COMPLAS 2025

Ballistic Impact on Recycled 6xxx Aluminum Alloys

  • Göçmen, Yağmur (NTNU)
  • Dæhli, Lars Edvard Blystad (NTNU)
  • Børvik, Tore (NTNU)

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Aluminum’s excellent strength-to-weight ratio makes it a key material for many structural applications in the automotive and aerospace industries. Additionally, it is commonly used in protective structures, including bulletproof facades and armored vehicles. One of aluminum’s key advantages is its recyclability. However, contamination, particularly from iron-rich particles, can degrade its mechanical properties. For recycled aluminum alloys to be suitable for protective applications, they must offer the same level of protection as the primary alloys currently in use. This study investigates the effect of increased particle content on the ballistic resistance of aluminum alloys 6063 and 6110. Two variations of each alloy were tested: one standard commercial version and one tailor-made version with a higher content of iron-rich particles to mimic the effects of contamination during recycling. Ballistic impact tests were conducted using 7.62 mm armor-piercing bullets fired at 10 mm thick disks. The ballistic limit velocities and resistance characteristics of each material were analyzed. Moreover, a modified Johnson-Cook constitutive model and the Cockcroft-Latham failure criterion were calibrated using quasi-static and dynamic material tests. Finite element simulations were then performed to further assess the ballistic impact behavior. Our results show that the commercial and tailor-made alloys exhibit similar ballistic resistance, suggesting that a higher content of iron-rich primary particles does not compromise perforation resistance. This is a key finding of the current study, indicating that contamination due to recycling has negligible influence on the behavior of protective structures subjected to ballistic impact, provided that recycling does not change the strength and work hardening capacity. The numerical simulations also closely matched experimental data, validating the reliability of the numerical model for the current application.