Monahan, D. J. "Quantifying Ballistic Glass Delamination with the Boeing Wedge Test." International Mechanical Engineering Congress & Exposition 2025 (IMECE 2025). American Society of Mechanical Engineers (ASME). Memphis, TN. 18 Nov. 2025. Conference Presentation.
A large multi factorial evaluation of delamination in elastomeric bonds was performed to identify the most significant factors causing reduced fracture toughness and secondary crack acceleration leading to delamination in vehicular ballistic glass systems. Vehicular ballistic glass systems, which provide both clear lines of sight and impact resistance, are typically constructed with multiple layers of glass and elastomeric interlayers, culminating with a final, thicker elastomeric interlayer bonded to a backing polycarbonate sheet for spall protection. The ballistic glass system is then fastened to vehicles with application of a potting adhesive. Delamination in the final interface is a pervasive problem, resulting in bubbles, spots, discoloration, and overall loss of visual acuity. This delamination occurs in a variety of operating environments and even in storage, and to date has proven to be unpredictable, resulting in an estimated $10-100 million in annual costs for the US Department of Defense replacing parts that delaminated prematurely.