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<p>This study presents an integrated experimental–numerical–optimization framework for designing additively manufactured metallic cellular panels against 7.62 × 39 AP BZ projectiles in accordance with STANAG 4569 level 2. Maraging steel M300 specimens, plates and cellular cores are produced by Selective Laser Melting. A triaxiality–Lode–rate dependent Tabulated Johnson–Cook model is calibrated using quasi-static perforation tests reproducing experiments within excellent quantitative and qualitative correspondence. The validated model is applied to a vertical–horizontal (VH) cellular topology: ballistic tests at 709.8&#xa0;m/s give a mean residual velocity of (122.1&#xa0;m/s), while simulations predict 115.7&#xa0;m/s (5.2% deviation) and capture the observed failure modes. A simplified model enables radial-basis-function metamodel-based optimization. The optimal VH core (relative density 0.49) arrests the AP BZ bullet with penetration limited to ~ 66% of its height, indicating potential for further mass reduction. Finally, a hybrid panel combining a perforated nanostructured bainitic-steel face plate, shortened VH backing and witness plate is numerically designed. Four variants satisfy level 2 for three critical hit positions; the best concept attains 103&#xa0;kg/m² areal density, 6.2% below a 14&#xa0;mm monolithic M300 plate and ~ 43% below the optimized VH core.</p>

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Optimization of maraging steel cellular topologies for ballistic panel design

  • 期刊论文

  • 发表日期：

    2026年4月14日

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  • Paweł Baranowski,
  • Michał Kucewicz,
  • Paweł Płatek,
  • Arkadiusz Popławski,
  • Kamil Cieplak,
  • Narcis Bârsan

摘要

This study presents an integrated experimental–numerical–optimization framework for designing additively manufactured metallic cellular panels against 7.62 × 39 AP BZ projectiles in accordance with STANAG 4569 level 2. Maraging steel M300 specimens, plates and cellular cores are produced by Selective Laser Melting. A triaxiality–Lode–rate dependent Tabulated Johnson–Cook model is calibrated using quasi-static perforation tests reproducing experiments within excellent quantitative and qualitative correspondence. The validated model is applied to a vertical–horizontal (VH) cellular topology: ballistic tests at 709.8 m/s give a mean residual velocity of (122.1 m/s), while simulations predict 115.7 m/s (5.2% deviation) and capture the observed failure modes. A simplified model enables radial-basis-function metamodel-based optimization. The optimal VH core (relative density 0.49) arrests the AP BZ bullet with penetration limited to ~ 66% of its height, indicating potential for further mass reduction. Finally, a hybrid panel combining a perforated nanostructured bainitic-steel face plate, shortened VH backing and witness plate is numerically designed. Four variants satisfy level 2 for three critical hit positions; the best concept attains 103 kg/m² areal density, 6.2% below a 14 mm monolithic M300 plate and ~ 43% below the optimized VH core.