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Ballistic Testing of ThyssenKrupp Steel Europe Armor Steel in Accordance

with U.S. Military Armor Specifications

Conference Paper · September 2011

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 26th International Symposium on Ballistics
Hyatt Regency Hotel
Miami, Florida, USA
12-16 September 2011

Ballistic Testing of ThyssenKrupp Steel Europe Armor Steel in

Accordance with U.S. Military Armor Specifications
Dr. H.-J. Kaiser, Prof. Dr. A. Kern, Dipl.-Ing. S. Scharf1
Mr. William A. Gooch Jr2

This paper provides the ballistic results for five grades of SECURE M
armor steels produced by ThyssenKrupp Steel Europe in the hardness range
of 280 to 640 brinell hardness. The SECURE M-steels were tested in ac-
cordance with the acceptance standards of the three primary US Military
specifications for wrought armor plate. The chemical composition and
mechanical properties are provided. The SECURE M-steels also met the
acceptance standards of these military specifications for First Article Certi-
fication and were certified for use on US production armored systems.

INTRODUCTION

ThyssenKrupp Steel is Germany’s largest steel manufacturer, producing a

wide range of armor steels for the ballistic protection of military vehicles since the
1960’s at their production facility in Duisberg, GE. These steels, distributed under
the ThyssenKrupp brand SECURE M, not only provide excellent protection against
soft core and AP ammunition, but also provide enhanced protection against blast
threats. Steels, with various hardness levels, have been developed for armored vehi-
cle applications and are widely used by the producers of military vehicles world-
wide. The improved ballistic resistance of steel as a function of increasing hardness
is well established in the ballistic community, particularly by Rapacki et al in the
15th Ballistic Symposium [1]. The five grades of SECURE M steels discussed in
this paper range in hardness from 280 to 640 BHN.
The SECURE M armor steels of ThyssenKrupp can fully comply and be cor-
related with the mechanical properties and ballistic requirements of the three main
US Army military specifications for wrought steel armor plate for armored vehi-
cles: MIL-DTL-12560J for rolled homogeneous armor (RHA) [2] with hardness
from 241 to 460 BHN; MIL-DTL-46100E high hard (HH) armor [3] with hardness
from 477 to 534 BHN and the recent MIL-DTL-32332 ultra high hard (UHH) ar-
mor [4] with hardness higher than 570 BHN.
1
ThyssenKrupp Steel Europe AG, Heavy Plate Unit, Duisburg, Germany
2
WA Gooch Consulting Inc, 10460 Roosevelt Blvd N, Suite 263, St. Petersburg,
FL 33716
 The following paper provides an overview of the production and resultant me-
chanical properties of the SECURE M-steels as well as their ballistic properties
relative the three US Military specifications for wrought armor plate. The SECURE
M-steels were tested in accordance with the acceptance standards of these military
specifications for First Article Certification for use on US Combat vehicles. The
SECURE M steels were tested in a range of plate thicknesses: for RHA, five thick-
ness between 6.5mm to 21.6mm; for HH, six thicknesses between 3.2mm to
12.4mm; and for UHH, seven thicknesses between 4.5mm to 12.5mm. For these
thicknesses, the required test projectiles are the US 0.30-cal APM2 and US 0.50-cal
APM2 armor-piercing (AP) projectiles. The ballistic tests were conducted at both
the U.S. Army Research Laboratory (ARL), and U.S. Army Aberdeen Test Center
(ATC) of Aberdeen Proving Ground, MD and First Article Certifications were is-
sued for these thickness ranges.

PRODUCTION AND PROPERTIES OF SECURE M

The production facilities of ThyssenKrupp Steel Europe are concentrated in

Duisburg, in the western part of Germany. For the production of SECURE M steels,
the blast furnace process is followed by an oxygen-steelmaking process (TBM- or
Thyssen Blowing Metallurgy-process) and a state-of-the-art secondary metallurgic
treatment (Figure 1), which includes a vacuum treatment and a calcium treatment
by the TN (Thyssen Niederrhein)-process to achieve high level of sulfides cleanli-
ness, low levels of Phosphor and Sulfur and a forming of the sulfides into globular
shape. The continuously cast slabs are then rolled into plates either on a highly
modern 4-high-mill or via a hot strip mill and a cut-to-length-line. The latter pro-
duction route offers the advantage of a very tight thickness tolerance which is
roughly half that of material produced on a 4-high-mill. Therefore, plates produced
via the hot strip route lead to a reduced vehicle weight and offer also advantages for
cold formed vehicle components. All SECURE M plates are subjected to a quench-
ing process after hot rolling and can be done either in water or oil. To get optimal
properties, a tempering process finishes the production of SECURE M steels. The
whole production process at ThyssenKrupp Steel Europe is certified according to
EN ISO 9001 [5]. Finally, the ballistic and mechanical properties of the SECURE
M-steels are tested in ThyssenKrupp laboratories. Ballistic testing, in accordance
with international standards can also be arranged via independent test laboratories
or government facilities.

STEEL GRADES SECURE M

SECURE M steel grades are produced with different hardness levels ranging
from rolled homogeneous armor (RHA) steel to ultra high hard (UHH) steel. Table
I gives an overview on the different steel grades of SECURE M steels and the cor-
relation with grades according to US military armor standards. The SECURE M
steel grades are certified by the German Army BWB (Bundesamt für Wehrtechnik
und Beschaffung) and are widely used for armored projects according to standard
TL 2350-0000 [6], specifically protection of vehicles for the German Army. The
most common grade for application in combat vehicles is SECURE M 500 (HH),
which provides a very good combination of toughness and hardness.
 Blast Furnace Steel works
Cleanliness:
P ≤ 0,015 %
S ≤ 0,003 %

Oxygen steel making

with TBM® process Secondary metallurgy
with TN ® process
Continuous casting process

Quality control Heat treatment Rolling

mill

Hardness
Strength

Toughness Furnace Four-High-Mill

Ballistic Hot-Strip-Mill

Figure 1. Production of SECURE M-steels at ThyssenKrupp Steel Europe

The hardest steel available is SECURE M 600 which is mainly used for add-
on armor applications and can even be used up to 10 mm plate thickness for struc-
tural components in accordance with approval of the German Army. This steel of-
fers a further thickness reduction in correlation to RHA or HH steel. The chemical
composition and mechanical properties of SECURE M steels which comply with
the relevant military specifications are shown in Tables IIA and IIB [7-11].

TABLE I. US MILITARY SPECIFICATIONS AND CORRESPONDING SECURE M GRADES

THICKNESS RANGE OF
THYSSENKRUPP
SPECIFICATION MILITARY SPECIFICATION
ARMOR STEEL
[mm]

3.0 – 15.8 SECURE M 400

15.8 – 31.7 SECURE M 350

MIL-DTL-12560J 31.7 – 50.8

50.8 – 101.6 SECURE M 300

101.6 – 152.4

MIL-DTL-46100E 3.0 – 50.8 SECURE M 500

MIL-DTL-32332 4.0 – 16.0 SECURE M 600

 TABLE IIA. CHEMICAL COMPOSITION OF SECURE M STEEL (MAXIMUM VALUES)
Thickness
Speci- Chemical Composition (max. values)
Steel range
fication
mm C Si Mn P S Cr Mo Ni
SECURE M
3 - 150 12560
300
SECURE M
3 - 50 12560 ≤ 50 mm : 0.70
350
0.32 0.40 1.00 0.015 0.005 1.50 0.50
SECURE M
3 - 150 12560 > 50 mm: 3.50
400
SECURE M
3 - 150 46100
500
SECURE M
4 - 40 32332 0.40 0.80 1.50 0.025 0.010 1.50 0.50 1.50
600

TABLE IIB. MECHANICAL PROPERTIES OF SECURE M STEEL (TYPICAL VALUES)

Charpy-V - Yield Strength Tensile Elongation
Hardness
Steel 40°C Rp 0.2 Strength A
BHN J N/mm² N/mm² %
SECURE M
280 - 330 60 630 800 13
300
SECURE M
330 - 380 40 850 950 12
350
SECURE M
380 - 430 25 950 1150 11
400
SECURE M
480 - 530 25 1300 1600 9
500
SECURE M
570 - 640 ~15 ~1500 ~2000 ~8
600

BALLISTIC TEST PROCEDURE V50

The ballistic properties of the relevant SECURE M steel grades were deter-
mined by obtaining the V50 ballistic limit for each thickness of plate against the
corresponding specified test projectile. The test methodology is described in detail
in the MIL-STD-662F [12]. The V50 ballistic limit is the velocity at which an equal
number of fair impact complete penetration (target is defeated) and partial penetra-
tion (target is not defeated) velocities are attained using the up-and-down firing
method. Fair impact is defined as occurring when a projectile with an acceptable
yaw strikes the target at a distance of at least two projectile diameters from a previ-
ously damaged impact area or edge of plate. A complete penetration is determined
by placing a 0.5 mm (0.020”) 2024T3 aluminum witness plate 152.6 mm (6.00”)
behind and parallel to the target. If any penetrator or target fragment strikes this
witness plate with sufficient energy to create a hole through which light passes, the
result is considered a complete penetration. A partial penetration is any impact that
is not a complete penetration. For the military-specifications, the V50 ballistic limit
is defined as the average of six fair impact velocities comprising the three lowest
velocities resulting in complete penetration and the three highest velocities resulting
in partial penetration. A maximum spread of 45.7 m/s (150 fps) shall be permitted
between the lowest and highest velocities employed in determination of ballistic
limits. The results of the ballistic tests, which were carried out at the ATC or ARL
(First Article Tests) are summarized in the following tables and figures, where the
measured data were compared to the base line data comprising the minimum re-
quired velocities according to the different Military Standards.
The different test projectiles used in the corresponding Military Standards are
shown in Figure 2. The 0.30-cal APM2 steel core weighs 5.2 g; with the copper
jacket and lead filler, the total projectile weight is 10.6 g. The total length of the
projectile is 35.6 mm (1.4”). The 0.50 cal APM2 also has a steel core along with a
copper jacket and lead filler. The steel core weighs 25.4 g with total weight of 44.9
g. The total length is 57.5 mm (2.26”). This projectile is also shown in Figure 2.

Figure 2. 0.30-Cal APM” and 0.50-Cal APM2 Projectiles

BALLISTIC TESTS FOR MIL-DTL-12560J

Table III shows test results of First Article and Production acceptance testing
for different thickness ranges of MIL-DTL-12560J. Figure 3 shows the V50 results
versus plate thickness for the thickness range from 5.84 to 16.51 mm and a compar-
ison with the required velocities (solid lines) according to the military specification.

TABLE III. FIRST ARTICLE & PRODUCTION ACCEPTANCE TESTING - MIL-DTL-12560J

Actual Thickness Obliquity V50, V50
Projectile
Steel Thickness Range of MIL Angle required obtained
(mm) (mm) (deg.) (m/s) (m/s)
SECURE M
6.5 5.84 – 16.51 0.30 APM2 0 495 525
400
SECURE M
8.3 5.84 – 16.51 0.30 APM2 0 576 596
400
SECURE M
10.5 5.84 – 16.51 0.30 APM2 0 663 721
400
SECURE M
12.4 5.84 – 16.51 0.30 APM2 0 734 754
400
SECURE M
20.6 13.9 – 30.5 0.50 AP M2 0 725 773
350
 900
0.30 AP M2, Angle: 0°
850
First Article
result
800

750

V50 velocity, m/s

700

650

600

550

500

450

400
5 7 9 11 13 15 17

thickness, mm
Figure 3. V50 Results versus Plate Thickness for MIL-DTL-12560J
First Article Result and Production Acceptance Tests

BALLISTIC TEST RESULTS FOR MIL-DTL-46100E

Table IV shows test results of First Article and regular production acceptance
testing for different thickness ranges of MIL-DTL-46100E. Figure 4 shows the V50
results versus the plate thickness for SECURE M 500 and the comparison with the
required velocities (solid lines) according to the specification.

TABLE IV. FIRST ARTICLE & PRODUCTION ACCEPTANCE TESTING - MIL-DTL-46100E

Actual Thickness Obliquity V50, V50
Projectile
Steel Thickness Range of MIL Angle required obtained
(mm) (mm) (deg.) (m/s) (m/s)
SECURE M
3.2 2.5 – 8.6 0.30 APM2 30 301 349
500
SECURE M
4.3 2.5 – 8.6 0.30 APM2 30 470 552
500
SECURE M
7.1 2.5 – 8.6 0.30 APM2 30 740 769
500
SECURE M
8.4 7.4 – 15.9 0.50 APM2 30 587 613
500
SECURE M
10.2 7.4 – 15.9 0.50 APM2 30 660 691
500
SECURE M
12.4 7.4 – 15.9 0.50 APM2 30 735 750
500
 980

0.30 AP M2, Angle: 30° 0.50 AP M2, Angle: 30°

880

First Article First Article

780 results results
V50 velocity [m/s]
680

580

480

380

280

180
2 4 6 8 10 12 14 16

thickness [mm]
Figure 4. V50 Results versus Plate Thickness for MIL-DTL-46100E
First Article Result and Production Acceptance Tests

BALLISTIC TEST RESULTS FOR MIL-DTL-32332

Table 5 shows the test results of the First Article tests for different thickness
ranges of MIL-DTL-32332. These tests were among other data used to specify the
minimum requirements regarding the mechanical and ballistic properties of the new
MIL-DTL-32332. Figure 5 exhibits the obtained V50 results versus the plate thick-
ness for SECURE M 600 and the specified minimum values (solid lines). Figures 6
and 7 show the front and back of the SECURE M 600 plates after impact with both
the 0.30-cal and 0.50-cal APM2 test projectiles. The plate hardness was measured
at 578 BHN and 600 BHN on each plate, respectively and exhibited no cracking
after nine impacts on each of the acceptance plates.

TABLE V. FIRST ARTICLE AND PRODUCTION ACCEPTANCE TESTING - MIL-DTL-32332

Actual Thickness Obliquity V50, V50
Projectile
Steel Thickness Range of MIL Angle required obtained
(mm) (mm) (deg.) (m/s) (m/s)
SECURE M
4.5 2.5 – 8.6 0.30 APM2 30 607 692
600
SECURE M
5.2 2.5 – 8.6 0.30 APM2 30 673 774
600
SECURE M
6.0 2.5 – 8.6 00.30 APM2 30 745 829
600
SECURE M
8.4 2.5 – 8.6 0.30 APM2 30 857 912
600
SECURE M
8.4 7.4 – 15.4 0.50 APM2 30 661 714
600
SECURE M
10.5 7.4 – 15.4 0.50 APM2 30 729 780
600
SECURE M
12.5 7.4 – 15.4 0.50 APM2 30 793 820
600
 1080
0.30 AP M2, Angle: 30° 0.50 AP M2, Angle: 30°
980

880
V50 velocity [m/s]

780

680

580
All results First Article

480

380

280

180
0 2 4 6 8 10 12 14 16
thickness [mm]

Figure 5. V50 Results versus Plate Thickness for MIL-DTL-32332

First Article Tests

Front of Plate Rear of Plate

Figure 6. Shots 7634-7642 on 8.4mm SECURE M 600 Plate by 0.30-cal APM2
 Front of Plate Rear of Plate
Figure 7. Shots 7213-7221on 8.4mm SECURE M 600 Plate by 0.50-cal APM2

Figure 8 summarizes the results of the ballistic tests for the three US Military
Specifications for SECURE M steels of 6 mm thickness. As expected, the ballistic
performance is improved with increasing hardness of the plate. The ultra high hard-
ness steel SECURE M 600 offers the best ballistic performance and therefore, fur-
ther weight reductions for the vehicle designers.

980

0.30 AP M2
880

780
V50 velocity [m/s]

680

580

480

380

280

180
300 400 M 400
SECURE 500 M 500
SECURE 600 M 600
SECURE 700

Steel grade

Figure 8. Improvement of Ballistic Performance as a Function of Steel Hardness

(Results for 6 mm thickness)
 CONCLUSIONS

This paper has provided the ballistic results for five grades of SECURE M
armor steel produced by ThyssenKrupp Steel Europe. The SECURE M-steels were
tested in accordance with the acceptance standards of the three primary US Military
specifications for wrought armor. The SECURE M-steels also met the acceptance
standards of these military specifications for First Article Certification and were
certified for use on US production armored systems. The SECURE M 600 test data
were also used by the US Army Research Laboratory along with other data to gen-
erate the acceptance curves for the recently approved MIL-DTL-32262 specifica-
tion for ultrahigh hard steels. The SECURE M family of armor plate provide cost-
effective, high ballistic performance steels that can be readily fabricated using well
established production techniques for tactical and armored vehicles.

ACKNOWLEDGEMENT

ThyssenKrupp Steel Europe would like to acknowledge the assistance of the

Armor Mechanisms Branch, US Army Research Laboratory, Aberdeen Proving
Ground, MD, USA in conducting First Article and Production Acceptance Testing
of SECURE M Plate.

REFERENCES

1. Rapacki, E., K. Frank, B. Leavy, M. Keele and J. Prifti, “Armor Steel Hardness Influence on
Kinetic Energy Penetration”, 15th Int. Symposium on Ballistics, (1995).
2. U.S. Military Specification, MIL-DTL-12560J (MR), “ARMOR PLATE, STEEL, WROUGHT,
HOMOGENEOUS” U.S. Army Research Laboratory, APG, MD, 29 July 2009
3. U.S. Military Specification, MIL-DTL-46100E (MR), “ARMOR PLATE, STEEL, WROUGHT,
HIGH-HARDNESS”, U.S. Army Research Laboratory, APG, MD, 08 July 2008
4. U.S. Military Specification, MIL-DTL-32332 (MR), “ARMOR PLATE, STEEL, WROUGHT,
ULTRA-HIGH-HARDNESS” U.S. Army Research Laboratory, APG, MD, 24 July 2009
5. Certificate for DIN EN ISO 9001 : 2008 of TÜV Nord for ThyssenKrupp Steel Europe AG, reg-
istry number 44 100 060770
6. Bundesamt für Wehrtechnik und Beschaffung, Technische Lieferbedingungen 2350-0000, Issue
4, Panzerstahl, II.Generation 16 June 2008
7. ThyssenKrupp Steel Europe Data Sheet No. 1930: SECURE M 300, Version April 2010,
ThyssenKrupp Steel Europe AG 47161 Duisburg
8. ThyssenKrupp Steel Europe Data Sheet No. 1939: SECURE M 350, Version May 2006,
ThyssenKrupp Steel Europe AG 47161 Duisburg
9. ThyssenKrupp Steel Europe Data Sheet No. 1940: SECURE M 400, Version April 2010,
ThyssenKrupp Steel Europe AG 47161 Duisburg
10. ThyssenKrupp Steel Europe Data Sheet No. 1941: SECURE M 500, Version April 2010,
ThyssenKrupp Steel Europe AG 47161 Duisburg
11. ThyssenKrupp Steel Europe Data Sheet No. 1934: SECURE M 600, Version June 2008,
ThyssenKrupp Steel Europe AG 47161 Duisburg
12. MIL-STD-662F, Department of Defence Test Standard, U.S. Army Research Laboratory, Weap-
ons & Materials Research Directorate, ATTN: AMSRL-WM-M, APG, MD 21005-5069, 18 De-
cember 1997

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