Experimental Study on the Impact Resistance of UHMWPE Flexible Film Against Hypervelocity Particles

The increasing threat posed by micrometeoroids and orbital debris to in-orbit spacecraft necessitates the development of lightweight and deformable shielding systems capable of withstanding hypervelocity impacts. Ultra-high-molecular-weight polyethylene (UHMWPE) films, owing to their high specific strength and energy-absorption capacity, present a promising candidate for such applications. However, the hypervelocity impact response of thin, highly oriented UHMWPE films—distinct from bulk plates or composites—remains poorly understood, particularly for micron-scale particles at velocities relevant to space debris (≥8 km/s). In this study, we systematically investigate the impact resistance of 0.1 mm UHMWPE films using a plasma-driven microparticle accelerator and a hypervelocity dust gun to simulate impacts by micron-sized Al2O3 and Fe particles at velocities up to ~8.5 km/s. Through detailed analysis of crater morphology via scanning electron microscopy, we identify three distinct damage modes: plastic-dominated craters (Type I), fracture-melting craters (Type II), and perforations (Type III). These modes are correlated with impact energy and particle size, revealing the material’s transition from large-scale plastic deformation to localized thermal softening and eventual penetration. Crucially, we provide quantitative penetration thresholds (e.g., 2.25 μm Al2O3 at 8.5 km/s) and establish a microstructure-informed damage classification that advances the fundamental understanding of UHMWPE film behavior under extreme strain rates. Our findings not only elucidate the energy-dissipation mechanisms in oriented polymer films but also offer practical guidelines for the design of next-generation, flexible spacecraft shielding systems.