Improving Ballistic Resistance of Armor Steel by FCAW with Hardfacing Alloys of Fe–Mo–Mn–B–C System

Armor steels can be strengthened against modern ballistic threats through surface hardfacing with advanced Fe-based alloys. This study develops a series of flux-cored arc welded (FCAW) hardfacing alloys in the Fe–Mo–Mn–B–C system to enhance the ballistic resistance of Armox® 440T steel. Single-layer...

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Published inManagement systems in production engineering Vol. 33; no. 3; pp. 380 - 387
Main Authors Prysyazhnyuk, Pavlo, Biały, Witold, Bembenek, Michał, Panchuk, Vitalii, Medvid, Iuliia, Duriagina, Zoia, Romanyshyn, Taras, Vytvytskyi, Vasyl
Format Journal Article
LanguageEnglish
Published Gliwice Sciendo 01.09.2025
De Gruyter Poland
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ISSN2450-5781
2299-0461
2450-5781
DOI10.2478/mspe-2025-0036

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Abstract Armor steels can be strengthened against modern ballistic threats through surface hardfacing with advanced Fe-based alloys. This study develops a series of flux-cored arc welded (FCAW) hardfacing alloys in the Fe–Mo–Mn–B–C system to enhance the ballistic resistance of Armox® 440T steel. Single-layer (~3 mm) hardfacings were deposited on 6 mm armor plates using an automated hardfacing device, and subsequently characterized with respect to their microstructure, phase composition, and ballistic performance. Thermodynamic calculations and microscopy revealed an austenitic matrix reinforced by hard boride inclusions. By increasing the Mo and B concentrations, the alloy solidification shifted from a primary austenite + austenite boride mixture to a primary boride + austenite boride mixture structure. The compositions with high Mo:B ratio yielded a ~25% volume fraction of Mo2(Fe,Mn)B2 borides. Ballistic tests using 7.62 mm steel-core bullets (~830 m/s) showed that uncoated Armox 440T was completely perforated, whereas all hardfaced plates prevented penetration. Notably, coatings with higher boride content eliminated rear-side spalling, indicating superior energy absorption and projectile fragmentation. These findings demonstrate that FCAW-applied hypereutectic Fe–Mo–Mn–B–C hardfacing alloys can significantly improve the ballistic performance of armor plates.
AbstractList Armor steels can be strengthened against modern ballistic threats through surface hardfacing with advanced Fe-based alloys. This study develops a series of flux-cored arc welded (FCAW) hardfacing alloys in the Fe–Mo–Mn–B–C system to enhance the ballistic resistance of Armox® 440T steel. Single-layer (~3 mm) hardfacings were deposited on 6 mm armor plates using an automated hardfacing device, and subsequently characterized with respect to their microstructure, phase composition, and ballistic performance. Thermodynamic calculations and microscopy revealed an austenitic matrix reinforced by hard boride inclusions. By increasing the Mo and B concentrations, the alloy solidification shifted from a primary austenite + austenite boride mixture to a primary boride + austenite boride mixture structure. The compositions with high Mo:B ratio yielded a ~25% volume fraction of Mo2(Fe,Mn)B2 borides. Ballistic tests using 7.62 mm steel-core bullets (~830 m/s) showed that uncoated Armox 440T was completely perforated, whereas all hardfaced plates prevented penetration. Notably, coatings with higher boride content eliminated rear-side spalling, indicating superior energy absorption and projectile fragmentation. These findings demonstrate that FCAW-applied hypereutectic Fe–Mo–Mn–B–C hardfacing alloys can significantly improve the ballistic performance of armor plates.
Author Vytvytskyi, Vasyl
Panchuk, Vitalii
Prysyazhnyuk, Pavlo
Bembenek, Michał
Romanyshyn, Taras
Biały, Witold
Medvid, Iuliia
Duriagina, Zoia
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Snippet Armor steels can be strengthened against modern ballistic threats through surface hardfacing with advanced Fe-based alloys. This study develops a series of...
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SubjectTerms Alloy solidification
Armor
Armox 440T
austenitic manganese steel
ballistic resistance
boride reinforcement
flux-cored arc welding
hardfacing
Steel
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Title Improving Ballistic Resistance of Armor Steel by FCAW with Hardfacing Alloys of Fe–Mo–Mn–B–C System
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