Experimental and numerical analysis of boron silicon carbide composite armor

Ceramic composite armor systems are widely employed in lightweight body armor for protection against ballistic threats. However, conventional hot-pressed boron carbide (HPBC) ceramics face limitations, particularly in manufacturing curved configurations and resisting shock-induced failures. As an alternative, boron silicon carbide (BSC) armor, produced via an enhanced reaction-bonding process, enables the fabrication of monolithic curved plates with improved fracture toughness and greater suitability for mass production. Although less resistant than HPBC, BSC armor meets international ballistic standards and offers promising scalability. This study validates the ballistic performance of BSC-UHMWPE composite armor through experimental testing and computational modeling. Ballistic tests were conducted using 7.62 mm hard steel-core rifle rounds (705–723 m/s) on limited samples, demonstrating an average back face deformation of 13 mm without perforation, satisfying critical protective standards. Unlike traditional V₅₀, residual velocity, or depth of penetration tests using gas guns, this study adopts a more practical field trial approach aligned to stringent BIS standards. A finite element model using LS-DYNA was developed, integrating the Johnson-Holmquist II (JH-2) constitutive model for BSC ceramics, smoothed particle hydrodynamics (SPH) for fracture simulation, and layered composite failure modeling for the UHMWPE backing. Microstructural analysis revealed a composite matrix of B4C, SiC, and B12(C, Si, B)3 phases, contributing to the observed toughness. This work presents a proof of concept experimental and numerical ballistic performance study of BSC ceramic composite armor, addressing gaps in existing literature by combining experimental testing, microstructural characterization and advanced computational modeling.