This program was initiated to evaluate the feasibility of using dual hardness steel armor as primary structure for a helicopter fuselage in order to enhance survivability in a hostile environment involving small-arms fire. The phase I effort involved the preliminary design of an aerial armored reconnaissance system (AARS) aircraft for the aerial scout mission, with a defined threat. An extensive materials study was also conducted to determine the characteristics of the armor under severe environmental conditions. The armor thickness required to defeat the defined threat was established by ballistic testing, which was followed by static and fatigue testing on damaged and undamaged armor specimens. Fatigue crack initiation and propagation were also measured, and residual life after ballistic damage was identified. Ballistic tests were conducted at high and low temperature to determine the effects of temperature on the ballistic capability of the armor. During Phase II, a special test facility was constructed, and a full-scale center section of the helicopter was fabricated and tested under loads determined in Phase I. Ballistic tests were also conducted on the center section test specimen while subjected to simulated flight loads. Design, analysis and test results indicate that dual hardness steel armor provides a structural material which is suitable for both primary structure and ballistic protection for an integrally armored helicopter fuselage.


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