Armour-piercing ammunition (AP) is a type of projectile designed to penetrate armour protection, most often including naval armour, body armour, vehicle armour.
The first major application of armour-piercing projectiles was to defeat the thick armour carried on many warships and cause damage to their lightly armoured interiors. From the 1920s onwards, armour-piercing weapons were required for anti-tank warfare. AP rounds smaller than 20 mm are intended for lightly armoured targets such as body armour, bulletproof glass, and lightly armoured vehicles.
As tank armour improved during World War II, anti-vehicle rounds began to use a smaller but dense penetrating body within a larger shell, firing at very high muzzle velocity. Modern penetrators are long rods of dense material like tungsten or depleted uranium (DU) that further improve the terminal ballistics.
History
The late 1850s saw the development of the ironclad warship, which carried wrought iron armour of considerable thickness. This armour was practically immune to both the round cast-iron cannonballs then in use and to the recently developed explosive shell.
The first solution to this problem was effected by Major Sir W. Palliser, who, with the Palliser shot, invented a method of hardening the head of the pointed cast-iron shot. By casting the projectile point downwards and forming the head in an iron mold, the hot metal was suddenly chilled and became intensely hard (resistant to deformation through a Martensite phase transformation), while the remainder of the mold, being formed of sand, allowed the metal to cool slowly and the body of the shot to be made tough (resistant to shattering).
These chilled iron shots proved very effective against wrought iron armour but were not serviceable against compound and steel armour, which was first introduced in the 1880s. A new departure, therefore, had to be made, and forged steel rounds with points hardened by water took the place of the Palliser shot. At first, these forged-steel rounds were made of ordinary carbon steel, but as armour improved in quality, the projectiles followed suit.
During the 1890s and subsequently, cemented steel armour became commonplace, initially only on the thicker armour of warships. To combat this, the projectile was formed of steel—forged or cast—containing both nickel and chromium. Another change was the introduction of a soft metal cap over the point of the shell – so called "Makarov tips" invented by Russian admiral Stepan Makarov. This "cap" increased penetration by cushioning some of the impact shock and preventing the armour-piercing point from being damaged before it struck the armour face, or the body of the shell from shattering. It could also help penetration from an oblique angle by keeping the point from deflecting away from the armour face.
World War I
Shot and shell used before and during World War I were generally cast from special chromium (stainless) steel that was melted in pots. They were forged into shape afterward and then thoroughly annealed, the core bored at the rear and the exterior turned up in a lathe. The projectiles were finished in a similar manner to others described above. The final, or tempering treatment, which gave the required hardness/toughness profile (differential hardening) to the projectile body, was a closely guarded secret.
The rear cavity of these projectiles was capable of receiving a small bursting charge of about 2% of the weight of the complete projectile; when this is used, the projectile is called a shell, not a shot. The high-explosive filling of the shell, whether fuzed or unfuzed, had a tendency to explode on striking armour in excess of its ability to perforate.
World War II
During World War II, projectiles used highly alloyed steels containing nickel-chromium-molybdenum, although in Germany, this had to be changed to a silicon-manganese-chromium-based alloy when those grades became scarce. The latter alloy, although able to be hardened to the same level, was more brittle and had a tendency to shatter on striking highly sloped armour. The shattered shot lowered penetration, or resulted in total penetration failure; for armour-piercing high-explosive (APHE) projectiles, this could result in premature detonation of the high-explosive filling. Advanced and precise methods of differentially hardening a projectile were developed during this period, especially by the German armament industry. The resulting projectiles change gradually from high hardness (low toughness) at the head to high toughness (low hardness) at the rear and were much less likely to fail on impact.