Sand inclusion composite structures for enhanced ballistic impact resistance

With the ever-increasing threat of ballistic impact, it is essential to provide a solution that is not only effective but also economical. In recent years polymer matrix sand composites (PMSCs) have emerged as a potential cost-effective solution. In this on-going effort, current investigation aims at offering more robust protection against varied ballistic impacts against potential ballistic threats. This research investigates the enhancement of ballistic impact resistance in polymer matrix composites through the inclusion of sand in a graded fashion. Variable material properties are obtained along the thickness by varying the sand inclusions size and weight fraction in the polymer matrix. The gradation offers a stepwise structure that has a prime base impact zone containing abrasive sand inclusions densely graded with a range of typical inclusion sizes which is brittle and hard enough to erode the projectile. Further gradation involves a less dense region providing tensile strength which is able to reflect the stress wave and reduce the impact energy with providing a backing to the frontal brittle region. The barely dense or neat matrix regions prevents backlash and offers cushioning effect. The addition of sand particles increases the surface area of the composite and improves adherence to the inclusions and matrix. This enhanced adhesion ensures efficient load transfer across the surface, which raises the composite’s overall hardness. PMSCs were fabricated for observing the effects on two matrix compositions improvising manufacturing procedures and subjected to a battery of tests, including tensile testing, Izod impact testing, Shore-D hardness testing, etc. in order to evaluate their mechanical properties comprehensively. The experimental results reveal that varying the weight fraction of sand content markedly influences the mechanical properties up to a certain weight fraction for a typical size range of inclusions. Experimental and simulation studies were involved in order to extract the mechanical properties and to observe the material behaviour against ballistic threats. The study reveals underscoring the potential of PMSCs as cost-effective and environmentally sustainable composites for advanced ballistic protection applications.