Formulation and analysis of novel hybrid material for shock wave endurance with integrated image processing techniques

Abstract

The growing demand for protective materials in high-stress environments, such as bomb squad suits, fire-resistant suits, and the oil and gas industry, has rendered their development more critical. Existing solutions have not succeeded in achieving a cohesive integration of structural integrity, thermal stability, and vibration dampening. This study addresses this gap by examining the shock wave penetration resistance of silica aerogel, sorbothane, and graphite composites. We used ANSYS to conduct simulations on the individual materials and six composite configurations to evaluate their mechanical properties in comparison. A high-pressure shock tunnel has been used to assess shock wave effects, while Scanning Electron Microscopy (SEM) has been utilised to examine the consequences on microstructure. Thermogravimetric Analysis (TGA), Differential Thermal Analysis (DTA), and image processing techniques have corroborated the results. The findings demonstrate that silica aerogel and graphite possess considerable strength, whereas sorbothane excels in vibration absorption. The SEM analysis indicates that their porous, clustered, and interplanar characteristics enhance their shock resistance. Combination 1 has shown superior performance among all composites, exhibiting excellent thermal stability under shock-inducing loads. This study demonstrates that the silica aerogel–sorbothane–graphite composite exhibits a synergistic equilibrium of mechanical strength, thermal resistance, and vibration attenuation, making it suitable for advanced protective applications.