The Effect of Layered Cover Plate Material on the Ballistic Performance of Ceramic Armors: Experimental and Numerical Study

Abstract

This study investigates the ballistic performance of silicon carbide (SiC) ceramic armor systems reinforced with single and hybrid metallic cover plates composed of Ti-6Al-4V (Ti64) and copper. Controlled ballistic experiments combined with validated LS-DYNA simulations were conducted to examine how cover-plate material, thickness, and stacking sequence influence penetration resistance, energy dissipation, and failure mechanisms. The experimental results revealed that metallic cover plates significantly enhance protection by improving projectile erosion and extending dwell time. While both Ti64 and copper single layers increased the antipenetration capability (APC) compared with bare SiC, hybrid configurations achieved the highest performance. The optimal design, consisting of a 2 mm Ti64 plate placed in front of a 1 mm copper plate, produced the greatest reduction in penetration depth and the highest APC value. Numerical analyses closely replicated the experimental trends and provided insight into stress-wave interactions, pressure evolution, and damage progression within the ceramic. The findings demonstrate that hybrid Ti64-Cu systems not only improve initial impact resistance but also redistribute energy toward the front layers, reducing stress transmission to the backing and mitigating catastrophic ceramic failure. The combined experimental and numerical results establish a clear design framework for developing lightweight, high-efficiency ceramic armor through tailored hybrid layering strategies.