Linking Theory to Practice: Predicting Ballistic Performance from Mechanical Properties of Aged Body Armor

It has long been a goal of the body armor testing community to establish an individualized, scientific-based protocol for predicting the ballistic performance end of life for fielded body armor. A major obstacle in achieving this goal is the test methods used to ascertain ballistic performance, which are destructive in nature and require large sample sizes. In this work, using both the Cunniff and Phoenix-Porwal models, we derived two separate but similar theoretical relationships between the observed degradation in mechanical properties of aged body armor and its decreased ballistic performance. We present two studies used to validate the derived functions. The first correlates the degradation in mechanical properties of fielded body armor to the degradation produced by a laboratory accelerated-aging protocol. The second examines the ballistic resistance and the extracted-yarn mechanical properties of new and laboratory-aged body armor made from poly(p-phenylene-2,6-benzobisoxazole), or PBO, and poly(p-phenylene terephthalamide), or PPTA. We present correlations found between the tensile strengths of yarns extracted from armor and the ballistic limit (V50) when significant degradation of the mechanical properties of the extracted yarns was observed. These studies provided the basis for a validation data set in which we compared the experimentally measured V50 ballistic limit results to the theoretically predicted V50 results. The theoretical estimates were generally shown to provide a conservative prediction of the ballistic performance of the armor. This approach is promising for the development of a tool for fielded armor performance surveillance relying upon mechanical testing of armor coupon samples.