Effect of core topology on projectile penetration in hybrid aluminum/alumina sandwich structures

A series of hybrid sandwich structures were fabricated by shrink-fitting precision-ground prisms of alumina (CoorsTek grade AD 995) with triangular, trapezoidal or rectangular cross-sections into the voids of extruded sandwich panels made from Al 6061-T6. The panels were subjected to impact tests using hard steel spheres over the velocity range 570–1800 m s−1. A combination of X-ray tomography, high-speed video imaging and cross sectioning of impacted samples was used to investigate the penetration mechanisms. We find that the ballistic performance of these structures, characterized by the ballistic limit and the exit velocity of impact ejecta beyond this limit, is significantly improved when triangular prisms are replaced by trapezoidal prisms, provided the base width of the prism exceeds about three times the projectile diameter. Additional performance improvements are obtained when the trapezoidal prisms are replaced by rectangular prisms, albeit at the expense of an increase in the lateral extent of damage. The variations in impact response are found to arise from: (i) the effect of prism size and shape on the degree of confinement of the ceramic by the metallic webs, (ii) the core web structure, which influences the fracture conoid angle in the transverse plane, and (iii) the spacing of web-face nodes on the back face, which governs the deflection and fracture of the back-face sheet.