The need for rapid advances in the effectiveness and affordability of lightweight protection materials and systems is compelling and will continue for the foreseeable future. The experience with body armor and vehicle armor in Iraq and Afghanistan has shown that the weight penalty of today’s materials exacts a significant toll on U.S. forces, both in human terms and in increased costs for equipment, maintenance, and fuel. Escalating threats have greatly accentuated the need for continued rapid development of lightweight armor.
The ideal situation is to have new materials available to meet these challenges. However, while new materials are the subject of research efforts, their introduction into military systems is very slow. As shown in Chapter 1 (Figure 1-3), the advances indicated by the areal density plot of lightweight protection materials have slowed in recent years. The inability to rapidly transition materials with the properties and behavior needed for armor systems is due not to a lack of excellent materials research, but rather to the approach by which protection materials research is accomplished.
As described in Chapter 2 (see also Figure 6-1), armor

FIGURE 6-1 Current paradigm for armor design. As mentioned in Chapter 2, a shoot-and-look approach is much more prevalent than a modeling approach.

FIGURE 6-2 New paradigm for armor development. The new design path for armor provides enhanced and closer coupling of the materials research and development community and the modeling and simulation community, resulting in significantly reduced time for development of new armor. This path connects the armor design process to the materials research and development community through canonical models to deal with the restricted information problem. The elements of armor system design are not themselves new, but the emphasis shifts from design-make-shoot-redesign to rapid simulation iterations, and from designing with off-the-shelf-materials to designing that explores materials for their protective properties. The feedback loop between armor system design and material design contrasts with current practice, in which a one-way flow puts new materials on the shelf to be tried in the make-shoot-look process.
systems in operational use today are the product of years of heuristic-based advances. Development of the protection materials used in these systems is coupled only loosely to armor system design, with the coupling taking the form of inferred desired properties. The current paradigm of material and system development can be characterized as a design-make-test-redesign-repeat … iterative loop. The time and expense involved in such an approach limit the number of optimization iterations and slow the advance of new material systems that could provide the needed protection with reduced areal density.
The current paradigm and the research programs and organizations that support it are not sufficient to accelerate advances in lightweight protection materials. New research initiatives, organizational structures, and implementation approaches will be needed to increase the rate of progress.
The committee concludes that the ability to design and optimize protection material systems can be accelerated and made more cost effective by operating in a new paradigm for lightweight protection material development (Figure 6-2). In this new paradigm, the current armor system design practice is replaced by rapid iterations of modeling and simulation, with ballistic evaluation used selectively to verify satisfactory designs. Strong coupling with the materials research and development community is accomplished through canonical models that translate armor system requirements (which are often classified) into characterizations, microstructures, behaviors, and deformation mechanisms that an open research community can use. The principal objective of this new paradigm is to enable the design of superior materials and to accelerate their implementation in armor systems. The new paradigm will build on the multidisciplinary collaboration concepts and lessons from other applications documented in Integrated Computational Materials Engineering (ICME),1 which cites many advances and several examples of successful implementation. It advocates pushing the large body
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1NRC. 2008. Integrated Computational Systems Engineering: A Transformational Discipline for Improved Competitiveness and National Security. Washington, D.C.: The National Academies Press.
of existing computational materials science to the next step. Unfortunately, while the optimization of the materials, manufacturing processes, and component design is well described in the ICME report, the path forward for protection materials is far more complicated, since designs must deal with highly nonlinear and large deformations typically not encountered in commercial products, where applied stresses are kept well below the elastic limit in the linear regime.
The new paradigm can be focused on the most promising opportunities in lightweight protection materials, bringing such current products as ceramic plates and polymer fiber materials well beyond their present state of performance and opening the possibility for radically new armor system solutions to be explored and optimized in tens of months rather than tens of years.
The added features (indicated in red in Figure 6-2) of the new paradigm compared to the current paradigm are these:
Successful implementation of the new paradigm can, by dint of the insights gained from modeling and simulation, give armor system designers the freedom to work with novel as well as established materials to meet performance requirements. It can identify more rapidly than in the past how newly envisioned and to-be-developed materials and systems could create new opportunities for the protection afforded personnel, vehicles, ships, aircraft, and structures at lower weight and cost. The new approach would enable the reliable identification of materials that could be advantageous in protection applications, establish their merits and limitations, drive research and development to exploit the protective capacity of the new materials and systems, and, most importantly, bring about their rapid insertion into the field.
To realize the vision of this new paradigm and achieve these benefits, advances are needed on multiple fronts, including these:
RECOMMENDATIONS FOR PROTECTION MATERIALS BY DESIGN
The recommendations in this section point out a way forward that will address the challenges outlined above by bringing together the efforts of university researchers, government labs, and industry to engage collaboratively in a long-term program of use-inspired fundamental research.
Overarching Recommendation. Given the long-term importance of lightweight protection materials to the Department of Defense (DoD) mission, DoD should establish a defense initiative for protection materials by design (PMD), with associated funding lines for basic and applied research. Responsibility for this new initiative should be assigned to one of the Services, with participation by other DoD components whose missions also require advances in protection materials. The PMD initiative should include a combination of computational, experimental, and materials testing, characterization, and processing research conducted by government, industry, and academia. The program director of the initiative should be given the authority and resources to collaborate with the national laboratories and other institutions in the use of unique facilities and capabilities and to invest in DoD infrastructure where needed.
This overarching recommendation requires actions in four important elements of the PMD initiative:
The first element of the PMD initiative would be to develop better fundamental understanding of the mechanisms of high-rate2 material deformation and failure in various protection materials, discussed in Chapter 3. As part of the new paradigm, armor development should be considered not from the viewpoint of conventional bulk material properties but from the viewpoint of mechanisms. The deeper fundamental understanding could lead to the development of more failure-resistant material compositions, crystal structures, and microstructures and to protective materials with better performance. Moreover, by identifying the operative mechanisms and quantifying their activity, mathematical damage models can be written that may allow computational armor design. Chapter 3 discusses failure mechanisms for the several classes of materials.
Recommendation 6-1. The Department of Defense should establish a program of sustained investment in basic and applied research that would facilitate a fundamental understanding of the mechanisms of deformation and failure due to ballistic and blast events. This program should be established under a director for protection materials by design, with particular emphasis on the following:
Element 2—Advanced Computational and Experimental Methods
The second element of the PMD initiative would be to advance and exploit the capabilities of the emerging computational and experimental methods discussed in Chapter 4. The first objective is to predict the ballistic and blast performance of candidate materials and materials systems as a prelude to the armor design process. The second objective is to define requirements that will guide the synthesis, processing, fabrication, and evaluation of protection materials. The PMD initiative would develop the next generation of
The high-priority opportunities identified in Chapter 4 will need sustained investment and program direction to advance computational and experimental capabilities. The envisioned computational capabilities must be devel-
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2Ballistic velocities typically range from several hundred to several thousand meters per second and can lead to strain rates of up to 105 s–1.
oped in partnership with a strong experimental effort that identifies the dynamic mechanisms of material behavior. These mechanisms must be understood and modeled for the activity to be successful, the material characteristics and properties must be known for the simulations to be carried out, and the outcomes of the computational modeling must be validated.
Recommendation 6-2. The Department of Defense should establish a program of sustained investment in basic and applied research in advanced computational and experimental methods under the director of the protection materials by design (PMD) initiative, with particular emphasis on the following:
Element 3—Development of New Materials and Material Systems
The third element of the PMD initiative is the development and production of new materials and material systems whose characteristics and performance can achieve the behavior validated in modeling and simulation of the new armor system. The recommendations in this element target the most promising opportunities identified in Chapter 5.
Recommendation 6-3. The Department of Defense should establish a program of sustained investment in basic and applied research in advanced materials and processing, under the director of the PMD initiative program, with particular emphasis on the following:
Element 4—Organizational Approach
The fourth element of the PMD initiative is an organizational construct for multidisciplinary collaboration among academic researchers, government laboratories, and industry, in both restricted-access and open settings. The PMD initiative will need strong top-level leadership with insight into both the open and restricted research environments and the authority to direct funding and set PMD priorities. The program will require committed funding to ensure long-term success and should be subject to periodic external reviews to ensure that high standards of achievement are established and maintained. To meet these requirements, the committee considered several organizational alternatives, described in the sections below, and concluded that the notional DoD organizational approach depicted in Figure 6-3 includes the features necessary for success.
Recommendation 6-4. In order to make the major advances needed for the development of protection materials, the Department of Defense should appoint a PMD program director, with authority and resources to accomplish the following:

CRITICAL SUCCESS FACTORS FOR THE RECOMMENDED NEW ORGANIZATIONS
DoD Center for the PMD Initiative
The essential features of the recommended organization are as follows:
The proposed research and development program would require the collaboration of scientists and engineers from DoD research laboratories, other national laboratories, universities, independent research institutes, and commercial companies in settings that can foster collaboration while maintaining boundaries for unclassified, proprietary, export controlled, and classified information.
Given the constraints of current classification guidelines, research and development involving specific threats and vulnerabilities will require access to a facility where restricted research and testing—that is, research that is either classified or otherwise not available for public release—can be conducted. The committee believes designation of an existing DoD organization as the lead laboratory for the PMD initiative would be the best way to meet this need. This open collaboration center would need to have capabilities for the following:
Such capabilities exist at the Army Research Laboratory facility in Aberdeen, Maryland, and at other DoD facilities.
To tap the sources of innovation in academia and industry, an environment for collaboration outside restricted governmental facilities would be needed. This open research community would have the following capabilities:
The key to success would be to link these two research environments through formal organizational relationships, personnel exchanges, funding and program direction, and processes to translate classified information on threats and materials into canonical models suitable for academic research topics. Procedures would be needed to adapt data from the classified center for use by the open environment.
Of the organizational elements, the newest and most far-reaching area for investment would be the open PMD collaboration center. This center would be a vibrant intellectual engine that attracts the best academic researchers across multiple organizations to address well-defined problems in material design, high-strain-rate experimentation, analytical and computational modeling across the length and timescales, and materials processing for protection applications. It could foster precompetitive collaboration with industry for both fundamental research and technology transfer.
The key features of the open center would include these:
The committee considered several organizational alternatives that might have the desired attributes of this new entity, including the following:
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3For more information, see http://www.wpafb.af.mil/library/factsheets/factsheet.asp?id=9327.
4For more information, see http://www.hawaii.edu/uhmfs/uarc/Attach_003.UARCMgmt.pdf.
needs for technology. The CTA model has most of the desired characteristics but has traditionally been used when technology advances are driven more by market forces than by government needs, which is not the case in protection materials.5
The committee concluded that none of these models would meet all the needs of an open PMD collaboration center but that the various university and industry consortium models have proven features that the Army could combine to define the contract for such a center.
Time Frame for Anticipated Advances
While it is always problematic to try to predict the future, it is apparent that some areas are ripe for rapid progress and discovery. The committee believes, for example, that increased funding of basic research on high-rate deformation of polymer fibers and ceramics could, within about 10 years (depending on the level of effort), achieve a level of understanding that would rival the current understanding of metals. Progress will be aided as national lab facilities for extremely fast data acquisition during high-rate events become available and as researchers design experiments to take advantage of such facilities.
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5For more information, see http://www.arl.army.mil/www/default.cfm?page=93.
6For more information, see http://www.fraunhofer.org/.
7For more information, see http://www.erc-assoc.org/index.htm.
8For more information, see http://www.nsf.gov/eng/iip/about.jsp.
9For more information, see http://www.ccmc.rutgers.edu.
10For more information, see http://www.ntcresearch.org/mission.htm.
11For more information, see http://www.src.org/about/.
12For more information, see http://www.nwec-dotc.org/.