A spall liner is a critical component of vehicle armour systems, designed to provide additional protection against secondary fragmentation inside armoured vehicles. Secondary fragmentation occurs when a projectile or explosive blast strikes the outer surface of the vehicle’s armour, causing fragments or spall to break off and potentially injure occupants inside the vehicle. The spall liner serves as a secondary barrier to contain and mitigate the effects of this fragmentation, thereby enhancing crew survivability.

Function and Construction:
Spall liners are typically composed of lightweight, high-strength materials such as ballistic-grade aramid fibres, ballistic nylon, or composite materials. These materials are layered or woven together to form a flexible yet resilient barrier that can absorb and dissipate the energy of incoming projectiles and fragmentation. The liner is installed on the interior surfaces of the vehicle’s crew compartment, covering areas such as the walls, ceiling, and floor.

Protection Against Spalling:
When a projectile strikes the outer surface of the vehicle’s armour, it can generate a shockwave that causes spall ? the detachment of fragments from the inner surface of the armour. These spall fragments pose a significant threat to the vehicle’s occupants, as they can travel at high velocities and penetrate unprotected surfaces. The spall liner acts as a catchment system, intercepting spall fragments before they can cause harm to the crew. By absorbing the energy of the projectile and fragmentation, the liner reduces the velocity and kinetic energy of the spall fragments, preventing them from penetrating the crew compartment and minimising the risk of injury.

Advantages and Considerations:
Enhanced Crew Protection: Spall liners significantly enhance crew survivability by reducing the risk of injury from secondary fragmentation, improving overall vehicle survivability in combat situations.
Lightweight and Flexible: Modern spall liners are designed to be lightweight and flexible, minimising added weight and bulk while maximising protection and occupant comfort.
Maintenance and Replacement: Spall liners require periodic inspection and maintenance to ensure continued effectiveness. Damaged or worn liners must be promptly repaired or replaced to maintain optimal protection levels.
Conclusion:
Spall liners play a crucial role in enhancing crew protection and vehicle survivability in armoured vehicles exposed to explosive blasts or ballistic threats. By intercepting and mitigating the effects of spalling, these specialised linings help minimise the risk of injury to occupants and contribute to overall mission success in hostile environments. Continued research and development in spall liner technology are essential to further enhance crew survivability and vehicle protection in modern combat scenarios.