Abstract

This research explored the role of casing material selection in shaping the formation process and terminal performance of explosively formed projectiles (EFP). Six casing types, including polymer materials, aluminum alloys, and structural steels, were analyzed using numerical simulation and experimental testing in identical warhead configurations. The results of numerical simulations conducted in Ansys Autodyn with calibrated material models closely mirrored the experimental measurements. Projectile velocity and penetration diameter differed by less than 6% from the values observed in tests. The aluminum alloy casings, particularly Al 7039, performed the best, producing high-velocity, streamlined projectiles with deep and stable penetration. Polyethylene was a balanced alternative, yielding consistent formation and good experimental correlation. Steel casings caused excessive confinement, leading to premature fragmentation of the projectile into two separate parts, and were deemed unsuitable for stable EFP formation. The results underscore the critical role of casing material selection in EFP design. Aluminum alloys are optimal for high-penetration applications, while polymer casings are a practical option for lightweight and balanced configurations.