Non-Destructive Delamination and Crack Detection Solution for USMC Hard Armor Plates

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Sustainment The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: Develop a low cost, portable solution to detect cracks and delamination in Enhanced Small Arms Protective Insert (ESAPI) and Lightweight Plate (LWP) hard armor plate systems. DESCRIPTION: Currently the USMC fields two different body armor protective plate solutions. Both body armor plate systems are comprised of a polyethylene backer (made of several consolidated layers of polyethylene material) and a ceramic strikeface. The specific material makeup and the number of polyethylene layers provide the ballistic and fragmentation protective properties of the body armor plates. There are generally two primary defect modes that can take a plate out of service by significantly reducing its protection capabilities; cracking of the ceramic layer and or delamination within the polyethylene layers or between the polyethylene backer and ceramic interface. It is imperative to Marine safety to ensure the plates do not contain either defect before issuing the plate for use. Currently the USMC checks the hard armor plates on a regular basis before and after Marines use the plate in a combat or training environment. Cracking of the ceramic layer is detected using an x-ray machine while delamination is detected through a manual tap test. The tap test is performed by tapping the back face of the armor plate with a metal rod. If a plate is in good condition, the noise reflected off of the plate sounds like a chime, however a delaminated plate produces a thud sound. While the sound difference in the legacy USMC plate is audibly distinctly different between a delaminated and non-delaminated plate, the newest plate fielded by the USMC does not produce an easily identifiable sound difference between good and bad plate conditions. Another alternative to detecting both cracks and delamination is to CT scan the hard armor plates. This method is extremely expensive and requires highly trained personnel. For these reasons, the USMC seeks to fund an SBIR effort that produces a solution to regularly survey both legacy and new USMC hard armor for cracks and delamination defects. The desired prototype should represent a solution that is low cost and easy to operate such that any person without any special skills could be quickly trained. The solution should allow operators to perform plate surveillance at a throughput rate of 2-5 plates/minute. If possible, the solution should also be portable. In summary, the crack and delamination detection system should be easy to use and understand, and accurately identify whether a hard armor plate contains a crack or delamination defect. The solution will identify the type of defect and notify operators of the plate's status (cracked vs. delaminated). The solution will also inform the operator if the plate is without defects. The solution shall not be a technology that becomes affixed to a plate. PHASE I: Develop concepts for a non-destructive crack and delamination detection solution for USMC hard armor plates. Demonstrate and evaluate their technical feasibility. Generate a prototype to demonstrate accurate defect detection; 70-80% accurate with a plan to improve/optimize. PHASE II: Optimize the prototype for accuracy (90% accurate with a 90% confidence level) and to include an easy-to-use user interface based on USMC feedback and data collected on hard armor plates. Demonstrate the ability to replicate the solution for a total of at least 12 detection systems. PHASE III DUAL USE APPLICATIONS: Two systems would go to each of the six USMC gear issuing facilities across the world. Personnel at the issuing facilities who are responsible for monitoring hard armor before re-issuing the gear to Marines would use the products to test each hard armor plate for defects. Presently, law enforcement does not monitor hard armor plates in the same way the military does. Instead, law enforcement bases the serviceability of a plate based on its recommended shelf life. If a relatively low-cost solution was created to detect cracks and delamination, law enforcement including SWAT teams (or others that employ hard armor solutions) may be interested in re-evaluating their plate surveillance methods. REFERENCES: 1. Product Management Infantry Combat Equipment (PdM ICE). Marine Corps Tap and Torque Tests for ESAPI plates. Youtube, https://youtu.be/31dO_Xyj5ik 2. Testing of Body Armor Materials Phase III (2012) https://nap.nationalacademies.org/catalog/13390/testing-of-body-armor-materials-phase-iii KEYWORDS: Armor; body amor; delamination; ceramic; cracks; non-destructive; Enhanced Small Arms Protective Insert, ESAPI; materials; Lightweight Plate; LWP