The Effect of Material Arrangement Order on Ballistic Resistance of Ceramic Composite Armor Structure

This study investigates the ballistic performance and energy-absorption behavior of advanced multilayer ceramic composite armor systems composed of silicon carbide (SiC) ceramics, composite metal foam (CMF), rolled homogeneous armor (RHA), ultra-high-molecular-weight polyethylene (UHMWPE), aluminum, and rubber interlayers. The objective is to enhance impact resistance and optimize energy dissipation efficiency against armor-piercing (AP) projectiles. Ballistic tests were performed following the NIJ Standard 0101.06 Level IV specifications using .30” caliber AP M2 rounds with an impact velocity of 784–844 m/s. Experimental results revealed that the SiC front layer effectively fragmented the projectile and dispersed its kinetic energy, while the CMF and UHMWPE layers were the primary energy absorbers, dissipating approximately 70% of the total impact energy (≈3660 J). The aluminum and RHA layers provided additional reinforcement, and the rubber interlayer significantly reduced stress-wave propagation and suppressed crack growth in the ceramic. The most efficient configuration 0.5 mm RHA + 7 mm SiC + 7 mm EPDM + 7 mm CMF + 5 mm UHMWPE achieved an areal density absorption of 77.2 J·m2/kg and a unit thickness absorption of 190.6 J/mm. These findings establish a quantitative layer-wise energy dissipation framework, highlighting the synergistic interaction between brittle, porous, and ductile layers. This work provides practical design principles for developing lightweight, high-efficiency composite armor systems applicable to defense, aerospace, and personal protection fields. Moreover, this study not only validates the NIJ Standard 0101.06 ballistic performance experimentally but also establishes a reproducible methodology for quantitative, layer-wise energy analysis of hybrid ceramic-CMF-fiber armor systems, offering a scientific framework for future model calibration and optimization.