CMEDE Highlights 2012-2022

WHAT IS CMEDE?

THE CENTER FOR MATERIALS IN EXTREME
DYNAMIC ENVIRONMENTS IS A
MULTI-INSTITUTION COLLABORATIVE
RESEARCH CENTER LOCATED WITHIN THE
HOPKINS EXTREME MATERIALS INSTITUTE
AT JOHNS HOPKINS UNIVERSITY.

The Center brings together academia, government, and industry to advance the state of the art for materials in extreme dynamic environments.



TABLE OF CONTENTS

From the Director...............................................................................................................................4 Composites.........................................................................................................................................35
About Us..................................................................................................................................................6 Metals.................................................................................................................................................... 45
Organization.......................................................................................................................................... 8 Integrative and Collaborative Tools......................................................................................55
Structure............................................................................................................................................... 10 People....................................................................................................................................................58
Supporting U.S. Army Multi-Domain Operations 2028...............................................14 Events.................................................................................................................................................... 60
Research Strategy............................................................................................................................16 Related Academic Programs.....................................................................................................63
MEDE Materials-by-Design Process........................................................................................18 Strategic Partnerships.................................................................................................................. 66
Research Activities........................................................................................................................ 20 Personnel 2012-2022.....................................................................................................................67
Acceleration of Armor Material Development.................................................................22 Abbreviations and Acronyms....................................................................................................73
Transitions from MEDE Program ��������������������������������������������������������������������������������������������23 Contact.................................................................................................................................................. 74
Ceramics...............................................................................................................................................25

CONSORTIUM MANAGEMENT COMMITTEE

FROM THE CMEDE DIRECTOR:

There’s a saying that time flies when you’re having fun. This program has developed the next generation of materials- LORI GRAHAM-BRADY
It’s been ten years since the establishment of Materials in by-design workforce who are already making a difference.
Extreme Dynamic Environments Collaborative Research Despite the challenges presented by COVID-19, everyone Director, CMEDE
Alliance (MEDE CRA), and I can confidently say that we’ve found a way to accomplish the research. We are truly
had a lot of fun advancing the state of materials science amazed at the resiliency of the MEDE CRA. Associate Director, Hopkins Extreme
while finding new and improved ways to protect our soldiers. Materials Institute (HEMI)
The information contained within this piece is the result of
Awarded in April of 2012, the MEDE CRA is a basic ten years of dedicated faculty, postdoctoral fellows, students, Professor, Civil and
research program which has developed a materials-by-design and staff working in close collaboration with DEVCOM ARL Systems Engineering
process which has improved protection materials for armor researchers. We are proud to say that the accomplishments Johns Hopkins University
applications. Commensurate with the recommendations of made by the MEDE program will save soldiers’ lives.
two National Research Council boards, only a program of
this scale could integrate experimental, computational, We are grateful for the support from the U.S. Army and the
testing, characterization, and processing research activities Department of Defense, the Enterprise for Multiscale Research
into a single program. Research activities were performed of Materials, Congressional delegations, and the partners in the
jointly amongst academia, the DEVCOM Army Research MEDE CRA, without whom none of this would be possible.
Laboratory (ARL), and industry.

The impact of the MEDE CRA has been significant. This
booklet includes the major technical, workforce development,
and collaborative highlights. We are proud of the over 600
individuals who have been involved in the MEDE CRA.

4 | CMEDE HIGHLIGHTS

SIKHANDA SATAPATHY KAUSHIK JOHN W. RICHARD HABER
BHATTACHARYA GILLESPIE, JR.
Collaborative Alliance Manager Professor, Materials Science
MEDE CRA Howell N. Tyson, Sr., Donald C. Phillips Professor of Civil
U.S. Army Combat Capabilities Professor of Mechanics and and Environmental Engineering and Engineering
Development Command Army Materials Science
Research Laboratory Professor, Mechanical Engineering, Rutgers University
Professor, Materials Science Materials Science and Engineering
California Institute of Technology University of Delaware

CMEDE HIGHLIGHTS | 5

ABOUT US National Research Council report

In 2010, two National Research Council boards established a committee to examine opportunities
in protection materials science and technology for future Army applications. This committee recommended
that the Department of Defense establish an initiative for protection materials-by-design. This initiative
would include a combination of computational, experimental, and materials testing, characterization, and
processing research to be conducted by academia, government, and industry.

In response to the committee’s recommendation, in April 2012 the U.S. Army Combat Capabilities
Development Command Army Research Laboratory (DEVCOM ARL) established a framework to integrate
the Army’s multiscale basic research in materials into one coordinated enterprise. Called the Enterprise
for Multiscale Research of Materials (EMRM), the focus of the program is to develop a materials-by-design
capability for the U.S. Army using validated multiscale and multidisciplinary modeling capabilities to predict
material structure, properties, and performance.

Called the Enterprise for Multiscale Research of Materials (EMRM), the focus
of the program is to develop a materials-by-design capability for the US Army
using validated multiscale and multidisciplinary modeling capabilities to predict
material structure, properties, and performance.

The EMRM enables DEVCOM ARL to coordinate its in-house activities with extramural research efforts.
The EMRM is organized into four major areas: protection materials, energetic materials, electronic materials,
and cross-cutting computational science.

To launch the protection materials research component of EMRM, DEVCOM ARL competitively awarded
and then signed the Materials in Extreme Dynamic Environments cooperative research agreement with
Johns Hopkins University (JHU), the California Institute of Technology (Caltech), the University of Delaware
(Delaware) and Rutgers University. The agreement allowed JHU, which is the lead research organization

6 | CMEDE HIGHLIGHTS

within the consortium of university and research partners, to establish the Center for Materials in Extreme
Dynamic Environments, or CMEDE. CMEDE is a center within the Hopkins Extreme Materials Institute
that focuses on advancing the fundamental understanding of materials in high-stress and high-strain-rate
regimes, with the goal of developing a materials-by-design capability for these extreme environments. This
10-year agreement, valued up to $90 million, represents a significant investment and demonstrates the
importance of the design of protection materials to the U.S. Army.

The MEDE program also supports the Presidential Materials Genome Initiative (MGI) for Global
Competitiveness. Established in June 2011, MGI aims to double the speed at which materials are discovered,
developed, and deployed. The MEDE program represents one of the Department of Defense’s largest
investments in extramural basic research in support of the MGI.

“This is some incredible work that was done. Figure 1: Materials Genome Initiative: MEDE focuses on
It’s cutting-edge technology as far what it’s developing the experimental and computational tools
done for body armor.” needed to develop protection materials for national security.

- GENERAL JAMES C. MCCONVILLE
40th Chief of Staff of the U.S. Army

CMEDE HIGHLIGHTS | 7

ORGANIZATION

The MEDE Collaborative Research Alliance is composed of a consortium of university and research partners and the DEVCOM Army Research Laboratory.
The MEDE consortium members include:

• Johns Hopkins University (Lead) • Lehigh University • Texas A&M University

• California Institute of Technology • Morgan State University • University of California Berkeley

• CoorsTek • New Mexico Institute for • University of California
Mining and Technology Santa Barbara
• Defence Science and Technology Laboratory
(United Kingdom) • North Carolina Agricultural • University of Delaware
and Technical State University
• Drexel University • University of Houston
• Northwestern University
• Ernst Mach Institut (Germany) • University of North Carolina
• Purdue University at Charlotte
• ETH Zürich (Switzerland)
• Rutgers University • University of Texas at San Antonio
• Lawrence Livermore
National Laboratory • Southwest Research Institute • Washington State University

The MEDE CRA is composed of a consortium of university and
research partners and the DEVCOM Army Research Laboratory.

8 | CMEDE HIGHLIGHTS

United Kingdom

Figure 2: MEDE Collaborative Research Alliance Germany
Switzerland

CMEDE HIGHLIGHTS | 9

STRUCTURE • A Collaborative Materials Research Group (CMRG) coordinates all research
activities for each material type. Each CMRG is co-led by a consortium
• The CMEDE Director is located at Johns Hopkins University, principal investigator and a DEVCOM ARL researcher.
the lead research organization for the MEDE CRA.
• Within each CMRG, there are multiple technical areas, separated by scale
• The MEDE Science Advisory Board complements DEVCOM ARL’s or mechanism. The CMRGs are highly integrated with a consortium PI and
Technical Advisory Board. It provides important scientific insight, a DEVCOM ARL researcher co-leading each major effort.
oversight, and expertise to the CMEDE consortium. The Board
reports to the CMEDE Director.

• The Consortium Management Committee (CMC) is composed of a senior
representative from the four major consortium partners and the DEVCOM
ARL Collaborative Alliance Manager. The CMC is the final decision
authority for the MEDE CRA.

10 | CMEDE HIGHLIGHTS

MEDE Science Consortium Management Committee Ceramics CMRG
Advisory Board
Composites CMRG
CMEDE Director
Metals CMRG
Figure 3: MEDE organizational structure
Polymers CMRG
(2012-2017)
CMEDE HIGHLIGHTS | 11

The outstanding accomplishments of the MEDE
program provide a shining example of a true
collaborative effort at its best. The results achieved
in this effort, which investigated materials
chosen as critical representatives in their areas
(metals - magnesium, ceramics - boron carbide,
composites - S2 glass and resins), are unparalleled’.
Additionally, advances in data management and
critical workforce development exhibit why this
cooperative research effort with the Army is the
benchmark for all others, and how it provides
the blueprint for future groundbreaking research.

- DR. DOUG TEMPLETON
Chair, MEDE Science Advisory Board

12 | CMEDE HIGHLIGHTS

MEDE SCIENCE ADVISORY BOARD MEMBERS

Dr. Douglas Templeton* Professor David McDowell* Professor Thomas Russell*

DWT Consulting (Chair) Georgia Institute of Technology University of Massachusetts Amherst

Dr. Charles E. Anderson, Jr.* Professor Steve McKnight* Professor Susan Sinnott*

CEA Consulting Virginia Polytechnic Institute Pennsylvania State University

Professor Irene Beyerlein Professor Marc Meyers* Professor Nancy Sottos*
University of California, Santa Barbara
University of California, San Diego University of Illinois at
Urbana-Champaign
Professor Horacio Espinosa* Professor Anthony Rollett*
Professor Susan Sinnott*
Northwestern University Carnegie Mellon University
Pennsylvania State University
Professor Rodney Clifton Dr. Donald Shockey
Emeritus, Brown University SRI International CMEDE HIGHLIGHTS | 13

*2022 board member

SUPPORTING U.S. ARMY MULTI-DOMAIN
OPERATIONS 2028

Advanced Experiments MATERIALS-BY-DESIGN STRATEGY Synthesis and Processing
Simulating ballistic events through Creating new materials to validate
Computational Modeling experimental and modeling data
high strain rate experiments Modeling from the atomistic to

the continuum scales

New lightweight Computational MATERIALS-BY-DESIGN RESULTS Scientific Use-inspired
materials codes for armor discovery research
material design Knowledge
products

14 | CMEDE HIGHLIGHTS

“Tactical overmatch is the product of adaptable, aggressive
leaders and soldiers organized in cohesive, well-trained
formations; and aircraft, fighting vehicles, small units, and
individuals with superior mobility, protection, and lethality.”

Army Material Modernization Priorities DEVCOM ARL Core Competencies
and Essential Research Programs
Developing material solutions to support new
protection concepts: • Terminal ballistics and materials research

• Soldier Lethality • Physics of soldier protection to defeat
• Next Generation Combat Vehicle evolving threats

Army Priority Research Area

• Materials by Design: Protection overmatch
against future threats

MEDE Provides Foundational Research • Advanced Experiments • Computational Modeling • Synthesis and Processing

CMEDE HIGHLIGHTS | 15

RESEARCH STRATEGY

The objective of the MEDE program is to develop the technical and Typically such a canonical model defines key variables and their ranges,
workforce capability to design, create, and optimize novel material systems defines critical mechanisms, and then prioritizes the variables and mechanisms.
that exhibit revolutionary performance in extreme dynamic environments. Beginning with a canonical model allows a large group of researchers to ensure
Achieving this objective requires a new paradigm for materials research and that efforts are relevant in terms of both science and application.
workforce development. One cannot use the classical materials science
structure-properties-performance approach because path-dependent and Once the canonical description is established, researchers can then proceed
time-dependent failure processes are involved in these dynamic environments, with the mechanism-based strategy. Researchers seek to see the mechanisms
and optimal solutions may not exist in the traditional design space. Instead, we during the extreme dynamic event, to understand them through multiscale
must design with knowledge of the dynamic failure processes (mechanisms) models, and to control them through synthesis and processing. Understanding
that are involved in the actual application. the mechanisms through multiscale models provides the capability to
define integrative experiments and to test the coupling of mechanisms. This
The objective is not necessarily to produce a specific material information leads to validated models and codes, which feed back into the
system that is optimized for a specific range of applications, canonical model, by transitioning into Department of Defense (DoD) and
but rather to produce a way of thinking that will allow the Department of Energy (DoE) codes. Similarly, controlling the mechanism
design of lightweight protective material systems that can through synthesis and processing leads to newly designed materials for the
be used for extreme dynamic environments. canonical environment. Industry helps to determine the scale-up feasibility of
these newly designed materials, which are then fed back to the experiments in
the canonical modeling effort.

To achieve the MEDE program objectives, research activities are focused on
a materials-by-design process involving a canonical model and a mechanism-
based strategy as shown in Figure 4. We have established a canonical model for
each model material under investigation. A canonical model is defined as:
“A simplified description of the system or process, accepted as being accurate
and authoritative, and developed to assist calculations and predictions.”

16 | CMEDE HIGHLIGHTS

Feasibility of Newly Designed Materials
Industry Scale-up

CANONICAL MODELING PROCESS MMEECCHHAANNIISSMM--BBAASSEEDDSSTTRRAATTEEGGYY

Identify Perform Instrumented Define Draft See it. Understand it. Control it.
Critical Application-level Canonical Fundamental Validated modeling Synthesis and
Application Experiments Model
Simulate multiscale and simulations processing
Application-level experiments to under canonical of desired
Experiments with identify behaviors compositions,
available Codes and mechanisms high-rate microstructures,
environments and architectures

Define integrative experiments to validate
models and test coupling of mechanisms

Transition into Validated Multiscale
DoD and DoE codes Models And Codes

Figure 4: Overall design strategy for protection materials. Left hand boxes are driven by DEVCOM ARL, while right hand boxes are driven by the MEDE Consortium.

CMEDE HIGHLIGHTS | 17

MEDE MATERIALS-BY-DESIGN PROCESS

Throughout the program, each CMRG has progressed through discovery,
integration, and transition for multiple candidate materials. The See/
Understand/Control mechanism-based framework has been a constant
throughout the program. The final and critically important piece of the program
is workforce development, which encompasses all aspects of MEDE.

Mechanism-based, See It/Understand It/Control It Paradigm:
• See It: Observe mechanisms through testing in extreme environments
• Understand It: Computational models to understand mechanisms
• Control It: Synthesis and processing to control mechanisms
• Discovery Phase: Evaluation and control of key mechanisms
• Integrative Phase: Consider competition between key mechanisms in

canonical model
• Transition Phase: Codes, datasets, scaled-up material specimens transitioned

to DEVCOM ARL
• Workforce Development: Throughout and across the entire program

18 | CMEDE HIGHLIGHTS

See! Understand
Existing
Material
Control

CMEDE HIGHLIGHTS | 19

RESEARCH ACTIVITIES

The MEDE program examines one model material in each of the following three material classes: ceramics, composites, and metals.
The discoveries and insights developed can be used for other materials in the same class.

Ceramics: Boron Carbide

Boron carbide is the model material for the Ceramics CMRG because it has the unrealized potential of dramatic improvements in ballistic performance
for vehicular and soldier protection at very low weight. The Ceramics CMRG seeks to understand and control the dynamic failure processes in this protective ceramic
material and to improve its dynamic performance by controlling mechanisms at the atomic and microstructural levels through multiscale modeling, advanced
powder synthesis, control of polytypes, and microstructural improvements.

Application: Boron carbide is one of the component materials used to protect soldiers and military vehicles from blast and ballistic threats.

Composites: S-2 Glass/Epoxy

Composite materials subjected to dynamic loads are essential examples of high performance systems in the conventional sense. In order to focus on the
complexities raised by the interfaces and architectures, S-2 Glass/Epoxy is the model system for the Composites CMRG. The Composites CMRG develops
the fundamental understanding of the role of interfaces, component interactions, and composite architecture over the full range of length scales and time
scales that are manifested in the system during the dynamic event.

Application: S-2 Glass/Epoxy provides a strong, structural backing system to support protective plates for military vehicles.

Metals: Magnesium

The magnesium alloy system is the model material for the Metals CMRG because it is the lightest-weight structural metal that offers the potential of approaching
steel-like ballistic performance while using conventional low-cost and time-tested processing techniques. We are enhancing the dynamic performance of this
hexagonally-close-packed metal using experimentally validated modeling and alloy design to control dynamic strengthening and failure mechanisms, including
deformation twinning.

Application: In comparison to steel, magnesium offers the potential for a lightweight metal system that could enhance the deployability and protection of military vehicles.

20 | CMEDE HIGHLIGHTS

CMEDE RESEARCH ACTIVITIES ADDRESS THE FOLLOWING MSU
FIVE CORE ELEMENTS:
JHU
• Advanced Experimental Techniques: Developing experimental methodologies to interrogate
and characterize the in-situ materials response to extreme dynamic environments at critical CMEDE HIGHLIGHTS | 21
length and time scales.
Delaware
• Modeling and Simulation: Developing computational approaches to predict the materials
response to extreme dynamic environments at critical length and time scales.

• Bridging the Scales: Developing physical and mathematical constructs necessary to bridge
critical length and time scales.

• Material Characteristics and Properties at Multiple Scales: Utilizing existing and novel
experimental methodologies to identify the comprehensive set of material characteristics,
microstructural features, and dynamic properties that govern high rate deformation and
failure phenomena, and to validate computational approaches in order to bridge the
characteristic length and time scales.

• Synthesis and Processing: Incorporating research discoveries to enable the synthesis of
novel materials and the processing of final products with critical material characteristics
and resulting properties.

ACCELERATION OF ARMOR
MATERIAL DEVELOPMENT

7 Since WWII, there have been significant advancements in
7 materials which have resulted in lighter and stronger body
armor as measured by the areal density. By the early 2000s,
6.5Areal Density (psf) 15–20%ExtraEpxtorlaaptoiolantioofnHoisf tHoirsitcoTrirceTnrdend improvements were minimal.
6.5 Areal Density (psf) 15R–e2d0u%ction
Reduction MEDE research has resulted in a 15 – 20% reduction in areal
6 ArealADreeanlsitDyen(siptsfy)(psf) density for all three classes of armor materials. Assuming the
6 potential for armor weight reduction is proportional to weight
reduction in component materials, MEDE has accelerated this
5.5 lightweighting by 10 -20 years.
5.5
MEDMEERDeEseRaercshearch Historic Trend Overview

30

30
25

25
20

20
15

1510

2010 2015 2020 2025 2030 2035 2040 2045 105
2020 2035 2040 2045 1950
2010 2015 2025 Ye2a0r30 2000 2050
5 2050
Year 1950 Year
2000

Year

22 | CMEDE HIGHLIGHTS

TRANSITIONS FROM THE MEDE PROGRAM

Throughout the program, each CMRG has progressed through discovery, integration, and transition for multiple candidate materials. The See/Understand/Control
mechanism-based framework has been a constant throughout the program. The final and critically important piece of the program is workforce development,
which encompasses all aspects of MEDE.

People Materials

• STEM workforce skilled in materials design for extreme environments • New materials developed through materials-by-design loops

• Balance of academic, industry, DoD career paths • New processes for making designed materials

Codes and Models • Collaboration/partnership with industry

• Understanding material response in extreme dynamic environments Legacy Publications

• Controlling synthesis and processing of new materials • Legacy articles from each CMRG in journal special issues

• Designing materials for extreme dynamic environments Datasets

• Valuable data from novel experimentation, models, and synthesis/processing

CMEDE HIGHLIGHTS | 23

Artistic rendering of the atomic-level view of
boron carbide as seen through a transmission
electron microscope.





CERAMICS

PROF. RICHARD HABER DR. JERRY LASALVIA

Consortium Lead, DEVCOM ARL Lead,
Ceramics CMRG Ceramics CMRG

26 | CMEDE HIGHLIGHTS

CANONICAL TEST FOR BORON CARBIDE

To improve the ceramics that provide personnel protection to U.S. soldiers, the Ceramics CMRG, led by Prof. Richard Haber (Rutgers) and Dr. Jerry
LaSalvia (DEVCOM ARL), sought to understand and control the dynamic failure processes in boron carbide with the goal of improving its dynamic
performance by controlling mechanisms at the atomic and microstructural levels through multiscale modeling, advanced powder synthesis, control
of chemistry, and microstructural improvements.

Summary

• Experiment: 3 mm diameter tungsten carbide sphere impact on 2 inch x 2 inch x 9-mm pressure assisted densified boron carbide
target on a 6 inch thick aluminum backing.

• Computational Model: Multi-mechanism model that integrates and tracks damage due to fracture, amorphization and granular flow.

1.2 km/s 3.8 km/s
Images from impact testing using a sphere on a boron carbide target.

CMEDE HIGHLIGHTS | 27

MEDE CERAMIC 1: NO FREE CARBON Key Improvements

Summary • Increased modulus (≈12%), hardness (≈3%), and dynamic strength (≈11%)
relative to baseline pressure assisted densified boron carbide.
The Ceramics CMRG developed boron carbide with reduced free carbon,
a new designer lightweight material. • 11-18% decreased depth of penetration in aluminum backing at high velocities
relative to baseline .
The key mechanisms that guided design of this new material were fracture
and granular flow that lead to impact-induced failure of boron carbide. • 26% decreased crater volume at 1.3 km/s.

A materials-by-design process showed that fracture initiates from large • These key improvements result in ≈11-18% weight reduction
carbonaceous defects observed in the baseline boron carbide - pressure for similar performance.
assisted densified boron carbide (PAD BC).
Newly designed material resulted in ≈11-18% reduction of depth
Advancements made through synthesis, testing, and evaluation allowed the of penetration into an aluminum backing.
Ceramics CMRG to share processing routes with industrial partner CoorsTek,
who scaled up specimens for impact experiments.

Plates and tiles of reduced carbon specimens showed multiple improvements
relative to baseline PAD BC.

Newly designed material resulted in ≈11-18% weight reduction for
similar performance.

28 | CMEDE HIGHLIGHTS

Multi-scale Models Reduced Free Carbon via Increased Boron
suggest reduce carbonaceous defects

2012 2021
Baseline PAD B4C NFC B4C

Improved modulus, hardness, dynamic strength

Transition to Industry High-velocity Impact Performance
Scale-up processing to develop tiles at a Hypervelocity impact—3 mm WC spheres @ 3.0 km/s
scale suitable for testing at JHU and ARL on 2”x2”x 9 mm thick BC w/ Al backing

2012 2021 2012 2021

2” x 2”
x 9 mm tiles

DoP = 8.8 mm3 DoP = 7.6-7.8 mm3

Baseline PAD B4C­ NFC B4C—3 mm
3 mm WC sphere impact WC sphere impact
velocity=1.31 km/s velocity=1.25 km/s

CMEDE HIGHLIGHTS | 29

MEDE CERAMIC 2: SILICON (SI)-DOPED BORON CARBIDE WITH TITANIUM DIBORIDE (TIB2)

Summary Key Improvements Relative to Pressure Assisted
Densified Boron Carbide
The Ceramics CMRG developed a silicon-doped boron carbide with
TiB2 additive as a new designer lightweight material. • Increased amorphization resistance ≈39%.

This design was driven by the need to suppress the amorphization • 6% increase in density relative to PAD BC.
mechanism that is key to impact performance in boron carbide.
• 67% decrease in crater volume at 1.6 km/s impact.
In a multi-iteration materials-by-design process, it was found that
doping boron carbide with silicon atoms inhibits amorphization but Newly designed material resulted in 67% reduction of
reduces mechanical properties. The CMRG determined that adding crater volume under 1.6 km/s impact.
TiB2 reinforcement particles in Si-doped boron carbide improves
properties while inhibiting amorphization.

Processing routes were transitioned to CoorsTek, an industrial partner,
for scale-up. Integrative codes were also shared and demonstrated in
codes such as EPIC, ALE3D, and ABAQUS.

Plates and tiles of the new Si-doped + TiB2 added boron carbide
led to significantly improved impact performance.

Improvements made to the material resulted in an increased toughness
of ≈58% while maintaining comparable strength and hardness.

30 | CMEDE HIGHLIGHTS

Atomistic Modeling and Simulation Processing-Microstructure-Properties

Amorphization inhibited by replacing carbon 2012 Si-doped BC 2021
link with boron or silicon through doping (boron carbide)
PAD B4C Si-doped BC
As Is To Be (As is) 25.0 + TiB2
26.5 338 28.2
Si-doping Hardness (GPa) 398 2.1 410*
Strength (MPa) 2.4 2.50 3.79
Toughness (MPa∙√m) 2.52 +37% 2.68
Density (g/cc) -- +39%

Amorphization resistance

Impact Performance
Hypervelocity Impact: 3 mm WC sphere, 1.6 km/s

Transition to Industry
Scale-up processing

Scale-up processing

Route 1 2012 2021
Reactive
MEDE hot pressing

Route 2 Pre-reacted
powder

Hot pressing

2” x 2” x 9 mm tiles

CMEDE HIGHLIGHTS | 31

TRANSITIONS Scale-up processing

New Computational Models and Codes MEDE Route 1
Reactive
• Transition of models into Department of Defense and Department hot pressing
of Energy production codes: EPIC, Sierra/SM, ALEGRA, ALE3D.
Route 2 Pre-reacted
• The codes have been exercised by the U.S. Army, Defense Threat powder
Reduction Agency, and National Aeronautics and Space Administration.

New Designer Materials

• Transition of processing routes to industrial partners for: Si-doped
boron carbide, Si-doped with TiB2, and reduced free carbon.

• CoorsTek tiles supplied to MEDE universities and DEVCOM ARL
for impact testing.

Legacy Journal Articles

• Special issue in the Journal of the American Ceramic Society

Hot pressing

32 | CMEDE HIGHLIGHTS

LEGACY PUBLICATIONS Applications of analytical electron microscopy to guide the design of
boron carbide (Marvel, C., Yang, Q., Walck, S., Xie, K., Behler, K., LaSalvia, J.,
Special issue in the Journal of the American Ceramic Society Watanabe, M., Haber, R., and Harmer, M.)
(special issue coordinators: Haber, R. and LaSalvia, J.) containing
the following articles: Experimental observations of amorphization in multiple generations of boron
carbide (Xie, K., Yang, Q., Marvel, C., He, M., LaSalvia, J., Harmer, M., Hwang, C.,
Addressing amorphization and transgranular fracture of B4C through Si Haber, R., and Hemker, K.)
doping and TiB2 microparticle reinforcing (Hwang, C., Du, J., Yang, Q., Celik, A.,
Christian, K., An, Q., Schaefer, M., Xie, K., LaSalvia, J., Hemker, K., Goddard, W., Fragmentation and granular transition of ceramics for high rate
and Haber, R.) loading (Bhattacharjee, A., Hurley, R., and Graham-Brady, L.)

Models for the behavior of boron carbide in extreme dynamic environments Some programmatic and armor ceramics research history and new boron
(Ramesh, K., Graham-Brady, L., Goddard, W., Hurley, R., Robbins, M., Tonge, A., carbide approaches based on crystal physics, microstructure, and defects, using
Bhattacharjee, A., Clemmer, J., Zeng, Q., Li, W., Shen, Y., An, Q., and Mitra, N.) a material by design scheme (McCauley, J.)*

Mechanical characterization of boron carbide single crystals (Zare, A., He, *under review with the International Journal of Ceramic Engineering and Science
M., Straker, M., Chandrashekhar, M., Spencer, M., Hemker, K., McCauley, J.,
and Ramesh, K.)

Strengthening boron carbide by doping Si into grain boundaries
(Shen, Y., Yang, M., Goddard, W., and An, Q.)

CMEDE HIGHLIGHTS | 33

Artistic rendering of a cross-section of the
S-2 Glass/Epoxy composite material.





COMPOSITES

PROF. JOHN W. DR. DANIEL J. O’BRIEN
GILLESPIE, JR.
DEVCOM ARL Lead,
Consortium Lead, Composites CMRG
Composites CMRG

36 | CMEDE HIGHLIGHTS

CANONICAL TEST FOR GLASS EPOXY

The Composites CMRG, led by Prof. Jack Gillespie, Jr. (Delaware) and Dr. Daniel J. O’Brien (DEVCOM ARL), developed approaches to address
failure mechanisms in glass-epoxy composites that are critical to vehicle and personnel protection. Models suggested ways in which the epoxy
matrix and the fiber-matrix interphase could be improved, leading to the development of new techniques for improving these components of
the composite. Implementation in full-scale functionally graded panels with tailored performance led to significant ballistic performance.

Summary

• Experiment: Hardened steel projectile on 14 inch x 14 inch x 3/4 inch functionally graded capstone panel.

• Computational Model: Multi-scale model that incorporates delamination, fiber breakage, and interphase failure using a MAT162 constitutive model.

Vi : 1010 m/s (<V50) Vi : 1725 m/s (>V50)

CMEDE HIGHLIGHTS | 37

MEDE COMPOSITE 1: FUNCTIONALLY GRADED PLATE

Summary Key Improvements Relative to Baseline
Plain Weave SC-15 Composite
• Army Relevance: Composites found in both vehicular
and personnel protection. • Absorbs 34% more energy.

• Key Mechanisms: Matrix and fiber-matrix interphase failure at the • 16% higher V50 ballistic limit.
microscale cause delamination, tensile failure, and punch shear failure. • 23% thinner or 14% lighter for equivalent level of protection.

• Materials Design of Components: Use new epoxy resin, interphase
and architecture to fabricate strikeface with a 25% reduction in depth
of penetration and back face with enhanced delamination to increase
energy absorption.

• Demonstration of New Designer Material: Functionally graded plate (2/3
front face, 1/3 back face) exhibits 34% increase in energy absorption and
16% increase in V50 ballistic limit.

• Partnership with Industry: Partner with AGY (fibers) and FDI (weave)
for materials in order to fabricate 16 inch x 16 inch x 3/4 inch panels.

38 | CMEDE HIGHLIGHTS

Molecular-Scale Design of Epoxy Resin, Interphase

Strike Face with newly 8HS (933) PW (463) Back Face with newly
designed resin and interphase designed resin and interphase
New IFSS, Resin, & Architecture: vary V50 from
~25% reduction in DoP at 1km/s 250-400 m/s, extend delamination from 3" to ~10% increase in V5

Strike Face over 6" in thin laminates 14"x14"x3/4" Functionally Graded Plate
High FVF, IFSS, & Resin Toughness Impact testing relative to baseline PW/SC15

2/3 34% increase in energy absorption
1/3 16% increase in V50
Back Face
High FVF & Resin Toughness, Low IFSS

CMEDE HIGHLIGHTS | 39

MEDE COMPOSITES 2: BACKING PLATE

Summary Key Improvements of Newly Designed S2 Glass Composite
Panel with Polyurethane Interleaves Relative to Baseline S2
• Key Mechanism: Delamination plays a key role in stiffness retention and Glass-SC15 Epoxy Material
reflects performance under repeated impact.
• 91% stiffness retention vs. 44% in baseline material.
• Materials Design: Use polyurethane interlayers to reduce interlaminar stress
and increase interlaminar fracture toughness. • No delamination vs. significant delamination in baseline material.

• Demonstration of New Designer Material: Polyurethane interlayers eliminate
delamination and increase stiffness retention from 44% to 91%.

40 | CMEDE HIGHLIGHTS

Drop Tower Test

30x30x1 Baseline - 7.4kJ, 10-20 m/s,
hardened steel impactor, 3" diameter
with a tip radius of 80-mm.

Baseline: 44 layer S2 glass-SC15 epoxy

57% reduction 44% Stiffness
Retention;
Before Impact First Impact Second Impact Delamination
Length: 12-15"

91% Stiffness
Retention
Delamination:
None

TPU Panel: +10 Thermoplastic Polyurethane [UAF-472] Interlayers.

CMEDE HIGHLIGHTS | 41

TRANSITIONS

New Computational Models And Codes

• Transition of MAT162 constitutive code into ARL ALE3D
and EPIC implementation:
– Multi-scale model for S-glass composites
– Built from atomic to macro-scale

• The codes have been exercised by the U.S. Army, Defense Threat
Reduction Agency, and National Aeronautics and Space Administration.

New Designer Materials

• Partnered with industry to fabricate 16 inch x 16 inch panels:
– AGY glycerin sized (water soluble) tows
– FFDI woven fabric (8HS, unidirectional, plain weave) with AGY tows

Legacy Journal Articles

• Special issue in the Composites Part B: Engineering

42 | CMEDE HIGHLIGHTS

LEGACY PUBLICATIONS

Special issue in Composites Part B: Engineering, “Composite Materials Bridging length scales from micro to mesoscale through rate-dependent
in Extreme Dynamic Environments (CMEDE)” (guest editors: Gillespie, J. traction-separation law predictions (Meyer, C., Haque, B., and Gillespie, J.)
and O’Brien, D.) containing the following articles:
Mesoscale modeling of ballistic impact experiments on a single layer of
Mechanical properties and damage analysis of S-glass fiber: A reactive plain weave composite (Meyer, C., O’Brien, D., Haque, B., and Gillespie, J.)
molecular dynamics study (Yeon, J., Chowdhury, S., and Gillespie, J.)
Dynamic fracture of glass fiber-reinforced ductile polymer matrix composites
Synergistic fracture toughness enhancement of epoxy-amine matrices and the loading rate effect on their fracture toughness (Gao, Jinling, Kedir, N.,
via combination of network topology modification and silica nanoparticle Kirk, C., Hernandez, J., Gao, Jian, Horn, T., Kim, G., Fezzaa, K., Shevchenko, P.,
reinforcement (Gao, J., Kashcooli, Y., Palmese, G., Gillespie, J., O’Brien, D., Tallman, T., Palmese, G., Sterkenburg, R., and Chen, W.)
and Patterson, B.)
Stress field prediction in composite materials using deep learning
Modeling sizing emulsion droplet deposition onto silica using All—atom (Bhaduri, A., Gupta, A., and Graham-Brady, L.)
molecular dynamics simulations (Zarrini, S. and Abrams, C.)
Depth of Penetration Experiments of S-2 Glass/Epoxy Composites
Impact damage modeling in woven composites with two-level Parametrically- (Haque, B., Kubota, M., and Gillespie, J.)
Upscaled Continuum Damage Mechanics Models (PUCDM)” (Zhang, X., Xiao,
Y., Meyer, C., O’Brien, D., and Ghosh, S.) Strain-Rate Dependent Mode I Cohesive Traction Laws for Glass
Fiber-Epoxy Interphase using Molecular Dynamics Simulations
(Chowdhury, S. and Gillespie, J.)

CMEDE HIGHLIGHTS | 43

Artistic rendering of magnesium
as seen through a transmission
electron microscope.