Composite Materials in Defense: Typical Application Cases

The history of composite materials is closely intertwined with the numerous conflicts of the 20th century, especially as technology and materials continuously advanced, making composite materials a pivotal player in modern warfare. During the Second World War, the demand for air superiority spurred the application of composite materials, particularly in the development of fighter aircraft, where these materials achieved tremendous success on the battlefield for the first time. Lightweight and tough composite materials enabled military aircraft to achieve higher flight speeds, better maneuverability, and stronger durability, thereby changing the way combat is fought.

According to the latest data from JEC, the application of composite materials in the defense sector currently accounts for an estimated 5% to 10% of the global composite materials market, but the market size for defense is difficult to accurately assess. Due to the high degree of confidentiality surrounding defense technologies, the development of many new applications and materials research is conducted independently by various countries, which invest heavily in their defense budgets based on their respective military needs and international situations. Differences in military cultures among countries also lead to varying degrees of composite material usage, with Europe and North America adopting more widespread applications, while Asian countries are relatively more conservative.

Composite materials are used in nearly all branches of the military, including the army, navy, air force, and space force, covering a wide range of application areas. In land vehicles, composite materials are used to enhance armor, reduce vehicle weight, and improve deployment radius and autonomy. Additionally, the use of composite materials significantly reduces fuel consumption while enhancing body strength, thereby increasing vehicle lifespan and maintenance efficiency. In the aviation sector, composite materials have revolutionized aerial warfare. Through their lightweight and toughness, composite materials not only reduce the weight of aircraft but also decrease audio and magnetic field signals, providing a crucial stealth advantage in military operations.

Composite materials also play a significant role in combat personnel equipment. These materials are lightweight, significantly enhancing soldiers' mobility and deployment efficiency, especially in areas such as rifle stocks, ammunition, missile guidance equipment, and long-range munitions. Composite materials are widely used in the manufacture of bullet-proof protective plates in soldiers' combat uniforms and helmets, greatly enhancing personnel survival capabilities. Furthermore, as military drones become increasingly prevalent, composite materials are increasingly important in their manufacture, with these tactical assets playing an increasingly significant role in asymmetric conflict environments.

The pursuit of technological dominance drives ambitious research programs for composite materials. The defense sector is not only one of the largest testing grounds for composite materials but also a hotbed for their future civilian applications. Although many believe that military technology typically takes 40 years to transfer to the civilian market, many private enterprises are now actively involved in composite material research projects in the defense sector. Similar to the aerospace industry, private enterprises are increasingly collaborating with the military to participate in military innovation, which not only drives technological advancements in composite materials but also opens up broader prospects for their diverse applications.

Enhancing Ballistic Protection

Take the Merlin Mk3 helicopter as an example. It is a medium-lift transport helicopter for the Command Helicopter Force (CHF), designed and manufactured by AgustaWestland. These helicopters demonstrate exceptional versatility, meeting the Royal Navy's requirements for maritime protection and anti-submarine warfare, as well as CHF's troop transport and amphibious missions. In aviation, weight reduction is crucial, so Permali has developed lightweight composite panels made of ultra-high molecular weight polyethylene (UHMWPE). These panels are manufactured through a high-pressure compression process, subsequently cut with a water jet, and assembled internally, significantly enhancing the helicopter's protective capabilities while maintaining a lightweight design.

Permali's innovative panels not only excel in ballistic protection but also reduce the helicopter's overall weight, thereby improving its mobility and operational efficiency. The application of these composite materials marks another leap in military aviation technology, demonstrating the potential of composite materials to balance safety and performance.

Improving Missile Performance

The AGM-158 Joint Air-to-Surface Standoff Missile (JASSM) is a stealthy medium-range air-to-surface cruise missile designed specifically to attack high-defense targets with extreme accuracy. The missile's fuselage adopts a revolutionary composite structure combining high-strength fibers with a lightweight matrix, enabling the missile to enhance its range, payload capacity, and maneuverability while providing stronger shock resistance and durability. Due to the flexibility of composite materials, these missiles can be designed in complex shapes to reduce radar signal reflection, making them harder to detect on enemy radars.

AEC further enhances the fuselage design of JASSM missiles through its braiding technology, ensuring exceptional structural integrity while maintaining lightweight properties. This precise manufacturing process ensures the missile's survival capabilities in harsh environments, providing a significant technological advantage in modern warfare.

Enhancing Armored Vehicle Mobility

The mobility of armored vehicles is crucial in modern warfare, and Composite Rubber Tracks (CRT) represent a significant technological breakthrough in this field. CRT consists of a continuous rubber belt reinforced longitudinally and laterally with composite materials and steel cables. The integration of carbon nanotubes further enhances its strength and rigidity, with these properties enabling better thermal dissipation during use, effectively preventing hot spots and early failures.

The lightweight design of CRT significantly reduces the weight of armored vehicles, enabling them to operate without maintenance for up to 8,000 kilometers in most cases. Additionally, the rubber structure design of CRT greatly reduces vehicle noise, providing the military with more concealed and flexible operational options. These composite materials not only improve vehicle operational efficiency but also reduce long-term maintenance costs, further enhancing mobility and combat capabilities on the battlefield.

Looking Ahead: Diverse Applications of Composite Materials

The demand for composite materials in the defense sector not only drives current technological advancements but also lays a solid foundation for future innovations. As military needs continue to evolve, composite materials play an increasingly important role in enhancing military equipment performance, reducing weight, enhancing durability, and lowering maintenance costs. In the future, as military technology further transfers to the civilian market, the diverse application prospects for composite materials will be even broader.

The widespread application of composite materials in the defense sector not only enables combat personnel to operate in more dangerous and complex environments but also provides new impetus for future technological innovation and global military competition. With the continuous advancement of technology, composite materials will play an even more critical role on future battlefields, from drones to armored vehicles, missiles to combat personnel equipment, driving the development of military technology and ensuring countries maintain technological superiority on the battlefield.