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In the coming years, solving the problem of how to deal with advanced body armor may be one of the biggest challenges facing small arms ammunition designers. The problem is already seeping to the surface, as Level IV body armor—immune to nearly all general purpose rounds under .50 caliber—becomes available and cheaper. Already, a person can fit a full set of Level IV plates and a carrier for less than $1,000.

Tungsten Body Armor

A US Marine holding the plate that saved his life. Modern rifle plates are life-saving equipment for the United States military, but they will find their way more and more into the hands of our enemies as they become cheaper and more readily available. Image credit: United States Marine Corps, public domain.

Pdf) A Review Of Penetration Tungsten Based Projectile On Depth Of Penetration At Armor Of Ceramic Based

We then have to think about the possibilities of defeating sophisticated armor with small arms rounds. Up front, I have to say: the prospects don't look good. The power and penetration of small arms ammunition are limited by the practicalities of war. A round that is too large may penetrate body armor, but it will certainly put soldiers at a disadvantage against unarmored combatants with superior weapons that can put down a much higher volume of fire. This means that, in addition to the size and weight of the weapon required to fire the highest caliber bullets that can enter Tier IV, there is a limit to how powerful an infantry weapon can be. But first, a little background is in order.

To understand why the presence of Level IV and parallel armor is of such concern to small arms ammunition designers, we must first review what "Level IV" means. According to NIJ Standard-0101.05:

2.5 Type IV (Armor Penetrating Rifle) Type IV hard armor or plate inserts shall be tested in a conditional mode with .30 caliber armor piercing (AP) bullets (US military designation M2 AP) having a specified mass of 10.8 g (166 g) and a velocity of 878 m/s ± 9.1 m/s (2880 ft/s ± 30 t/s). Type IV flexible armor shall be tested in both "as new" and conditioned conditions with 0.30 caliber AP bullets (US military designation M2 AP) of mass Specified 10.8 g (166 g) and velocity of 878 m/s ± 9.1 m/s (2880 ft/s ± 30 t/s). In the case of rigid armor or Type IV plate additions tested as an integrated design, the flexible armor shall be tested in accordance with this standard and found to be compliant as independent armor at the specified threat level. The combination of flexible armor and hard/plate armor will then be tested as a system and found to provide protection at the specified system threat level. NIJ-approved hard armor and panels must be clearly marked as ballistic protection only when worn in conjunction with the NIJ-approved flexible armor system with which they were tested.

Along with this, we must note four things: First, that the .30 cal. The M2 Armor Piercing bullet is a very solid design using a high quality manganese-molybdenum steel core hardened to 785 Vickers, which also includes a lead cap which further improves penetration characteristics. This construction allows it to penetrate to a depth of 10.6 mm into a 22.2 mm RHA steel plate at a distance of 91 meters. Second, we note that the tests use the 105 ft/s higher speed than the M2 AP spec – 2,880 ft/s instead of 2,775 ft/s. This is designed to account for velocity transfer due to high temperature and other factors that could cause a spin to penetrate a plate that would normally be rated to stop it. Third, we note that no steel core armor penetrating small arms ammunition below the .50 standard exceeds the penetration capability of the .30 M2 AP by a margin significant enough to exceed Level IV at combat ranges. The two prominent AP steel core rounds in use are the Russian B-32 Armor Trawl Impact 7.62x54mmR, and the NATO M61 Armor Piercing 7.62x51mm, neither of which surpass the .30 M2 bullet in penetration. Fourth, Russian GOST Class 6a armor is equivalent to NIJ Level IV armor, and is proof against three B-32 API shots at no more than 10 meters.

Balancing The Importance Of Weight, Performance, And Cost For Advanced Ballistic Protection Solutions

Point 1: Current Level IV and GOST Class 6a *DEFINING* armor is immune to all current steel-plated armor piercing rounds in .30 caliber and below, at all ranges.

Therefore, we should explore the potential of rounds with non-steel cores. Among the main materials can be found tungsten alloys, especially tungsten carbides. Without a doubt, tungsten carbide core rounds are effective - 5.56mm M995 tungsten cores penetrate 12mm of RHA at 100 meters, more than 0.30 M2 AP. However, they have a fatal flaw, which is substance consumption. To explain, we will need an example. The 7.62mm M993 currently has a penetrating weight of 5.9 grams, but is not ballistically optimized and slows down quickly due to its flat bullet. The 1199 Level IV RMA M995 stops at about 2,900 ft/s, which represents a slightly smaller impact range. from 100 meters. So, in this example, a round is given with a middleweight punch. If we assume a low drag bullet with a diameter of 6.5 mm and a weight of 7 grams (108 grains), then the corresponding penetrating core for that bullet would be about 5.06 grams. Since the core is 84% ​​tungsten, it consumes 4.25 grams of tungsten per shot. To understand what liability the tungsten core will have in a situation where there is an economic tax, such as a long war. To understand this problem, we need to know two things: global production of tungsten alone and its sources; and two, expected ammunition consumption per year.

Regarding the latter, we first understand that the military's ammunition production requirements have a baseline of about a billion rounds per year. During a prolonged insurgency, this amount can be expected to rise to 2-2.5 billion rounds per year. During a global conflict against fellow nations, ammunition consumption can be expected to equal that of World War II, which was close to 22 billion rounds per year. In this example, there is an ongoing conflict against an insurgency.

Unfortunately for those looking to tungsten as a solution, 85-90% of the world's tungsten production comes from the People's Republic of China. In contrast, while US mines have little tungsten, they consume tungsten equivalent to 23% of the world's annual production, 60-70% of which is taken directly from the world's production (15% of the world's annual production). As of 2011, the US had 140,000 tons from tungsten reserves, and consumed about 18,200 tons from all sources.

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In the event of a proxy war, ammunition requirements would exceed a billion per year. In 2005 (before the Boro), the US consumed more than 1.7 billion rounds. It is likely that any new proxy war will consume similar or even more ammunition. We can make an estimate based on some levels of consumption:

Scenario: In 2031, the US and the PRC are engaged in a proxy war in Africa, where the PRC is distributing Level IV body armor to the rebel forces. The US had previously decided to issue a tungsten round as standard, despite the supply issues of the material. This is a 6.5mm round with a trigger that uses 4.25 grams of tungsten. China stopped exporting tungsten to the US to trigger it. So the math looks like this:

2031: The United States has 140,000 tons of tungsten plus 60,000 tons in recent imports. Total tungsten 200,000 tons. Initial munitions consumption in the first year of the war rises to 1.5 billion rounds, consuming 500 million rounds from inventory, while wasting 4,250 tons of tungsten from newly produced ammunition. Production in the US also accelerates, increasing consumption from processing processing and production to -60,000 tons per year. By the end of 2031, the U.S. has 135,750 tons in reserve. A program begins to reclaim tungsten used in production.

2032: 135, 750 tons in reserve. A trickle of tungsten from South America and Russia adds 10,000 tons of tungsten to reserves. The reclamation program produces an additional 5,000 tons. Total tungsten 150, 750

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