To improve the reliability and design of body armor, it is imperative to understand the failure modes and the degradation rates of the materials used in armor. Despite the best efforts of manufacturers, some vulnerability of armor materials to aging due to hydrolytic or oxidative environments is expected and may result in the degradation of material properties such as tensile strength. In this work, p-aramid yarns from two manufacturers were exposed to environmental conditions of various fixed temperature and humidity combinations. The maximum temperature and humidity condition was 70℃ and 76% relative humidity (RH). Tensile tests were performed on specimens extracted at several different times over the course of at least 1 year to determine the change in ultimate tensile strength and failure strain as a function of time, temperature, and humidity. Molecular spectroscopy was used to investigate any chemical changes as a result of the aging. The p-aramid materials were found to be generally resistant to degradation at most conditions, showing changes of less than 10% only at the highest temperature and humidity conditions.

It has long been a goal of the body armor testing community to establish an individualized, scientific-based protocol for predicting the ballistic performance end of life for fielded body armor. A major obstacle in achieving this goal is the test methods used to ascertain ballistic performance, which are destructive in nature and require large sample sizes. In this work, using both the Cunniff and Phoenix-Porwal models, we derived two separate but similar theoretical relationships between the observed degradation in mechanical properties of aged body armor and its decreased ballistic performance. We present two studies used to validate the derived functions. The first correlates the degradation in mechanical properties of fielded body armor to the degradation produced by a laboratory accelerated-aging protocol. The second examines the ballistic resistance and the extracted-yarn mechanical properties of new and laboratory-aged body armor made from poly(p-phenylene-2,6-benzobisoxazole), or PBO, and poly(p-phenylene terephthalamide), or PPTA. We present correlations found between the tensile strengths of yarns extracted from armor and the ballistic limit (V50) when significant degradation of the mechanical properties of the extracted yarns was observed. These studies provided the basis for a validation data set in which we compared the experimentally measured V50 ballistic limit results to the theoretically predicted V50 results. The theoretical estimates were generally shown to provide a conservative prediction of the ballistic performance of the armor. This approach is promising for the development of a tool for fielded armor performance surveillance relying upon mechanical testing of armor coupon samples.

Manufacturers of stab-resistant body armor continually strive to improve the comfort of the armor wearer and maximize protection. As female officers make up a larger portion of the law enforcement and corrections workplace, armor manufacturers have begun to offer designs that accommodate contoured body shapes, such as the female bust region, which results in non-planar armor. Conventional test methodologies for body armor were designed for armor to be tested flat and do not accommodate contoured armor. This work reviews the available literature concerning common bust sizes and discusses the research performed to specify bust surrogate size, shape, and materials for testing stab-resistant female body armor. Two standard cup sizes, B and D, modeled as a paraboloid with a modified base, are recommended to meet breast volume requirements. Recommendations for manufacture of these surrogates for incorporation into standardized test methods are provided. Instrumented stab testing of these surrogates shows that impact location on a structured armor and the type of backing material increase the maximum deceleration of a spike impact.