Solutions for improving vehicle and personal protective equipment Disruptive improvements in vehicle and personnel protection

We can help you make better protection systems by: • Improving the performance of conventional armour materials • Developing new nano-modified or hybrid materials and armour structures • Devising improved manufactur- ing and integration methods • Accelerating development and validation of new products • Assessing product performance through testing

Corporal Shilo Adamson, Canadian Armed Forces, Combat Camera © 2010 DND-MDN Canada Cover photo: MCpl Kevin Paul, Canadian Armed Forces Combat Camera

From ® to polymer composites, from RHA to advanced , and personal protective equipment based on conventional materials are rapidly approaching their performance limits.

It is only through new and The SMT program integrates key Collectively, NRC and DRDC have strengths and capabilities from the experience to develop high- advanced material technolo- both organizations. NRC is the only performance material solutions and gies that significant gains in organization in Canada, and one of multi-threat protection solutions. few in the world, with integrated performance will be We work directly with Canadian world-class expertise in engineered industry and other partners across achieved. That’s why the materials, processing and perfor- the security materials supply chain National Research Council mance currently focused on the to develop improved and disruptive, design, testing and production of of Canada (NRC) has joined game-changing armour products advanced protection products. For from concept to full-scale prototyping forces with Defence Research its part, DRDC has capabilities and and evaluation. and Development Canada experience in assessing and validating novel armour systems. (DRDC) to deliver the Security Our technical advice and consulting services are designed to help acceler- Materials Technologies (SMT) ate, and substantially de-risk product research program. development.

2 Working with Canada’s foremost research and technology organization

What we can provide Work with us • Reduced risk and significant cost Our technical advice and consult- • Access extensive scientific savings in product development ing services help our partners knowledge and technical succeed by capitalizing on NRC’s and • More efficient use of your valuable expertise – from constituent DRDC’s extraordinary strengths in the resources and research investments materials to armour science and engineering of advanced components and systems • More effective solutions in materials, manufacturing processes, less time and armour systems. • Access critical and world-class • Exploitation and transfer research infrastructure from of specialized knowledge nano-scale to full-scale • Develop unique customized solutions to maintain and NRC’s nanocomposites group, pictured below, was awarded the 2015 Public Service Award of Excellence improve your competitive edge

in the Scientific Contribution category for their breakthrough work enabling the world’s first pilot-scale production of nitride nanotubes. L to R: Keun Su Kim, Mark Plunkett, Benoit Simard, Chris Kingston, Jingwen Guan, Mike Jakubinek

3 Materials Processing Armour Characterization Technologies & Manufacturing Systems & Testing

About composites, hybrids and nano- modified materials • : A combination of two or more Stronger, tougher, lighter materials materials with very different properties, which creates a new material with characteristics possible, allowing for the creation different from the individual Nanomaterials of new, more efficient and higher- constituents. Improve and expand the performance material systems.

• Nanomaterials: Materials with1596_BNNT - CNT propertiesperformance - Revised 2.pdf of 1 conventional2015-05-22 11:26 AM We have extensive scientific at least one dimension between and advanced materials and engineering knowledge 1 nm to 100 nm, often exhibiting Nanomaterials, such as carbon and experience manufacturing, extraordinary mechanical, nanotubes (CNTs) and boron nitride handling and optimizing the thermal or other properties. nanotubes (BNNTs), can enhance the integration of nanomaterials into Example: single-walled carbon properties and functions of current conventional materials to produce nanotubes, with a diameter of materials and introduce new func- high-performance materials and about 1 nm, are over 100 times tionalities that weren’t previously structures. stronger than steel by weight. • Nano-modified material: A composite material with at least BNNTs CNTs one constituent being a nano- material, imparting some of the • White

extraordinary properties of the • Stable at higher nanomaterial(s) to the composite, temperature • Black • Low density even at low concentrations (>900 °C in air) • Stable at lower • High strength temperature (e.g. less than 1%). • Electrical insulator • High stiffness (400 °C in air) • Piezoelectric • Hybrid material: A type of • High thermal • Metallic or composite material with two • Transparent in the conductivity semi-conducting or more types of macroscopic visible and infra-red • High aspect spectrum (not nano-scale) constituents ratio • High neutron with quite different but comple- absorption mentary properties. For example, an /carbon hybrid com- bines stiffness and ballistic resistance.

4 Materials Processing Armour Characterization Technologies & Manufacturing Systems & Testing

Nano-modified materials and hybrids

Translating the extraordinary proper- stability, moisture resistance and ties of nanomaterials into real-world electrical properties. armour applications requires effective Some nano-modified materials are integration into conventional high ready for near-term armour applica- performance armour materials. Our tions, while others will require longer materials experts have applied their term investments to reach their truly world-class skill sets in chemistry, disruptive potential. In many cases, physics, and process engineering to shorter-term benefits can be achieved successfully nano-modify a broad through creative engineering of range of materials including polymers, hybridized structures. Combining adhesives, textiles, metals, ceramics conventional engineering materials (e.g. Boron nitride nanotubes and . aramid and carbon composites) in ways production capacity The resulting nano-modified engi- that leverage the best properties of neered materials can show not only each can create structures with greater The structural, electronic and improved strength, stiffness and performance than any single material. optical properties of BNNTs make toughness compared to the base Our team possess the skills in design, them promising candidates for material, but can also be designed materials, processing and manufactur- nano-modification of polymers, to improve flame and temperature ing to develop optimized hybrid glasses, metals and ceramics. material systems for your application. BNNTs are expected to lead to lighter and multifunctional materials for applications in Nanocomposite and hybrid materials can have a big aerospace, automotive, and effect on: defence and security. Of particular interest is the potential of BNNTs • Creating materials and structures • Materials designed for a specific as coatings or for bulk modifica- with unique properties possessed threat environment tion of transparent armour. by no single natural material • Multi-functional materials that • Functionally-graded materials avoid parasitic weight of multiple In 2015, NRC signed a licensing that transition from one property layers with different functions agreement with Tekna Plasma to another Systems Inc. allowing Tekna to • Improved armour system manufacture BNNTs in commercial performance quantities using NRC-developed methods. The patented technology produces BNNTs over 100 times faster than any earlier methods, opening the door to exploration of BNNTs in a wide range of applications.

Carbon nanotubes grown directly on alumina fabric 5 Materials Processing Armour Characterization Technologies & Manufacturing Systems & Testing

Flexible, scalable, industrial processes

Modelling Manufacturing Our capabilities allow modelling and High-quality, repeatable and cost- simulation of processing, properties effective manufacturing processes and performance of materials and are critical in order to successfully transi- structures from the nano-scale to tion the next generation of high- full-scale. These capabilities can performance materials into successful NRC’s hot press armour products. We have extensive substantially reduce materials Whether we add nanoparticles to the knowledge of advanced processing and process development time, polymers or other additives, the end and manufacturing technologies. and de-risk product development. result is a polymer composite in a Our world-class expertise includes form that can be shaped into per- nanomaterials production and sonal protective equipment (PPE) integration, joining technologies, Our modelling tools or vehicle armour (VA). help to explore a wide polymers and advanced composites processing, metals and ceramics At the core of our armour products range of challenges processing, coatings technologies, manufacturing capabilities is the • Manufacturing process non-destructive inspection and Hot Press, a multi-process moulding development additive manufacturing. platform. In addition to an infra-red oven, it boasts an array of features We can manufacture a broad • Environmental durability such as high speed ram movements range of materials and select the and degradation and rapid heating capabilities. best processing route for combining • Damage initiation and polymers with reinforcing fabrics. Our team has decades of experience propagation These include wet and pre-impreg- developing and transitioning state-of- • Translating nano-scale perfor- nated layups, micro foaming, com- the-art manufacturing technologies mance to macro-scale structures pression moulding, resin transfer to industry, particularly in the aero- • Low to high-speed velocity moulding, injection moulding, space, automotive and ground impacts reaction injection moulding, profile transportation sectors. We will and sheet extrusion, film blowing, work with you to rapidly identify the • Blast and structure interactions continuous fibre reinforcement, best manufacturing route for your • Vehicle control and dynamics filament winding, etc. product, and to develop and demon- strate a process that can be quickly transitioned to your own operation or your supply chain.

6 Materials Processing Armour Characterization Technologies & Manufacturing Systems & Testing

Scale-up production of nano-modified materials A challenge common to all new materials is scaling up from lab-scale demonstrators to industrial production. We are expanding our facilities and tools for the production, processing, formulating and integration of nanomaterials and nano- composites to fill this critical gap. Scale-up of these novel nano-modified materials to industrially relevant quantities enables thorough process troubleshooting and optimiza- tion in preparation for transfer to full-scale production lines. It also feeds our advanced manufacturing facilities with quantities of nano-modified materials sufficient for large- scale component manufacturing and prototype demonstrations.

NRC’s Boucherville facility

From nanomaterials to validated products

(m) 10 -9 10 -6 10 -3 10 0

7 Materials Processing Armour Characterization Technologies & Manufacturing Systems & Testing

Stronger, Personal protective equipment and vehicle armour tougher, Through the Security Materials Technologies program, we support the development, assessment and adaptation of next-generation materials lighter and and manufacturing technologies to enhance the performance and cost-effective reduce the weight of PPE and VA. Maximize effectiveness fibres. Another area of work is the and reduce costs application of our world-leading We are developing a range BNNT technologies to improve of materials and manufacturing polymer transparent armour through technologies leading to improved, both more durable surface coatings cost-effective PPE and VA compo- and bulk material modification. In all nents and systems. One example is cases, whether meeting a short-term our efforts to adapt an automotive client requirement or addressing technology called direct long-fibre longer-term challenges, our work is (D-LFT) to design aimed at transitioning advanced low-cost, high-complexity armour armour technologies to Canadian from long discontinuous aramid industry.

8 Materials Processing Armour Characterization Technologies & Manufacturing Systems & Testing

Modern armour systems are the result of complex system engineering • introduce you to the state-of-the-art processes that balance mobility, lethality, protection and cost to respond in computer modeling of ballistic and to evolving threats and operational requirements. Rapidly advancing blast processes, and establish the extent materials technologies and a highly competitive global armour industry to which they can help you optimize makes it challenging for companies to stay on top. the performance of your products; • help you establish linkages with If you manufacture PPE, VA, • introduce you to new materials key suppliers and partners; transparent armour components and manufacturing technologies • introduce you to test organizations and systems, or armoured vehicles to support your mission; that can evaluate ballistic or blast themselves, and you want to • identify ways to improve performance of your components, strengthen your position in the your existing products and products and systems; and marketplace, the SMT team can: manufacturing processes; • work with you on ITAR or non-ITAR technologies.

9 Materials Processing Armour Characterization Technologies & Manufacturing Systems & Testing Security Materials Technologies Roadmap Research and testing facilities VISION: To provide timely, effective, affordable and integrated solutions for vehicle armour and personal protective equipment in Canadian and global markets. Our partners have the opportunity to access our innovative research facilities to develop products and get them into the hands of customers better and faster 2016 2020 2025+ than before.

• Unparalleled industrial materials processing facilities The SMTRM process facilitates More dismounted, Market the timely identification and • Versatile mechanical testing facilities dispersed operations alignment of security materials • Access fast and cost-effective analytical services assets towards addressing Products / specific market demands Lighter, more ergonomic Systems and opportunities body armour Requirements Materials characterization services at a glance Mechanical • Micro- and nano-hardness testers Technical Reduce cost of promising Challenges new material characterization • Adhesion tests such as shock wave • Mechanical test rigs from micro-scale to full-scale Technology Identify advanced Physical • World-class electron microscopy Solutions manufacturing process and chemical • Chemical analysis characterization • Thermal and electrical properties Pilot scale production • Flame resistance R&D Projects using new process Non-destructive • Conventional and laser-ultrasonic, radiographic, materials testing photometric, and computed tomography Source of funding, Resources facilities and expertise Environmental • Immersion conditioning • Environmental and thermal aging chambers • UV resistance

Non-contact strain • Advanced digital image correlation measurements (high speed)

Polymer • Rheological properties characterization • Thermal properties • Morphology

Dynamic structural • Blast and quasi-static pressure with air cannons, characterization shock tubes, and devices • Low-to-high velocity ballistic impact tests from less than 15 m/s to beyond 3000 m/s with two-stage gas guns, plate impact testers, high-speed recording devices, and enhanced laser velocity systems

10 Security Materials Technologies Roadmap VISION: To provide timely, effective, affordable and integrated solutions for vehicle armour and personal protective equipment in Canadian and global markets.

2016 2020 2025+

The SMTRM process facilitates More dismounted, Market the timely identification and dispersed operations alignment of security materials assets towards addressing Products / specific market demands Lighter, more ergonomic Systems and opportunities body armour Requirements

Technical Reduce cost of promising Challenges new material

Technology Identify advanced Solutions manufacturing process

Pilot scale production R&D Projects using new process

Source of funding, Resources facilities and expertise

Get on the map! The Security Materials Technologies Roadmap (SMTRM) enables industry, For full versions of the roadmaps: end-user and research stakeholders to coordinate their combined resources www.nrc-cnrc.gc.ca/eng/solutions/ to quickly and effectively meet current and future armour system challenges. collaborative/smtrm.html The roadmap addresses ever-evolving threats, operational requirements, fiscal realities and global market opportunities in vehicle and personal armour To get involved or to learn more systems through timely, prioritized, research, development and demonstration. contact us:

Connect with the SMTRM if: NRC.SecurityMaterials-Materiel [email protected] • Your operations require more from your armour systems. • You are seeking to develop more competitive armour products or systems for local or international markets. • You have expertise or facilities in one or more of our technology areas of focus. 11 Five powerful reasons for collaborating with us

1. Create competitive armour products: Keep up with and surpass global competitors. 2. Get products to market faster: Shorten the time it takes to integrate new high-performance materials technologies into personal and vehicle armour systems. 3. Gain access to world-class research infrastructure and unique expertise: We provide an opportunity to access unique capabilities and facilities. 4. Enjoy intellectual property terms that match risks and levels of investment: Our goal is to support Canadian defence and security companies in becoming international market leaders and our intellectual property policies supports companies in doing so. 5. Stay visible and connected within the Canadian defence and security community: Our program gives companies the chance to interact with Photo: Corporal Nathan Moulton, peers and influence government investments. Land Task Force Imagery, OP REASSURANCE

www.nrc-cnrc.gc.ca

www.drdc-rddc.gc.ca

Contact

Marc McArthur Christopher Kingston, Ph.D. Client Relationship Leader Program Leader Tel.: 1-613-949-8680 Security Materials Technologies [email protected] Tel.: 1-613-990-0920

[email protected] October 2017 ISBN: Paper 978-0-660-20464-2 PDF: 978-0-660-20463-5 Cat. no. Paper: NR16-157/2017E PDF: NR16-157/2017E-PDF