Novel Defence Functional and Engineering Materials (NDFEM) Volume 2: Engineering Materials for Defence Applications (Indian Institute of Metals Series)

Zusammenfassung: This book provides the latest developments in functional and engineering materials for defence applications. It contains a total of 20 book chapters in 2 proposed volumes: Vol. 1. Defence Functional Materials and Vol. 2. Defence Engineering Materials. All the book chapters are authored by leading scientists from the premier institutes, such as DRDO laboratory, DMSRDE, Kanpur, India, and edited by Drs. N Eswara Prasad, RJH Wanhill, and DK Setua. Both the authors and the editors are well known internationally for their seminal works in the Functional and Engineering Materials R&D and S&T. The principal purpose of this two-volume book is to provide the salient features of materials selection, synthesis, development and qualification for many a classical applications encompassing aero, naval and ground-based defence systems. They would surely act as valuable vade mecums for both active researchers, defence experts, post-graduate students, and faculty members who like to work and contribute to defence forces through research in areas such as defence materials, products, prototypes, sub-systems and systems that need cutting edge technologies and the latest and best materials and materials solutions Series Editor’s Preface Foreword Preface Acknowledgements Current Series Information Contents Editors and Contributors 1 Polymer Matrix Composites (PMCs) for Defence Applications 1.1 Introduction 1.2 Polymer Matrix Composites (PMCs) 1.2.1 Overviews 1.2.2 Polymer Matrices 1.2.3 Filler Materials 1.3 Processing and Fabrication of PMCs 1.3.1 Types and Stages of PMC Manufacturing Processes 1.3.2 Challenges of PMC Manufacturing Processes 1.4 Thermoset Composites: Types and Overall Properties 1.4.1 Market for Thermoset Composites 1.5 Thermoplastic Composites: Types and Overall Properties 1.5.1 Market for Thermoplastic Composites 1.5.2 Thermoplastic Composites (TPCs) Versus Thermosetting Composites (TSCs) 1.6 Polymer Nanocomposites 1.7 Applications of PMCs 1.7.1 Aircraft Applications 1.7.2 Personnel Protection Systems 1.8 Special Topic: Self-healing PMCs 1.8.1 Design Methodologies for Self-healing Composites 1.8.2 Extrinsic Approaches for Self-healing Composites 1.8.3 Intrinsic Approaches for Self-healing Composites 1.8.4 Evaluation of the Healing Efficiencies of PMCs 1.8.5 Applications and Prospects for Self-healing Polymers and Composites 1.9 Technological Implications 1.10 Summary and Concluding Remarks References 2 Hybrid Polymeric Composites for Defence Applications 2.1 Introduction 2.2 Hybrid Composite Materials 2.3 Design Philosophy for Hybrid Composites 2.4 Candidate Materials 2.4.1 Reinforcement Materials 2.4.2 Matrix Materials 2.5 Composite and Hybrid Composite Processing Routes 2.5.1 Prepreg Moulding 2.5.2 Autoclave Moulding 2.5.3 Filament Winding 2.5.4 Hand Lay-Up Process 2.5.5 Spray Lay-Up Process 2.5.6 Resin Transfer Moulding (RTM) 2.6 Mechanical Property Evaluation of Hybrid Composites 2.6.1 Analytical Evaluations 2.6.2 Experimental Evaluations 2.7 Prospective for Hybrid Composites for Defence Applications 2.8 Conclusions References 3 Materials and Technologies for Personal Protection Systems (PPSs) 3.1 Bulletproof Jackets (BPJs) 3.1.1 Introduction 3.1.2 Components of BPJs 3.1.3 Threat Perceptions for BPJs 3.1.4 HAP Functions 3.1.5 Manufacture of HAPs 3.1.6 Ballistic Testing and Evaluation 3.2 Ballistic Helmets 3.2.1 Introduction 3.2.2 Design Criteria for the Helmet Shell 3.2.3 Threat Levels for Ballistic Helmets 3.2.4 Materials for Different Components of the Ballistic Helmet 3.2.5 Energy Absorption Mechanism in a Composite-Based Ballistic Helmet 3.2.6 Fabrication Methodologies 3.2.7 Hygroscopic Study of Helmet Shell Materials 3.2.8 Ballistic Evaluation of Helmet Shells 3.2.9 Scope of Future Upgrading and Improvement of Ballistic Helmets 3.3 Anti-Mine Infantry Boots (BAMI) 3.3.1 Introduction 3.3.2 Anti-Personnel Mines 3.3.3 Features of DMSRDE-Developed Anti-Mine Boots 3.3.4 Materials for BAMI 3.3.5 Fabrication Process of BAMI Boots 3.3.6 Characteristic Features of BAMI Boots 3.3.7 BAMI Boot Testing and Characterization 3.4 Technological Accomplishments 3.5 Conclusions References 4 Polymeric Materials for Defence Stores in Extreme Cold Weather 4.1 Introduction: High- and Low-Temperature Effects 4.2 Low-Temperature Behaviour of Polymers 4.2.1 The Ductile-to-Brittle Transition 4.2.2 Glass Transition Temperature (Tg) 4.2.3 Characteristic Ratio and Freely Jointed Chain 4.2.4 Couchman–Karasz (C–K) Equation 4.3 Characterisation and Testing of Polymers for Product Development 4.3.1 Impact Testing 4.3.2 Dynamical Mechanical Analysis (DMA) 4.3.3 Melt Flow Index (MFI) Test 4.3.4 Tensile Test: Standard Testing Methods 4.4 Polymeric Materials for Defence Stores 4.4.1 Polycarbonates (PCs) 4.4.2 Polyurethanes (PUs) 4.4.3 Ethylene Propylene Diene Monomer (EPDM) Rubbers 4.4.4 Linear Low-Density Polyethylene (LLDPE) 4.4.5 High-Density Polyethylene (HDPE) 4.4.6 Nylons 4.4.7 Bakelite 4.5 Material Selection, Product Development and Manufacturing Processes 4.5.1 Material Selection 4.5.2 Product Development 4.5.3 Manufacturing Processes 4.5.4 Defence Store Manufacturing Defects 4.6 Concluding Remarks References 5 Development of Non-metallic Structural Materials for Defence Systems 5.1 Introduction 5.1.1 Pilot Plants and DMSRDE Use 5.1.2 Supervisory Control and Data Acquisition (SCADA) 5.2 Silicon Carbide 5.2.1 Silicon Carbide Properties and Types 5.2.2 PDC-Derived Silicon Carbide 5.2.3 Synthesis Technologies for SiC Fibres 5.2.4 Directly Produced Silicon Carbide 5.3 Polyetheretherketone (PEEK) and Polyurethanes (PUs) 5.3.1 PEEK 5.3.2 PUs 5.4 Pilot, Laboratory, and Bench Scale Synthesis 5.4.1 PDMS Synthesis 5.4.2 PCS Synthesis 5.4.3 SiC Synthesis from Rice Husk by the Arc Plasma Method 5.4.4 Bench Scale Synthesis of PEEK 5.4.5 PUs Synthesis 5.5 Applications for Defence Systems 5.6 General Summary and Remarks References 6 Defence Protective Textiles 6.1 Introduction 6.2 Classification of DPTs 6.3 Manufacturing Process of DPTs 6.3.1 CBRN Agents 6.3.2 CBRN Protective Garments 6.4 Heavy Textiles 6.4.1 Hydrophilic Membranes 6.4.2 Hydrophobic Textiles 6.5 High Altitude Clothing Gear (HACG) 6.5.1 Inner Layer 6.5.2 Middle Layer 6.5.3 Outer Layer 6.5.4 New Trends in HACG 6.6 Research Initiatives at DMSRDE for Development of Functional DPTs 6.7 Innovative Materials 6.8 Test Methods for Characterization of DPTs 6.9 General Summary and Remarks References 7 Nanofibre Web Coatings Based on Nano-Spider (NS) Technology 7.1 Introduction 7.2 Description of NS Technology 7.2.1 Principles 7.2.2 Operation of a Nanospider (NS) Machine 7.3 Production of Nanowebs and Their Properties 7.3.1 Nanoweb Production 7.3.2 Nanoweb and Fibre Properties 7.4 Characterization Techniques for Nanofibre Webs 7.5 Nanofibre Webs for Defence Protective Textiles (DPTs) 7.5.1 Contributions to DPT Research by DMSRDE 7.5.2 Summary of Contributions to DPT Research by Other Organizations 7.6 Nanofibre Web Research Initiatives at DMSRDE 7.6.1 Nanofibre Web Characterizations 7.6.2 UV Protection of a PVDF Nanofibre Web on PP Nonwoven Fabric 7.7 Applications of Electrospun Nanofibre Webs 7.8 General Summary and Remarks References 8 Superhydrophobic Textiles for Protective Clothing 8.1 Introduction 8.2 Definitions and Terminology 8.2.1 Surface Tension and Surface Free Energy 8.2.2 Wettability 8.2.3 Contact Angle 8.2.4 Contact Angle Hysteresis 8.2.5 Factors Influencing the Hydrophobic Property 8.2.6 Mechanisms of Superhydrophobicity and Oleophobicity 8.2.7 Essential Parameters for Robust Cassie–Baxter States 8.3 Materials and Process Techniques 8.3.1 Roughening of Textile Surfaces 8.3.2 Lowering of Surface Energy by Chemical Modification 8.3.3 Evaluation Techniques 8.4 Select Scientific Studies at DMSRDE 8.4.1 Study #1 8.4.2 Study #2 8.5 Summary and Concluding Remarks References 9 High Temperature Composites for Aerospace Applications and Their (Select) Production Technologies 9.1 Introduction 9.2 Fibre Reinforcements 9.2.1 Carbon Fibres 9.3 Fabrication of Fibre Preforms 9.3.1 UD Preform Fabrication 9.3.2 2D Preform Fabrication 9.3.3 3D Stitched/2.5D Preform Fabrication 9.3.4 3D Preform Fabrication 9.3.5 4D Preform Fabrication 9.4 C/SiC Composites 9.4.1 C/SiC Fibre/Matrix Interface 9.4.2 C/SiC Composite Process Methods 9.4.3 XRD Analysis of Phases in the C/SiC Composites 9.4.4 Physical Properties (Densities) of the Differently Processed C/SiC Composites 9.5 Mechanical Properties of C/SiC Composites 9.5.1 Mechanical Properties of PIP-Based C/SiCs 9.5.2 Mechanical Properties of LSI-Based C/SiCs 9.6 Thermal Properties 9.6.1 Coefficient of Thermal Expansion (CTE) 9.6.2 Thermal Diffusivity 9.7 Summary of C/SiC Composite Properties 9.8 Behaviour of C/SiCs in an Oxidizing Environment 9.8.1 Oxidation Resistance Improvements for C/SiCs 9.9 Fabridated SiC & SiCf 9.9.1 Thermal Protection Systems (TPS) 9.9.2 C/SiC Nozzles and Components for Rocket and Jet Engines 9.9.3 C/SiC Jet-Vanes for Throat Vectoring Control Systems 9.9.4 C/SiC Nozzle Throat Inserts 9.9.5 ZrB2/SiC UHTC Materials 9.10 Summary References 10 Functional Materials for Stealth and Camouflage Applications 10.1 Introduction 10.2 Functional Materials for Stealth Applications 10.2.1 Classification of Functional Materials 10.2.2 Microwave Energy with Dielectric Substrates 10.2.3 Mathematical Modelling for the Design of Microwave Absorbers 10.2.4 Concise Description of the Microwave Absorption Mechanism 10.2.5 Functional Materials Based Microwave Absorbers: Dielectric Absorbers 10.2.6 Functional Materials Based Microwave Absorbers: Magnetic Absorbers 10.2.7 Artificial Materials (FSS-Based) Microwave Absorbers 10.2.8 Theoretical Design of FSS-Based Structures 10.2.9 Examples of FSS-Based Microwave Absorbers 10.3 Functional Materials for Camouflage Applications 10.3.1 Camouflage in the Visible Region 10.3.2 Camouflage in the Near Infrared (NIR) Region 10.3.3 Camouflage in the Thermal Region 10.4 Conclusions References