MIL-DTL-64154B.pdf

INCH-POUND

MIL-DTL-64154B

17 December 2008

SUPERSEDING

MIL-PRF-64154A

29 May 1998

DETAIL SPECIFICATION

LAMINATE: FIBERGLASS-FABRIC-REINFORCED, PHENOLIC

This specification is approved for use by all Departments and Agencies of the Department of

Defense

1. SCOPE

1.1 Scope. This specification covers a fiberglass-fabric-reinforced phenolic laminate for use in composite armor systems (see 6.1).

1.2 Classification. The laminates should be of the class and code specified (see 6.2).

1.2.1 Class of fibers (see 6.1 and A.1.2).

1.2.1.1 Class A. A family of glasses composed primarily of the oxides of magnesium, aluminum, and silicon.

1.2.1.2 Class B. A family of glasses that are composed primarily of the oxides of silicon, aluminum, magnesium, and calcium

1.2.2 Code of reinforcements.

1.2.2.1 Code 1. G-filament (0.00035 – 0.000399 inches) [8.89 – 10.15 micron (µ)].

1.2.2.2 Code 2. J-filament (0.00045 – 0.000499 inches) [11.43– 12.69 micron (µ)].

Comments, suggestions, or questions on this document should be addressed to: Director, U.S.

Army Research Laboratory, Weapons and Materials Research Directorate, Materials Application Branch, Specifications and Standards Office, Attn: AMSRD-ARL-WM-MC, Aberdeen Proving Ground, MD 21005-5069 or emailed to rsquilla@arl.army.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at http://assist.daps.dla.mil/.

AMSC N/A FSC CMPS

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

http://assist.daps.dla.mil/

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified (see 6.2), the issues of these documents are those cited in the solicitation or contract.

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-662 - V50 Ballistic Test for Armor MIL-STD-810 - Environmental Test Methods and Engineering Guidelines

(Copies of these documents are available online at http://assist.daps.dla.mil/quicksearch/ or http://assist.daps.dla.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.3 Non-Government publications. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated (see 6.2), the issue in effect on the date of invitation for bids or request for proposal should apply.

ASTM INTERNATIONAL

ASTM D123 - Standard Terminology Relating to Textiles (DoD Adopted ASTM D2563 - Standard Practice for Classifying Visual Defects in Glass-Reinforced Plastic Laminate Parts (DoD Adopted) ASTM D3776 - Fabric, Mass per Unit Area (Weight) of (DoD Adopted)

(Copies of these documents are available from http://www.astm.org or ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959.)

2.4 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified in the contract or purchase order, a sample shall be subjected to first article inspection (see 4.2.1 and 6.2). The purchase document will identify the geometry of the parts required. Production parts may be of thickness or areal density (weight/unit surface area) different from those of the ballistic control panels. If that is the case, first article will include both panels made to the drawings (geometry specified) and 3 panels 24” x 24” of 25 plies or 5.0 +/- 0.4 pounds/ft 2 (psf) areal density for first article ballistic proof testing. The intent is to use identical manufacturing process on the 5.0 psf panels as used for the production articles. Adjustment to dwell time for panels of thickness or ply count higher than the ballistic test articles is anticipated and will likely be greater, but the cycle should include similar ramp rates for temperature and pressure, identical hold pressures and identical pressure release points.

All subsequent laminates delivered to the procuring activity shall conform to these samples in all of their pertinent physical and performance attributes.

3.2 Materials. The fiber reinforcement is glass and the resin is phenolic. The materials shall be as specified herein or as otherwise indicated in the documentation as specified in the contract or purchase order (see 6.2). Materials shall be free of any and all defects that adversely affect the performance or serviceability of the finished product as required by this specification. Changes in the fabric weave, the reinforcement material, the laminating resin, the laminate construction (including resin content and through thickness reinforcement), or the manufacturing process including changes in the place or location of manufacture shall require a resubmission of all first article testing unless otherwise specified in the contract or purchase order (see 6.2).

3.2.1 Reinforcement. The reinforcement (see 1.2.1) shall be a high tensile strength fiberglass meeting the requirements specified in Appendix A and consisting of either a G filament (Code

1) or a J filament (Code 2) and a sizing system compatible with epoxy resin. The two codes of reinforcement shall differentiate the materials into two separate products. The two fiber products are different in chemistry and process, hence different in mechanical, physical and ballistic properties. The surface finish, fabric architecture, resin chemistry and resin distribution are intended to be identical, regardless of which reinforcement is used. The finished laminates will be differentiated by class identification and need to be specifically identified in the purchase document as to which is desired (see 6.1).

3.2.2 Fabric. The fabric shall be fiberglass single tow plain weave or a multi tow basket weave equivalent to a plain weave with the construction of 5 +/- 0.5 ends in the warp and 5.2 +/- 0.9 ends in the fill with a nominal weight of 24 ounces/square yard +/- 5% (814 g/m2 +/- 5%). A single colored tracer yarn of K-18 1/0 E-glass or equivalent is to be woven in the warp direction in the center width of the fabric.

Class A - Red Tracer Class B - Blue Tracer

3.2.3 Phenolic Resin. The phenolic resin shall be in accordance with the requirements specified in Appendix B. [Note: these tests involve laminated plates cut into coupons for testing. The reinforcement fiber, reinforcement architecture and resin content are not similar to those properties of the laminated product developed by this specification. The evaluation of the appropriate resin chemistry and curing cycle shall be performed independently on these different laminates.] Once confirmed, then the resin shall be combined with the fabric as specified in 3.2.2.

3.2.4 Resin Content. Resin content of glass fiber reinforced laminate after coating shall be 18 to 22 weight percent solids (volatile free) based on the weight of glass fabric as determined by ASTM D3776 (option C) with moisture content reduced to less than 2 percent.

NOTE: A sample of resin coated fabric that has been placed in a forced air circulating oven at 330 +10 degrees Fahrenheit (F) [154 +6 degrees Celsius (C)] for 10 minutes is considered to be volatile free.

3.3 Construction (fabrication).

3.3.1 Dimensions and structure. The laminates shall conform to the dimensions and shape (flat or curved) (see 6.5) as stated in the contract or purchase order (see 6.2). The laminates shall consist of the specified number of plies of prepreg or areal density of the finished panel made with the above fabric and resin. The laminates shall be symmetric about the center line.

Laminates of 25 plies or more shall have no more than 4 of plies containing a splice.

Laminates of less than 25 plies shall have no splices.

3.3.2 Thickness. The average thickness of the finished laminates shall fall within the ranges established by Table I and Table Ia (see 4.2.3).

3.3.3 Unit weight. The unit weight or areal density of the finished laminates shall fall within the ranges established by Table II and Table IIa (see 4.2.4).

3.3.4 Finished laminate. The finished laminate shall consist of the specified number of plies or areal density with exterior peel-plies incorporated in the lamination process. All cutting and machining of laminate panels shall be done with the peel-plies intact. Wet cutting and machining procedures shall be followed by a drying process. Any resulting moisture film remaining on cut surface shall be removed by local heat application (heater/blower) or by using clean, dry toweling. The finished laminate shall have an epoxy resin sealed surface on all cut, trimmed or drilled hole edges which is applied after any required drying process. The epoxy resin used shall have a service temperature of not less than 250F (121C) and meet the requirement of 3.2.4. Application of the resin shall not interfere with the peel-ply removal. The use of CARC paint coating, if covering the cut surfaces, would preclude the need for additional epoxy sealing.

3.4 Performance.

3.4.1 Peel-ply removal. The peel-plies are intended to keep panel surfaces clean and shall be easily removable by hand, without requiring heat or solvents. Laborious or difficult removal shall be unacceptable (see 4.2.5).

3.4.2 Temperature resistance. The composite armor laminate shall not show evidence of delamination following a two-cycle exposure to a temperature range of -65F to 250F (-54C to 121C) (see 4.2.6).

TABLE I. Finished laminate thickness range (inches). 1/

PLIES

THICKNESS

RANGE

(Inches)

RANGE

(Inches)

1 0.019 - 0.021 11 0.207 - 0.233 21 0.395 - 0.445 31 0.583 - 0.657 2 0.038 - 0.042 12 0.226 - 0.254 22 0.414 - 0.466 32 0.602 - 0.678 3 0.056 - 0.064 13 0.244 - 0.276 23 0.432 - 0.488 33 0.620 - 0.700 4 0.075 - 0.085 14 0.263 - 0.297 24 0.451 - 0.509 34 0.639 - 0.721 5 0.094 - 0.106 15 0.282 - 0.318 25 0.470 - 0.530 35 0.658 - 0.742 6 0.113 - 0.127 16 0.301 - 0.339 26 0.489 - 0.551 36 0.677 - 0.763 7 0.132 - 0.148 17 0.320 - 0.360 27 0.508 - 0.572 37 0.696 - 0.784 8 0.150 - 0.170 18 0.338 - 0.382 28 0.526 - 0.594 38 0.714 - 0.806 9 0.169 - 0.191 19 0.357 - 0.403 29 0.545 - 0.615 39 0.733 - 0.827

10 0.188 - 0.212 20 0.376 - 0.424 30 0.564 - 0.636 40 0.752 - 0.848

1/ Laminates greater than 40 plies shall use the thickness range 0.0188n - 0.0212n (inches), where n is the number of plies.

TABLE Ia. Finished laminate thickness range (millimeters). 1/

(millimeters)

RANGE

(millimeters) 1 0.478 - 0.538 11 5.25 - 5.92 21 10.0 - 11.3 31 14.8 - 16.7 2 0.955 - 1.08 12 5.73 - 6.46 22 10.5 - 11.8 32 15.3 - 17.2 3 1.43 - 1.62 13 6.21 - 7.00 23 11.0 - 12.4 33 15.8 - 17.8 4 1.91 - 2.15 14 6.69 - 7.54 24 11.5 - 12.9 34 16.2 - 18.3 5 2.39 - 2.69 15 7.16 - 8.08 25 11.9 - 13.5 35 16.7 - 18.8 6 2.87 - 3.23 16 7.64 - 8.62 26 12.4 - 14.0 36 17.2 - 19.4 7 3.34 - 3.77 17 8.12 - 9.15 27 12.9 - 14.5 37 17.7 - 19.9 8 3.82 - 4.31 18 8.60 - 9.69 28 13.4 - 15.1 38 18.1 - 20.5 9 4.30 - 4.85 19 9.07 - 10.2 29 13.8 - 15.6 39 18.6 - 21.0

10 4.78 - 5.38 20 9.55 - 10.8 30 14.3 - 16.2 40 19.1 - 21.5

1/ Laminates greater than 40 plies shall use the thickness range 0.4775n - 0.5385n (millimeters), where n is the number of plies.

TABLE II. Finished laminate unit weight - pounds/square foot (lb/ft2). 1/

WEIGHT

(lbs/sq.ft.)

RANGE

(lbs/sq.ft.)

1 0.184 - 0.216 11 2.02 - 2.38 21 3.86 - 4.54 31 5.70 - 6.70 2 0.368 - 0.432 12 2.21 - 2.59 22 4.05 - 4.75 32 5.89 - 6.91 3 0.552 - 0.648 13 2.39 - 2.81 23 4.23 - 4.97 33 6.07 - 7.13 4 0.736 - 0.864 14 2.58 - 3.02 24 4.42 - 5.18 34 6.26 - 7.34 5 0.920 - 1.08 15 2.76 - 3.24 25 4.60 - 5.40 35 6.44 - 7.56 6 1.10 - 1.30 16 2.94 - 3.46 26 4.78 - 5.62 36 6.62 - 7.78 7 1.29 - 1.51 17 3.13 - 3.67 27 4.97 - 5.83 37 6.81 - 7.99 8 1.47 - 1.73 18 3.31 - 3.89 28 5.15 - 6.05 38 6.99 - 8.21 9 1.66 - 1.94 19 3.50 - 4.10 29 5.34 - 6.26 39 7.18 - 8.42

10 1.84 - 2.16 20 3.68 - 4.32 30 5.52 - 6.48 40 7.36 - 8.64

1/ Laminates greater than 40 plies shall use the unit weight range 0.184n - 0.216n (pounds/square foot), where n is the number of plies.

TABLE IIa. Finished laminate unit weight - kilograms/square meter (kg/m2). 1/

(kg/sq.meter)

RANGE

(kg/sq.meter) 1 0.900 - 1.06 11 9.90 - 11.6 21 18.9 - 22.2 31 27.9 - 32.8 2 1.80 - 2.11 12 10.8 - 12.7 22 19.8 - 23.3 32 28.8 - 33.8 3 2.70 - 3.17 13 11.7 - 13.7 23 20.7 - 24.3 33 29.7 - 34.9 4 3.60 - 4.23 14 12.6 - 14.8 24 21.6 - 25.4 34 30.6 - 35.9 5 4.50 - 5.28 15 13.5 - 15.9 25 22.5 - 26.4 35 31.5 - 37.0 6 5.40 - 6.34 16 14.4 - 16.9 26 23.4 - 27.5 36 32.4 - 38.0 7 6.30 - 7.40 17 15.3 - 18.0 27 24.3 - 28.5 37 33.3 - 39.1 8 7.20 - 8.46 18 16.2 - 19.0 28 25.2 - 29.6 38 34.2 - 40.2 9 8.10 - 9.51 19 17.1 - 20.1 29 26.1 - 30.6 39 35.1 - 41.2

10 9.00 - 10.6 20 18.0 - 21.1 30 27.0 - 31.7 40 36.0 - 42.3

1/ Laminates greater than 40 plies shall use the unit weight range 0.900n - 1.058n (kilograms/square meter), where n is the number of plies.

3.4.3 Ballistic resistance. The V50 protection ballistic limit, as defined by MIL-STD-662, the velocity at which the probability of penetration of an armor material is 50 percent, shall not average less than 2455 ft/s (748 m/s) for Class A, Code 1, and 2152 ft/s (656 m/s) for Class B, Code 1 or Class B, Code 2 for a laminate of nominal five pounds per square foot (4.6 to 5.4 lbs/ft2) areal density. This areal density is achieved with nominal 25 plies of the coated fabric.

3.5 Workmanship. The laminates shall satisfy visual acceptance Level 1 of ASTM D2563 for the following defects: (1) blister, (2) burned, (3) crack, (4) crack surface, (5) crazing, (6) edge delamination, (7) internal delamination, (8) dry spot, (9) lack of fillout, and (10) wrinkles.

Fabric reinforcement layers shall not have pleats, wrinkles, or creases. Fabric layers shall be free of tears, reasonably straight, and perpendicular warp-to-fill (see 4.2.2.4).

4. VERIFICATION

4.1 Verification alternatives. Alternative test methods, techniques, or equipment, including the application of statistical process control, tool control, or cost effective sampling procedures may be proposed by the contractor. Acceptable alternative verification approaches shall be identified in the contract or purchase order (see 6.2), if required.

4.1.1 Material conformance. Materials used to construct the laminate (3.2.1 to 3.2.4) shall be inspected for compliance and their certification records shall be maintained by the contractor for a minimum of six years. Records shall be subject to review by the Government and shall include date, part, inspection results, and disposition of lot (accepted or rejected). Corrective action taken on noted defects shall be subject to approval by the Government.

4.1.1.1 Resin testing. The resin shall be tested in accordance with Appendix B. The methods of testing specified/listed in Appendix B shall be followed.

4.1.2 Parts and components. Components and assemblies shall be inspected for conformance to specified requirements of drawings and in accordance with pertinent specifications and standards.

4.2 Classification of inspection. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2.1)

b. Conformance inspection (see 4.2.2)

4.2.1 First article inspection. When required (see 3.1), the first article sample shall be examined for compliance with the requirements and verifications in section 3 and section 4. All samples shall be produced with materials and processes proposed for use on production laminates.

Inspection shall be carried out by the contractor under Government surveillance, unless otherwise specified in the contract or purchase order (see 6.2). First article inspection shall consist of all quality conformance examinations and control tests.

4.2.1.1 Sampling for first article inspection. The contractor shall supply five (5) samples for first article inspection. Two (2) samples shall measure 24 inches by 24 inches (610 mm by 610

mm) by the number of plies or by the designated areal density specified in the contract or purchase order (see 6.2), within the tolerance limits specified by the contract or purchase order (see 6.2). The other three (3) samples shall measure 24 inches by 24 inches of 25 plies or 5.0 +/- 0.4 pounds/ft 2 areal density for ballistic test.

4.2.1.1.1 Ballistic tests. The three (3) ballistic samples shall be forwarded to the test site identified (see 4.2.1.1.1.1). The test samples shall be adequately identified as to contractor, contract number, manufacturer, and date.

4.2.1.1.1.1 Ballistic testing facility. Unless otherwise specified in the contract or purchase order (see 6.2), the ballistic samples shall be forwarded to the Commander, USA ATC, ATTN:

CSTE-DTC-AT-SL-V, Building 358, 400 Colleran Road, APG, MD 21005-5059 for ballistic testing for first article or conformance acceptance.

4.2.1.2 First article inspection failure. Failure of any first article sample to pass specified examinations or tests shall be cause for refusal to grant first article approval and reject product until corrective action by the contractor has been approved by the procuring agency.

4.2.2 Conformance inspection.

4.2.2.1 Lot formation. An inspection lot shall consist of all the laminated assemblies of one class, and one code, from an identifiable production period, from one manufacturer, submitted at one time for acceptance. Unless otherwise specified in the contract or purchase order (see 6.2), the default definition of a lot shall be 30 days of production of the product or 1/12 of the average yearly production of the product, which ever is larger, utilizing the same components . Any changes in materials, composition, fabric weave, the reinforcement material, the laminating resin, the laminate construction (see 3.2) or the manufacturing process including changes in the place or location of manufacture shall constitute another lot and therefore require a separate set of testing requirements.

4.2.2.2 Sampling for conformance inspection. Each sample selected from an inspection lot shall be examined as specified herein for the visual defects listed in 3.5. Conformance to a lot shall be accepted when zero (0) defects are found and rejected when one (1) or more defects are found. First article test samples shall not be shipped.

4.2.2.3 In-process examination. The contractor shall initiate, perform, and document on a recurring basis an in-process procedure consisting of process controls and examination criteria satisfactory to the Government, and include the requirements and verifications in section 3 and section 4.

4.2.2.4 Control test. The contractor shall supply two (2) test samples 24 in. by 24 in. (610 mm by 610 mm), for each lot of laminate fabrication, for control testing. The samples shall have the contract designated number of plies or areal density and shall be produced with materials and processes used for production laminates. Testing shall be carried out by the contractor under Government surveillance and shall consist of tests to show conformance to the requirements in 3.3.2, 3.3.3, 3.4.1, 3.4.2, and 3.5. The contract or purchase order (see 6.2) shall identify an inspection delegation to the QAR that services the contractor’s facility.

4.2.3 Determination of laminate thickness. The thickness of a finished laminate is determined as follows: Choose a square laminate of nominal size at least 24 in. by 24 in. (610 mm by 610 mm), and remove peel-plies. Measure thickness to nearest 0.001 in. (0.0254 mm) at least 1.0 in.

(25.4 mm) in from each of four (4) corners. Average the four (4) readings (see Table I and Ia).

4.2.4 Determination of unit weight. The unit weight or areal density of a finished laminate is determined as follows: Choose a square laminate of nominal size at least 24 in. by 24 in. (610 mm by 610 mm), and remove peel-plies. Dry the panel in a forced draft or convection type oven in a stream of ambient air heated to 200 10F (93 5C). Dry the panel until no further change of mass occurs when it is weighed with an error of less than 0.1 after cooling to room temperature in the standard atmosphere for testing textiles as defined in ASTM D123. Calculate the unit weight to three significant figures as follows:

Unit weight = 144M lb/ft2

LW

Where M is the dry panel weight in pounds measured with an error of less than 0.1, L is the length of the panel in inches measured to the nearest 0.063 in. and W is the width of the panel in inches measured to the nearest 0.063 inch (see Table II).

Unit weight = 1 x 106 M kg/m2

LW

Where M is the dry panel weight in kilograms measured with an error of less than 0.1, L is the length of the panel in millimeters measured to the nearest 1.5 mm, and W is the width of the panel in millimeters measured to the nearest 1.5 mm (see Table IIa).

4.2.5 Peel-ply test. The peel-ply test shall consist of removing the peel-plies by hand.

4.2.6 Temperature resistance test. The temperature resistance test shall be performed in accordance with method 503.4 of MIL-STD-810, except the temperature extremes and number of cycles shall be as specified in 3.4.2.

4.2.7 Ballistic control test. The contractor shall supply three (3) test samples 24 in. by 24 in.

(610 mm by 610 mm) by 25 plies or 5.0 +/- 0.4 pounds/ft 2 areal density for each lot of laminate fabrication for ballistic control testing at a Government approved facility (see 4.2.1.1.1.1) to show conformance to 3.4.3. The test panels shall be adequately identified as to contractor, contract number, manufacturer, and date. The testing facility shall report raw data, velocities, penetration observation, thickness, and the laminate classification (see 1.2) for each test sample.

4.2.7.1 Ballistic test. The ballistic resistance test shall be conducted in accordance with MIL- STD-662. The test projectile shall be a 0.30 caliber (7.62 mm) (44 grain) fragment-simulating projectile at 0 obliquity. The V50 ballistic limit protection reported shall be the average of three (3) determinations made on separate nominal 25 plies laminate panels. Each determination shall be a six round (three pair) V50 ballistic limit with a maximum velocity spread of 125 ft/s (38 m/s).

4.2.8 Failure. Failure of the samples to meet any of the test requirements shall be cause for the procuring activity to stop acceptance of quality conformance samples and reject the specific lot of material until the cause of the failure(s) is identified, corrective action is taken by the contractor, and approval is granted by the procuring activity.

5. PACKAGING

5.1 Packaging. For acquisition purposes, the packaging and marking requirements shall be as specified in the contract or order (see 6.2). When packaging of materiel components are to be performed by DoD or in-house contractor personnel, these personnel need to contact the responsible packaging activity to ascertain packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activities within the Military Service or Defense Agency, or within the military service’s system commands. Packaging data retrieval is available from the managing Military Department’s or Defense Agency’s automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6. NOTES

(This section contains information of a general or explanatory nature that may be helpful, but is not mandatory.)

6.1 Intended use. The laminates furnished under this specification are military unique because they are intended for use as a component of composite armor and must meet ballistic limit protection requirements. Legacy systems requiring prior version of this specification, namely, MIL-L-64154 or MIL-PRF-64154, should use material designated as Class A of this specification to ensure compatibility.

6.2 Acquisition requirements. Acquisition documents should specify the following:

a. Title, number, and date of the specification.

b. Specify class of fiber (see 1.2.1), and code of reinforcement (see 1.2.2).

c. If issues of documents are different (see 2.2 and 2.3).

d. If first article is required (see 3.1).

e. Specify the documents (specifications, standards, or drawings) that indicate the material that are to be specified (see 3.2).

f. If a resubmission of all first article testing is not required (see 3.2).

g. Specify the dimensions and shape (flat or curved) of the laminate (see 3.3.1)

h. If alternative verification approaches are identified (see 4.1)

i. Whether First Article inspection is carried out by the contractor under Government surveillance or by someone else (see 4.2.1).

j. Specify number of plies or areal density for the first article samples (see 4.2.1.1).

k. Specify the tolerance limits for the number of plies or areal density for the first article samples (see 4.2.1.1).

l. If the ballistic testing facility is different than that listed (see 4.2.1.1.1.1).

m. If the default definition of a lot is different (see 4.2.2.1).

n. Specify the responsible Government Agency that will witness the contractor’s testing (see 4.2.2.4).

o. Specify packaging and marking requirements (see 5.1).

6.3 Alternate ballistic testing facility. Request for approval for an alternate ballistic testing facility should be forwarded by the procuring activity to the Director, U.S. Army Research Laboratory, Weapons and Materials Research Directorate, Specifications and Standards Office, Attn: AMSRD-ARL-WM-MC, Aberdeen Proving Ground, MD 21005-5069 and should be obtained prior to the contract award. Please note that alternate ballistic testing facilities are being considered but at the present time, the requirements needed for approving an alternate facility are not fully known. A reasonable option to consider would be to perform an initial comparison between the government test facility and one chosen by the contractor. If a bias is identified through this comparison it could be useful to the contractor to adjust the values obtained by the independent test facility, allowing a more frequent sampling rate using the independent test facility. This would not remove the requirement for control testing performed by the government laboratory.

6.4 First time suppliers. First time suppliers who have not previously supplied composite armor laminate to MIL-DTL-64154 and wish to have their material tested, may do so at their own expense. It is recommended that inquires for testing be directed to Commander, U.S. ATC, ATTN: CSTE-DTC-AT-SL-V, Bldg 358, 400 Colleran Road, Aberdeen Proving Ground, MD 21005-5059. Technical questions regarding testing may be directed to U.S. Army Aberdeen Test Center, Vulnerability/Lethality Division, ATTN: TEDT-AT-SLV, Aberdeen Proving Ground, MD 21005.

6.5 Shape of laminates. Both flat and curved laminates are produced by this specification. A suggested molding cycle could consist of the following sequence:

1. Preheat press platens to 275 F.

2. Charge press with required prepreg, and insert hard press stops at finished panel thickness.

3. Close to contact pressure of 25 psi

4. Monitor temperature in center of laminate, about 1 inch from edge, until laminate center reaches 265 F.

5. Increase laminating pressure to 125 psi, and increase platen temperature to 345 F at a rate of 4 to 7 F per minute. Platens should close to hard stops.

6. Hold pressure and temperature until laminate centerline reaches 340 F.

7. Hold pressure and temperature for 30 minutes once a laminate center temperature of 340 F is reached.

8. Once 30 minutes has elapsed, cool laminate under pressure until laminate center is 180 F or below.

9. Open press and trim panels to desired dimensions

6.6 Peel-ply. It is recommended that the peel-ply be porous and polytetra-fluoroethylene (PTFE) coated with a thickness of 0.003 in. (0.076 mm).

6.7 Subject term (key word) listing.

Ballistic resistance Composite armor Resin Peel-ply

6.8 Changes from previous issue. Marginal notations are not used in this revision to identify changes with respect to the previous issue due to the extent of the changes.

APPENDIX A

HIGH TENSILE STRENGTH FIBERGLASS REINFORCEMENT

A.1 SCOPE

A.1.1 Scope. This appendix provides the requirements for the two (2) classes of reinforcement materials that will be used in the construction of the laminates. This appendix is a mandatory part of this specification. The information contained herein is intended for compliance.

A.1.2 Applicability. The requirements specified in this appendix are required. The content of this appendix was taken from specification, MIL-R-60346C. The requirements of MIL-R-60346C, type IV, Class 1 material is a general purpose high tensile strength glass, G filament (Code 1) with a sizing system compatible with epoxy resin and is classified as Class A (see 1.2.1 of the main document). Class B material is a general purpose high-strength glass, J filament (Code 2) with a sizing system compatible with epoxy resin. Specific property requirements for both classes are listed in Table A-III (see 6.1).

A.2 APPLICABLE DOCUMENTS (This section is applicable to this appendix only)

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-129 - Military Marking for Shipment and Storage

(Copies of these documents are available online at http://assist.daps.dla.mil/quicksearch/ or http://assist.daps.dla.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

ASTM INTERNATIONAL

ASTM D618 - Plastics Conditioning for Testing ASTM D2343 - Glass Fiber Strands, Yarns, and Rovings used in Reinforced Plastics, Tensile Properties of ASTM D2344/D2344M - Standard Test Method for Short-Beam Strength of Polymer Matrix Composite Materials and Their Laminates

(Copies of these documents are available from www.astm.org or ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959.)

A.3 REQUIREMENTS

A.3.1 Roving.

A.3.1.1 Construction. The roving shall consist of a number of continuous glass filaments coated with suitable sizing system (see A.3.1.5) and laid essentially parallel with little or no twist. The filaments may or may not be grouped into strands, intermediate in size, between a single filament and the roving itself (see A.6.3). The roving shall be supplied in the form of roving balls (see A.3.3). The construction shall be in accordance with A.3.3, and the acceptable quality levels (AQL), specified in Table A-I (see A.4.2.1) or as otherwise specified in the contract or purchase order (see A.6.2).

TABLE A-I. Examination of Roving Ball for Visual Defects.

EXAMINE

AQL

PERCENT

DEFECTIVE

DEFECT 1/ METHOD

INSPECTION

1.0 Dirt, grease, oil or foreign matter in

quantity sufficient to be detrimental to end use.

Visual

1.0 Any knot or fuzz accumulation. Visual

1.0 Any splice or group of two or more

splices not in accordance with A.3.4.1.

Visual

Workmanship:

Outer layer 2/ Of roving ball

(see A.3.4, A.3.4.1 &

A.6.2) 3/ Difference in color, transparency or other appearance of the filaments.

Visual

2.5 Not cylindrical within 5/16 inch

Carpenter’s square & scale

2.5 Not centered on tube, where applicable, within 1/8 inch.

Carpenter’s square & scale

2.5 Diameter or length improper. Scale

2.5 Direction and angle of winding improper.

Scale and visual

Package (ball) build:

Roving ball (see

A.3.3, A.6.2, and A.6.4)

2.5 Number of turns per transverse improper. Visual

2.5 Inside diameter or length improper. Visual Tube (see A.3.3 and A.6.2) 2.5 Not suitable, color code improper. Visual

1/ The lot shall be evaluated separately in respect to each category or defect.

2/ Unless the external appearance of a ball or supplier’s previous history shows interior of the ball may contain defects, a ball shall not be unwound merely for examination for visual defects.

3/ The lot shall be rejected if there is a visual difference in color, transparency, or other appearance of the filaments indicating a possible mixing of different types of glass fibers.

A.3.1.2 Glass.

A.3.1.2.1 Chemical composition. The chemical composition of high tensile strength glass and general purpose high tensile strength glass shall be certified (see A.4.2.1) as being within the limits listed in Table A-II. Any deviation from the composition ranges listed in Table A-II shall require the approval of the procuring activity (see A.6.5).

TABLE A-II. Chemical composition range (weight percent).

Oxides Class A Class B

SiO2 64.0 – 66.0 61.0 – 63.0 Al2O3 24.0 – 26.0 18.0 – 20.0 MgO 9.0 – 11.0 9.0 – 11.0 CaO < 0.2 7.0 – 9.0

A.3.1.2.2 Properties. The properties listed in Table A-III shall be required for both classes of glass (see A.6.3). Any new or modified glass shall not be acceptable unless approved by the procuring activity (see A.6.5).

A.3.1.3 Filament diameter and code letter of current commercial filaments. The nominal filament diameter range and code letters shall be as listed in Table A-IV.

A.3.1.4 Roving yield. Each roving package fabricated by either conventional or non conventional roving winding processes shall contain a sufficient number of filaments of the specified diameter code (see A.3.1.3) to produce the nominal roving yield specified in the Table A-III, unless otherwise specified in the contract or purchase order (see A.6.2) to within a tolerance of ± 5.0 percent (see A.4.3.4, A.6.3, and A.6.4).

A.3.1.5 Sizing system The roving shall have a sizing system selected and applied so as to provide compatibility between the glass and epoxy resin (see A.6.3).

A.3.2 Property requirements. The roving shall conform to the property values specified in Table A-III, when tested as specified in the applicable testing procedure as specified in section A.4.3 (see A.4.2.2).

A.3.3 Package build. (see Table A-I) The roving shall be wound with uniform tension on a tubeless package or a heavy duty winding tube of the dimensions and color code as specified in the contract or purchase order (see A.6.2) to make essentially cylindrical roving package. The dimensions, direction and angle of winding, the number of turns per transverse, and the spacing of the roving, shall be as specified in the contract or purchase order (see A.6.2) When not specified, the manufacturer’s standard dimensions, winding pattern, and color code shall be considered acceptable. The roving shall unwind from the package on commercial filament winding equipment without excessive process interruptions or excessive tension variation.

A.3.4 Workmanship. The material shall be free from visible dirt, grease, oil, or foreign matter. Any group of knots, strands or fuzz accumulation occurring at any point in the package which is sufficient to cause an appreciable change in the smoothness of the roving shall be cause for rejection unless the defect can be removed without rendering the remainder of the package rejectable (see Table A-I). There shall be no visible differences in color, transparency, or other appearance of the filaments which may indicate mixing of different types of glass fibers for conventional roving products.

TABLE A-III. Property Requirements.

PROPERTY

CLASS A /

Code 1 (G filament)

CLASS B /

Code 1

(G filament)

CLASS B /

Code 2

(J filament)

1/ Package (ball density (pounds/cubic inch) minimum maximum

0.035 0.065

0.035 0.065

N/A N/A

1/ Shore "O" package ball hardness minimum maximum

Catenary, 2/ inches/50 feet, maximum 1.0 1.0 N/A

Total Roving yield (multi-tow), yds/lb

244 +/- 5% 244 +/- 5% 820 +/- 8% 5/

Tensile strength, psi, minimum 450,000 400,000 400,000 Horizontal shear strength (after 6-hour boil) psi, minimum

3/ 3/ 3/

Resistance to Fusion Test 4/ 4/ 4/

1/ The supplier has the option to perform either the Package (Ball) Density or the Shore "O" Package Hardness test for multiple end roving. Only one of the two tests is required for multiple end roving. Shore “O” Package Hardness data is given only for reference for a single end package.

2/ Unless otherwise specified, the catenary requirement applies only to rovings having a yield of 700 or less yards per pound.

3/ Applicable only when specified by the procuring activity (see A.4.3.6 and A.6.2). Actual values are dependent upon a given resin. Therefore, values shall be agreed upon between the supplier and the procuring activity for the matrix resin which is to be used. Using NOL Ring method in ASTM D2344/D2344M, normal values are 8,500 psi for epoxy and 7,000 psi for polyester resin matrices.

4/ The specimens of A.4.3.8 shall not fuse.

5/ Single end roving.

TABLE A-IV. Filament diameter and code.

Filament Diameter range, inches Diameter range, microns

G 0.00035 – 0.000399 8.89 – 10.15 J 0.00045 – 0.000499 11.43 – 12.69

A.3.4.1 Splices. When insertion of a broken strand by skip knotting or mechanical insertion method is not acceptable, it shall be spliced with cellulose acetate cement, or any mutually acceptable substitute, with a one inch minimum overlap. When two or more ends are spliced simultaneously, splices shall be spaced so as to prevent any overlapping of the spliced areas, with the exception of gang splices. The maximum number of splices shall not exceed an average of one splice per pound of roving.

A.4 VERIFICATION

A.4.1 Testing responsibility and facilities. Unless otherwise specified in the contract or purchase order (see A.6.2), the contractor is responsible for the performance of all the requirements as specified herein. Unless otherwise specified in the contract or purchase order (see A.6.2), the contractor may use his own or any other facilities suitable for the performance of the requirements specified herein, unless disapproved by the Government.

The Government reserves the right to perform or check any of the inspections set forth in this specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements and to determine the validity of the certifications.

A.4.2 Lot. Unless otherwise specified in the contract or purchase order (see A.6.2), a lot shall consist of all material of the same filament code, and class and manufactured at the same place and location utilizing the same equipment and submitted for delivery at one time.

A.4.2.1 Supplier’s certification. The supplier shall certify that (a) all roving packages were produced under the same manufacturing process; (b) the glass is Class A or Class B, or general purpose high tensile strength Class A or Class B, as specified (see A.3.1.2); (c) the nominal filament diameter corresponds with code letter designation applicable to the strand specified (see A.3.1.3); (d) the sizing on the glass is compatible with the epoxy resin specified; (e) that all splices, if used, were made in accordance with A.3.4.1.

A.4.2.2 Testing. The material shall be tested for characteristics listed in Table A-III, in accordance with the test methods specified herein. The lot size for the purpose of determining sample size for testing shall be expressed in units of one roving ball. The sample unit shall consist of sufficient material to prepare all required specimens. Testing for hardness, package (ball) density, catenary and roving yield shall be as specified in the contract or purchase order (see A.6.2).

A.4.3 Testing Methods.

A.4.3.1 Specimen conditioning and testing. Unless otherwise specified in the contract or purchase order (see A.6.2), specimens for tensile and shear testing shall be conditioned in accordance with procedure A of ASTM D618. Specimens for other testing shall be conditioned for a minimum of 2 hours in accordance with ASTM D618. Testing shall be at

73.4 ± 3.6 F (23 ± 2 C) and 50 ± 5 percent relative humidity.

A.4.3.2 Hardness. A shore "O" durometer or equivalent shall be used to test as follows: Set the roving ball on its end on a horizontal flat surface. Support the ball with one hand, hold the durometer in the other, and bring the instrument plunger and foot into contact with outermost layer of roving. Apply such pressure as is required to bring about constancy in the reading attained on the dial indicator. Three readings shall be made randomly spaced around the circumference and along the length of the ball.

A.4.3.3 Catenary. Unless otherwise specified in the contract or purchase order (see A.6.2), this test is not applicable to roving having a yield less than 700 yards per pound. One specimen per roving ball shall be tested and each obtained by pulling roving from the ball until the slack is taken off, then tying a knot in the roving approximately 12 inches from the package. The roving shall be pulled over a spindle and clamped to a strand which is located approximately 50 feet from the spindle. After returning to the roving ball and holding a 50 foot portion of the strand tight, a hard knot shall be tied. A clamp and sufficient weights to give a total of 2 ± 0.1 pounds shall be placed on the hanging end of the roving. The roving shall be grasped lightly at the center of the span (25 feet) and pulled down 1 foot. The roving shall be released. The pull down and release shall be repeated three additional times. The distance between the furthermost separated strands perpendicular to the lengthwise direction shall be measured.

A.4.3.4 Roving yield. One specimen shall be tested per roving ball sample. The roving yield shall be computed by dividing the weight into measured length resulting in units such as yards/pound (see A.6.3).

A.4.3.5 Tensile strength. Five specimens per roving ball shall be tested in accordance with ASTM D 2343. The roving shall be tested on specimens made with resin specified in the contract or purchase order (see A.6.2).

A.4.3.6 Horizontal shear strength test. When specified in the contract or purchase order (see A.6.2), a horizontal shear strength test shall be performed. Unless otherwise specified in the contract or purchase order (see A.6.2), a minimum of five (5) specimens per roving shall be tested in accordance with ASTM D2344/D2344M when this test is required.

A.4.3.7 Package density. One density determination is made for each ball (package) in the sample from the lot being tested. Density (reported to the nearest 0.001 pounds/cubic inch) is determined by measuring inside diameter to the nearest 1/16 inch with a steel rule, outside diameter to the nearest 1/16 inch with a circumference tape (or steel rule), length to the nearest 1/16 inch with a steel rule and ball (package) weight to the nearest 0.1 pound and calculating the following:

D = 1.27 x weight .

length (do

2 – di 2) where D = package (ball density, lbs/cubic inch) do = outside diameter, inches di = inside diameter, inches

A.4.3.8 Resistance to fusion. One specimen per roving ball shall be tested for resistance to fusion. Class A material shall not fuze when ignited at a temperature of 1500 o +/-45o F (816 o +/-25o C). Class B material shall not fuze when ignited at a temperature of 1400 o +/-45o F (760 o +/-25o C), but they will fuse when ignited at 1500 o +/-45 o F. Standard E-glass will fuse when ignited at a temperature of 1400 o +/-45 o F (760 o +/-25 o C) or higher.

A.4.3.9 Marking. In addition to any special marking specified in the contract or purchase order (see A.6.2), containers shall be marked in accordance with MIL-STD-129. If special storage conditions are required, containers shall be so marked to specify the complete conditions for storage.

A.5 PACKAGING

A.5.1 Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see A.6.2). When packaging of materiel components are to be performed by DoD or in-house contractor personnel, these personnel need to contact the responsible packaging activity to ascertain packaging requirements.

A.6 NOTES

A.6.1 Intended use. The high tensile strength fiberglass covered by this appendix is intended to be used as reinforcement for the laminates specified in the specification this appendix is a part.

A.6.2 Acquisition requirements. Acquisition documents should specify the following:

a. Specify the acceptable quality levels (AQL), if different (see A.3.1.1 and Table A-I).

b. Specify nominal roving yield, if different (see A.3.1.4).

c. Specify the dimensions and color code of a heavy duty winding tube, if required (see A.3.3).

d. Specify dimensions, direction and angle of winding, the number of turns per transverse, and the spacing of the roving (see A.3.3).

e. If someone besides the contractor is responsible for the performance of all the requirements (see A.4.1).

f. If the contractor can not use his own or any other facility for testing (see A.4.1).

g. If the definition of a lot is different (see A.4.2).

h. Specify the testing for hardness, package (ball) density, catenary and roving yield (see A.4.2.2).

i. If specimens for tensile and shear testing are to be conditioned differently (see A.4.3.1).

j. If a catenary test is applicable to roving having a field less than 700 yards per pound (see A.4.3.3).

k. Specify the resin the roving specimens will be made from (see A.4.3.5).

l. Specify if a horizontal shear strength test is required (see A.4.3.6 and Table

A-III).

m. If the number of specimens and the test method are different (see A.4.3.6).

n. Specify any special markings (see A.4.3.9).

o. Specify packaging requirements (see A.5.1).

A.6.3 Definitions. For the purpose of this appendix, the following definitions have been used.

A.6.3.1 Filament. Filament - a single glass fiber, as drawn.

A.6.3.2 Strand. Strand - a plurality of filaments gathered together with little or no twist and bonded with sizing.

A.6.3.3 Roving. Roving - a plurality of strands of filaments gathered together with little or no twist.

A.6.3.4 Roving yield. Roving yield - the roving yield in yards per pound is obtained as follows:

Roving yield = 453.6 X length of specimen (yards) Yards per pound weight of specimen (grams)

Upon request, the supplier should provide a value for a yield in grams per kilometer (roving weight in TEX).

A.6.3.5 Roving designation. Roving designation - a roving ordinarily is designated by a roving yield (yards per pound) and a filament diameter code; i.e., “700G” plus the class.

A6.3.6 Sizing system. Sizing system - a surface treatment or coating applied to the glass during the fiber forming operation to improve its ability to bond to a laminating resin.

Different sizing systems may be necessary for use with different resins. The Class A or Class B, and general purpose high tensile strength Class A or Class B glass is a magnesia-alumina-silicate glass of higher tensile strength and melting point than “E” glass.

A.6.4 Construction. In the past, it was common practice to attenuate glass through bushings having 204 or 408 holes to produce strands containing those numbers of filaments and then to supply 1, 12, 15, 20, 30 and 60–end rovings made from those strands as described in A.6.3. Although many suppliers still are using this practice, others are attenuating fiber glass through bushings containing up to several thousand holes so that they can make a heavy roving containing only a single strand. Since the strands are not twisted, rovings made with the larger single strands are equivalent, for most purposes, to those made with the smaller multiple strands. Since existing drawings may specify rovings in accordance with the old multiple strand designation, a purchasing activity receiving a requisition for roving having a specific strand yield and end count should check with the purchaser to determine whether or not there may be considered for substitution.

A.6.5 Glass composition and properties. To insure that the final laminate does not vary from what was tested, any new glass material should not be acceptable unless approved by the procuring activity. Approval requires that each class of new or modified glass must be tested by an independent facility and pass all the required tests specified by the Procuring Activity. These tests should include but not be limited to the following; environmental, mechanical, and ballistic requirements. Subsequently, when the new or modified glass is approved by a Procuring Activity (Buyer), a new or modified classification will be added to Appendix A of this specification with corresponding requirements, such as, chemical composition and the property requirements listed in Table A-III. Finally when enough ballistic data has been collected and analyzed, a V50 requirement will be determined.

Alternative glass chemistries that demonstrate acceptable performance for all the required properties should be encouraged, such as, the new Class B material of this specification. Prior to this revision, the procuring activity realized that a new glass fiber was available. Therefore, laminates were made utilizing this new fiber and a trial and error type program was initiated to develop its’ properties. Testing continued and subsequently the company did demonstrate that the new or modified glass does not cause any problems. The procuring activity notified Army- MR Standardization Office (see contact information on first page of this specification) of the variations and once received, changes to this specification were made by adding an additional class of fiber, namely, Class B.

APPENDIX B

RESIN, PHENOLIC, LAMINATING (GRADE B – IMPROVED PROPERTIES)

B.1 SCOPE

B.1.1 Scope. This appendix provides the requirements for an improved grade of resin that will be used in the construction of the laminates. This appendix is a mandatory part of this specification. The information contained herein is intended for compliance.

B.1.2 Applicability. The requirements specified in this appendix are required. The content of this appendix was taken from specification, MIL-R-9299C.