This paper presents the computational-based ballistic limit of laminated metal panels comprised of high strength steel and aluminium alloy Al7075-T6 plate at different thickness combinations to necessitate the weight reduction of existing armour steel plate. The numerical models of monolithic configuration, double-layered configuration and triple-layered configuration were developed using a commercial explicit finite element code and were impacted by 7.62 mm armour piercing projectile at velocity range of 900 to 950 m/s. The ballistic performance of each configuration plate in terms of ballistic limit velocity, penetration process and permanent deformation was quantified and considered. It was found that the monolithic panel of high-strength steel has the best ballistic performance among all panels, yet it has not caused any weight reduction in existing armour plate. As the weight reduction was increased from 20-30%, the double-layered configuration panels became less resistance to ballistic impact where only at 20% and 23.2% of weight reduction panel could stop the 950m/s projectile. The triple-layered configuration panels with similar areal density performed much better where all panels subjected to 20-30% weight reductions successfully stopped the 950 m/s projectile. Thus, triple-layered configurations are interesting option in designing a protective structure without sacrificing the performance in achieving weight reduction.

This paper presents the effect of laminated aluminium-steel panel with different configurations in a high-speed impact test. Layering aluminium plate with high strength steel has become an interest in reducing the overall density of armour vehicle body while improving the ballistic resistance. Different layering configurations differ in laminated panel performance. Two layering configurations of double-layered panel achieving 25% of existing panel weight reduction were tested using experiment and computational method to investigate their behaviours when impacted with 7.62-mm full metal jacket at velocity range of 800–850 m/s. The ballistic performance of each configuration plate in terms of ballistic limit velocity, penetration process and permanent deformation was quantified and considered. Laminated panel with aluminium as the front layer reduced the ballistic performance of existing panel to 50% and the other panel maintained its performance. Thus, the laminated panel with aluminium as the back layer can be used in designing a protective structure for armoured vehicle while maintaining the performance of the existing vehicle in achieving weight reduction.