.5 kilogrammes. Ceradyne also offers large and extra-large body armour inserts, which weigh slightly more.

Ceradyne began deliveries of the body armour inserts this June, one month ahead of schedule. The company is scheduled to complete deliveries under this order in fourth quarter 2017.

Protecting Vehicles and Their Crews MT offered RUAG Defence its assessment on the challenges of pro­

tective armour in the vehicle sector as being between cost-effective and light armour solutions (to permit off-road transit, air lift, etc.) and protec­ting crews and vehicles against increasing ly dynamic and lethal threats. RUAG Defence's spokesperson responded: "Specific requirements obvi­ously differ from scenario to scenario but you are always trying to find this perfect balance between protection capability and mobility. You are right that threats are dynamic, but so are we constantly looking for new ideas in either materials or design."

Indeed, the spokesperson then pointed to a blurring of lines between contemporary threat scenarios and the challenges they present to pro­tective armour suppliers. ''Threat scenarios are not as clear as they used to be. A distinction between symmetrical and asymmetrical warfare is no longer possible. Hybrid solutions capable of covering a much wider range of threat as previously expected are required."

For its part, RUAG's protection kits are mounted on vehicles from light 4x4 vehicles up to MBTs, such as the LEOPARD 2 - and the company's portfolio in this sector continues to expand.

He further noted: "We are delivering the mine protection shield amongst other protection components for the German PUMA IFV. RUAG has taken on the complete mine, /ED and KE [kinetic energy] protection upgrade for the Austrian and Belgian PANDUR I vehicles. Production and deliveries of our Roof PRO ballistic kits for a major vehicle original equipment manufac­turer are ongoing."

The Security Compendium 5th Edition MT 11 /2016 · 67

Ammid fibres are man-made high-performance fibres, with molecules that are characterised by relatively rigid polymer chains. These molecules are linked by strong hydrogen bonds that transfer mechanical stress very efficiently, making it possible to use chains of relatively low 111olec11lar weight. Tejin are always looking at new ways to optimise its offering and to adrl value to the products of its customers, having developed a range of am mid brands, each with its own properties and format possibilities, in order to help customers meet their different requirements: From Twaron to Tee/mom, and from Teijinconex to Sulfron.

Another concurrent, competing set of requirements in the vehicle pro­tective armour sector was pointed out by Margaret Cosentino, Senior Vice President for Business Development at Alcoa Defense. According to her, after a significant focus on up-armouring for operations in Iraq and Afghanistan, there is now a pivot back towards speed, mobility and ma­noeuvrability as a means of survivability: "For example, special operations are fielding ultralight weight vehicles for brigade combat teams. Alcoa is working with the US Army R&D community on its new Mobile Protected Firepower programme to help inform material and technology selection for a protected, long-range, precision direct-fire capability. "

Alcoa Defense's portfolio spans the life cycle of defence vehicles and includes products for legacy and new fleets. Indeed, Alcoa's multi-material products, including extrusions, forgings, castings, fastening systems and a full range of rolled products, are on the tactical wheeled vehicle and ground combat vehicle fleets, from aluminium up-armouring in the HMWWV fleet-in response to IEOs-to applications on HEMTis (helping logistical support), to aluminium components for new platforms like the JLlV.

"Alcoa Defense is first, a multi-material company, with our business evenly split between aluminium-, titanium- and nickel-based applications, allowing us to work with the military and OEMs [original equipment manu­facturers] alike to get the right material, alloy and temper to meet specific mission requirements," explained Cosentino. "Second, we are focused on full vertical integration -material to product form to machining and subas­sembly. Making Alcoa more efficient helps our customers be more efficient - and competitive."

Another supplier of protection equipment in the military vehicle mar­ket place is OinetiO North America (ONA). The company's LAST Armor Spall Liners have been fielded on numerous US-variants of MRAP vehicles and the firm's BlastRide energy attenuating seats are· in service on inter­national IFVs and APCs. Jeff Rioux, Business Development Manager for Survivability at the company noted: "Additionally our Q-NET passive RPG defeat solutions are installed on over 13,000 vehicles worldwide provi­ding protection to vehicles such as the MAXXPRO, M-ATV, HEMMT, and STRYKER as well as international platforms. The Q-NET has potential to be fielded on select variants of the US Army/USMC JLN."

ONA also provides personal protection solutions for rotary and fixed wing platforms Rioux also shared some of his company's "secret sauce" for taking its customers' requirements for cost, weight, and performance into account in order to provide them with the best solution for their needs. "We achieve this by working with a variety of high performance materi­als including RHA {rolled homogeneous armour] steel, various grades of advanced ceramics and the latest in high performance ballistic fibres. We also work diligently to engineer new and innovative solutions such as our energy attenuating seats and our BlastPro ·vehicle blast mitigation technology."

<l RUAG's protection kits are mounted on vehicles from Jig/it 4x4 vehicles up to MBTs such as the LEOPARD 2. Tile Digital LEOPARD 2A4 has fi 1/I roof-, side-, and mine protection kits. (Photo: RUAG)

Sector Business Models One common theme emerging in discussions with experts in the protec­

tive armour sector include agreements to gain best-of breed suppliers and other partners - multiple entities in some cases - beyond exclusive part­nering agreements commonly found in other defence market segments.

In one instance DSM's Manique attributed his company's ability to be innovative and optimise new technology offerings in its business network and internal R&D investments.

While DSM has preferred partners In the defence and adjacent securi­ty sectors, some of these partners have stronger links to the company a result of their ability to innovate. "If we have a partner who has the ability to bring innovation faster than anyone else, [that is beneficial because] there are articles and end-products beyond our materiel. That is why we need to work with partners who in some way can match our speed in innovation," Manique emphasised.

DSM Dyneema's most recent business partnerships have included First Armour, an affiliate of the KADDB Investment Group. This June, First Armour unveiled a lightweight insert panel, to be ~orn in combination with a protective vest. First Armour's new insert is made with Dyneema grade HB212, a ultra-high molecular weight polyethylene fibre-based composite laminate for low weight, hard armour applications that are created using DYNEEMA Force Multiplier Technology.

3M Cemdyne's lightweight enhanced small arms protective inserts provide torso protection against small-arms fi re. Cemdyne began deliveries of the body armour inserts this June, one month ahead of schedule. The company is scheduled to complete deliveries under this order in fourth q11arter 2017. (Photo: 3M/Ceradyne)

Marty Kauchak is a retired US Navy Captain, a defence writer, and a regular con­tributor to MT. Brian Kindamo is a senior defence reporter and a regular contributor to MT.

The Security Cotnpendium 5th Edition MT 11/201 6 · 69

First Armour will soon start offering various types of other body armour based on different high-performance grades of DYNEEMA.

This January, another DSM partner, Point Blank Enterprises, introduced its ALPHA ELITE Black, a product extension of the ALPHA ELITE Series. "The latest ALPHA ELITE Black ballistics model is an enhancement to the previous design, offering an additional 17% weight reduction while still providing the same high level of protection, 11 a company press release stated. ALPHA ELITE Black uses the latest generation of DYNEEMA Force Multiplier Technology by DSM.

RUAG also casts its collaboration net far across this sector. RUAG's spokesperson explained the company, "regularly scans the market for new developments and materials; and we pride ourselves on the quality of the tests and trials we perform to accurately define their protection capa­bilities. This enables RUAG to tailor protection solutions to any individual vehicle and threat at an optimised weight and cost. 11

QNA's Rioux further pointed out: "We have developed strong relation­ships with some of leading manufacturers of advanced ceramics, ballistic impact metals and composite fibres. Leveraging these relationships allows us to develop and deliver products that outperform the competition."

DuPont is another supplier which has hit a "sweet spot" for providing a materiel used in different applications. In this instance, its Kevlar technolo­gy is used in diverse applications - different ballistic vests, plates, helmets, extremity protection, and vehicle armouring applications to increase the survivability of military personnel - providing soft- and hard armour protec­tion - common terms in this sector. "Soft armour refers to vests and other apparel items that are frequently made of woven fabrics, and other flexible structures for improved fit, comfort and mobility for the wearers, 11 Joseph Hovanec, Global Technology Manager for DuPont Protection Solutions, explained. "Hard armour refers to more rigid composite structures such as plates, helmets and vehicle armour where in addition to Kevlar, DuPont a/so provides Tensy/on polyethylene sheet structures for use in these applications."

Hovanec then provided insights on one aspect of DuPont's business model, noting the company supplies Kevlar fibres, fabrics and other struc­tures to leading vest, helmet and armoured vehicle manufacturers who use these materials in the design and manufacturing of their products. The community expert added: "We focus on localised solution development with leading manufacturers working through our four global technical cen­tres around the world. 11

While QNA and other businesses mentioned earlier deliver products to different end users, another company serving multiple markets is Combat Clothing Australia (CCA) Protect. The firm is a global provider to defence and security with proven experience in the design and manufacture of bal­listic protection for people, vehicles and aircraft. Lee O'Shea, Business Development Manager at the company, pointed out "CCA Protect serves markets in Australia, United States, Hong Kong, Malaysia, Singapore, UAE, New Zealand and Papua New Guinea."

Specifically, CCA Protect provides hard and soft body armour up to threat level IV multi-strike and special threat vehicle armour capable of withstanding anti-tank rounds. O'Shea continued: "CCA Protect's ad­vanced armour solutions were selected to provide the Australian Defence Force with ballistic protection for the UH-60 BLACKHAWK and CH-47 CHINOOK helicopters. CCA Protect's manufacturing facilities allow it to create large, single armour panels which make it the ideal choice to supply armour for the Australian Defence Force Land 400 Phase 2 project. " This project will provide a modernised mounted combat reconnaissance capability.

I

I J

<l QinetiQ North America's LAST Armor's interior spall liners offer increased protection for behind armour effects. (Photo: QinetiQ North America)

CCA Protect's calculus for meeting its international customers' require­ments includes analyses to achieve the optimal balance between cost, mobility, protection and weight. O'Shea concluded, "The rapidly chang ing battlespace is constantly driving innovation in the ballistic protection in­dustry. CCA Protect's state of the art facilities and engineers meet this challenge through combining the advanced composites and unique bonding methods to create the armour that is ultralight, strong and thin."

Garant develops state-of-the-art ballistic protection solutions for differ­ent types of applications. Along with the implementation of latest materials resulting from intensive R&D activities, Garant also benefits from its expe­rience gained through long-term developing programmes with both mate­rial suppliers and end-users. Materiel used are para-aramid, polyethylene, polypropylene, and fibre glass.

Other Recent and Near-Future Developments

Alcoa is building upon its heritage as a partner and supplier to the mili­tary for nearly a century - with products supporting weapons platforms in the air, land and sea domains - to further focus on innovation.

To start, Cosentino noted a single piece structure with the strength of a forged product, and the flexibility to place more metal in critical areas and less in non-critical areas, is a powerful design idea - and one that is achievable today thanks to Alcoa innovation. Alcoa, working with the US Army and DARPA, brought this concept to fruition by pioneering an approach to manufacture the world's biggest single-piece forged alumin­ium hull for combat vehicles - the largest closed die forging reported­ly ever made. Cosentino placed this achievement in perspective. "This game-changing forging replaces the lower hull of a combat vehicle - a single piece is stronger than traditional welded hulls - making it safer. But the Alcoa process a/so reduces vehicle weight and assembly time - and cost. If a design requires more protection (i.e. more metalj in certain are­as, a forging can meet that need. Another benefit of forging is our ability to tailor the design process to make a more near net shape and reduce machining costs. 11

Alcoa is collaborating with the military on material and manufacturing innovations aimed at yet further enhancing best-in-class protection for combat and tactical vehicles. "We recently [this March] signed a five-year contract with the US Army worth up to US$50 million to drive collaboration on aluminium survivability solutions, 11 Cosentino emphasised. "We have worked closely with the US military to co-develop a monolithically forged lower hull for combat vehicles. By eliminating welds, we can significantly improve survivability against JED and other threats. Through parts consol­idation and supply chain efficiency, we drive at a more affordable solution. We believe that combining state-of-the-art passive armour solutions like monohul/ with enhanced active protection systems under evaluation will provide the best possible survivability package for our ground vehicles."

Back in the personal protection sub sector, Ceradyne is undergoing latter stages of qualification testing for the Vital Torso Protection (VTP) portion of the US Army's Soldier Protection System (SPS) programme. VTP will help

<l Australia-based CCA Protect is a global provider to defence and security with proven experience in the design and manufacture of ballistic protection for people, vehicles and aircra~. The company's calculus for meeting its international customers' requirements includes analyses to achieve the optimal balance between cost, mobility, protection, and weight. (Photo: CCA Protect/Australian DoD)

70· MT 11 /2016 The Security Compendium 5th Edition

the Army meet its goal of reducing body armour insert weight, while still achieving the required levels of protection. lngstad added, "We are also currently in the development phase of the SPS programme's Integrated Head Protection System, which will be a next-generation helmet for the Army. 3M's expertise in building comfortable, unified protection solutions for the commercial segment across our family of businesses will help us meet the needs of these programmes."

In the adjacent security sector, Ceradyne will be delivering its 3M Ultralight Weight Ballistic Bump Helmet N49 (ULW-BBH N49) to US law enforcement agencies. "This helmet is also well-suited for global special forces. It uses a proprietary, bolt/ess, retention-system design, and has a finished shell weight of only 575 grams (1.271bs)," lngstad concluded.

Innovation is also a priority at DuPont, which according to Hovanec con­tinuously leverages its science and applications expertise to explore and develop new advanced materials. "Recently we introduced several new materials for hard and soft armour including Kevlar unidirectional, multiaxial and anti-stab offerings as well as additional Tensylon products," he added. Beyond new personal protective equipment, QNA's Rioux was asked for his near-term assessment of how the sector will respond to the services' requirements for keeping their vehicles and crews safe in harm's way. He responded: "At ONA we continue to push the envelope on achieving better multi-hit performance of our advanced composite solutions in combination with system weight reductions and will be working with our customers to field these solutions. We are also working to bring new advancements for both passive and active RPG defeat to market."

Rioux further offered the this higher-level forecast: "We see the con­tinued threat of blast and IEDs to drive the requirements for lightweight mitigation solutions which can either be incorporated into the design of the vehicle or used as an applique. Our high performance spa/I liners as well as energy attenuating seats and vehicle underbelly blast mitigation will provide vehicle manufacturers with cost effective solutions to provide the highest level of protection to the warfighter."

DuPont's Hovanec sees growth and continued evolution in this sector: "Given the increasingly asymmetric threats around the world for military and law enforcement, we see more and more agencies asking for pro­tection from multiple threats - ballistic as well as non-ballistic. We also expect an increasing trend toward 'mandatory wear' which means body armor comfort, fit and flexibility could be a key requirement in the next two-to-three years."

Armoured Vehicle Protection Global military expenditure on armoured vehicles and personal protec­

tion equipment is estimated to lie somewhere between U$20-25 million per annum.

On 9 August 2016, Permali Gloucester announced it would be providing composite armour solutions for the UK MoD's AJAX. combat vehicle, in a £15 million contract from General Dynamics European Land Systems (GDELS).

Asked which customer demand is prevailing in this sect01; Marcio Manique, Global Business Director for Life Protection, DSM Dyneema, responded: "They want a lighter version of the product." (Photo: DSM)

DuPont Kevlar is another technology used in

different applications - different ballistic e ts, plates, helmets, extremity protection and vehicle

armouring applications to increase the survivability of military personnel -providing so~- and hard armom protection -

common terms in this sector. (Photo: DuPont)

According to Permali sources, composite materials will provide a critical element in the ballistic protection measures of the vehicle, 589 of which have been ordered by the MoD as a medium armoured fighting and recon-naissance platform. ·

Specialising in lightweight passive ballistic and blast resistant light­weight armour panels, tested up to STANAG 4569 and AEP-55, Permali's armour solutions are manufactured using glass, aramid or ultra high molecular weight polyethylene (UHMWPE) materials as well as thermoset resin and advanced thermoplastic technologies.

"These can also incorporate ceramic tiles, for protection against ar­mour piercing rounds, and aluminium or steel skins for greater rigidity or increased protection levels. Panels can be supplied as applique upgrades or designed for integration into new build platforms, working closely with users and vehicle manufacturers to design optimise the armour solution for improved protection and reduced weight," a company spokesperson explained.

Solutions also feature a Tufshield Polyurethane coating providing en­vironmental protection against the elements with Permali armour sys­tems already equipping a variety of MoD platforms including the CVRT, WARTHOG and VIKING tracked vehicles; as well as Oshkosh Heavy Equipment Transports and Wheeled Tankers. Additionally, company has provided armour solutions to Supacat's HMT EXTENDA Vehicle, an open­top SOF type vehicle which similar to other vehicle types, requires the minimum level of top cover protection in order to allow soldiers maximum situation awareness (SA) while conduct surveillance/reconnaissance mis­sions as wel l as direct action taskings. Composite ballistic armour panels will be supplied to Supacat in 2017 and 2018, company officials explained.

The UK MoD's Defence Equipment and Support Organisation's Director of Land Equipment, Maj.Gen: Robert Talbot Rice, explained: "The AJAX vehicle is at the heart of the UK's new Strike Brigades, giving our Armed Forces the ability to respond rapidly and effectively across a huge vari­ety of terrains [with] world class protection for the British Army's fleet of next-generation fighting vehicles."

Explaining how the company now works in a much more integrated pat­tern with OEMs at the earliest stages of vehicle design and development, Permali described how ceramic composite armour offered much greater levels of protection compared to metallic armour solutions, especially in terms of providing protective solutions against a variety of threats ranging from small arms fire (SAF) and heavy machine gun rounds up to medium cannon rounds, and IEDs - the latter of which scourged coalition forces operating in Afghanistan and Iraq over the past decade or so of operations.

"On each of these programmes, we worked alongside the vehicle prime, the authority and the end user to deliver bespoke solutions that met chal­lenging technical and project requirements," he said.

The UI< MoD's Armour Programmes Another major UK MoD initiative is the upgrade programme of its

CHALLENGER II MBT fleet with Lockheed Martin revealing it had joined forces with Elbit Systems on 10 August 2016 to bid for the contract. The total programme, worth more than £600 million, will see the upgrade of up to 227 MBTs with competition expected to be coming from BAE Systems and General Dynamics, Rheinmetall, RUAG, Krauss-Maffei Wegman (KMW), and CMI Defence/Ricardo.