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AD-E403 121
Technical Report ARAET-TR-07009
BLENDED METAL TECHNOLOGY PROJECTILES
REVIEW AND ANALYSIS
Shawn P. Spickert-FultonJeffrey Schutz
June 2007
Further dissemination only as directed by U.S. Army ARDEC, ATTN: AMSRD-AAR-EMK, PicatinnyArsenal, NJ 07806-5000; June 2007; or higher DoD authority.
AD
ARMAMENT RESEARCH, DEVELOPMENT ANDENGINEERING CENTER
Armaments Engineering & Technology Center
Picatinny Arsenal, New Jersey
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The views, opinions, and/or findings contained in thisreport are those of the author(s) and should not beconstrued as an official Department of the Army posi-tion, policy, or decision, unless so designated by otherdocumentation.
The citation in this report of the names of commercialfirms or commercially available products or services doesnot constitute official endorsement by or approval ofthe U.S. Government.
Destroy this report when no longer needed by any methodthat will prevent disclosure of its contents or reconstructionof the document. Do not return to the originator.
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REPORT DOCUMENTATION PAGE
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4.TITLEANDSUBTITLE
BLENDEDMETALTECHNOLOGYPROJECTILESREVIEWANDANALYSIS
5c.PROGRAMELEMENTNUMBER
5d.PROJECTNUMBER
5e.TASKNUMBER
6.AUTHORS
ShawnP.Spickert-FultonandJeffreySchutz
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7.PERFORMINGORGANIZATIONNAME(S)ANDADDRESS(ES)
U.S.ArmyARDEC,AETC
MunitionsSystemsandTechnology(AMSRD-ARR-AEM-I)PicatinnyArsenal,NJ07806-5000
8.PERFORMINGORGANIZATIONREPORTNUMBER
10.SPONSOR/MONITORSACRONYM(S)
9.SPONSORING/MONITORINGAGENCYNAME(S)ANDADDRESS(ES)
U.S.ArmyARDEC,EMTechnicalResearchCenter(AMSRD-AAR-EMK)PicatinnyArsenal,NJ07806-5000
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TechnicalReportARAET-TR-0700912.DISTRIBUTION/AVAILABILITYSTATEMENT
FurtherdisseminationonlyasdirectedbyU.S.ArmyARDEC,ATTN:AMSRD-AAR-EMK,PicatinnyArsenal,NJ07806-5000;June2007;orhigherDoDauthority.13.SUPPLEMENTARYNOTES
14.ABSTRACTLeMasLtd.promotedaseriesofpatentedblendedmetaltechnology(BMT)RBCDprojectilesandassertedthattheyaresuperiortomilitaryandlawenforcementalternatives.Thislightweight,highvelocity,smallarmsammunitionperformedwellatshootingcompetitionswhereitexhibitedtheabilitytoperforateasteelplate,automobileglass,andselecttargets.TheLeMascartridgesweremarketedwithclay,meat,andliveanimalteststhatprovedthepurportedeffectivenessoftheproduct.Theclaimsofcontrolled,buteffectivepenetrationgainedtheattentionofCongress,whichissueda$1,050,000defenseappropriationtoUSSOCOMtosupportgovernment-widetestingofrevolutionarysmallarmsammunitionwithfullspectrumoflethalandpenetratingeffects.USSOCOMtookthemandateandformedajointserviceIPTthatincludedparticipationfromtheNavy,Army,USSOCOM,FBI,andOSD.ThisIPTthenproceededtoprocureandtestseveralmodelsofLeMasammunitionincluding9mm,5.56mm,and7.62mmvariants.ThetestshowedthattheLeMasriflecartridgeswereconstructedwithcommercialbulletsthatweremarkedwithathincoatingofmolybdenumdisulfide(adrylubricant).OperationaltestswiththeammunitionshowedthattheLeMasprojectilesperformedwellagainstspecifictargetsinspecificscenarios,butdonotmeettherangeofrequirements,specifications,andoperationalneedsthatarerequired.Additionally,LeMasammunitioncomeswithadditionallogisticalcomplexitiesandahighcomparativecost.ThissurveyreportsummarizestheeffortsofCrane,ARDEC,theFBEAcademy,USSOCOM,andotherstotestLeMasammunitioninafairandunbiasedmanner.ItoutlineswhatLeMasammunitionis;isitsafe;howitperforms;andhowitcompareswiththeM855,M118LR,M882,andsome
commercialequivalents.Someeffortisalsomadetoshowthecomparativeperformanceofpowdermetallurgyprojectilestocurrentoptions.15.SUBJECTTERMSLeMas,RBCD,Blendedmetaltechnology(BMT),Molybdenum,Gelatin,Clay,Liveanimal,Steel,Armor,Glass,Pig,Goat,Hardtarget,Softtarget,Exteriorballistics,Woundballistics,Terminalballistics,Lethality,Smallarms,Ammunition,Pistol,Sierra,Nosler,Speer,ARL,FBI,Crane,M855,M882,M118LR,5.56mm,7.62mm,9mm,EPVAT,(P/M),Lightweight,Softpoint,andBallistictip.16.SECURITYCLASSIFICATIONOF: 19a.NAMEOFRESPONSIBEPERSON
ShawnSpickert-Fulton/JeffreySchutza.REPORT
Ub.ABSTRACT
Uc.THISPAGE
U
17.LIMITATIONOFABSTRACT
SAR
18.NUMBEROFPAGES
16919b.TELEPHONENUMBER(Includearea
code)(973)724- StandardForm298(Rev.8/98PrescribedbyANSIStd.Z39.18
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CONTENTS
PageExecutiveSummary 1
PreliminaryIPTMeetingwithLeMasLtd. 2 InitialTests 3 PreludetoOperationalandSafetyTests 5 ExecutiveSummaryConclusions 7Introduction 8 InitialIPTMeeting(February2004) 8 2004JS-IPTProposedPlan 9 TaskDistribution 10 FundingandCosts 11
LeMasLTD.MarketingClaims 11 MostSignificantTechnologicalAdvancement 11 ProduceImmediateZeroMissionCapability 12 Non-comparablePerformanceinLivingTissue 13 ProduceEnhancedFragmentationPatterns 14 UniqueManufacturingProcess 15 UsedLeadFreeComponents 15 PatentedAmmunitionProducts 15WhatisBlendedMetalTechnology(BMT) 15 LeMasLtd.DefinitionofBMT 15 AmericanSocietyofMetals(ASM)DefinitionofBlendingMetals 16 UnitedStatesPatentNo.US6,363,856B1 16AnalysisofLeMas(RBCD)Projectiles 18 VisualTests 19 MetallurgicalandStructuralTests 35 SpectrometryandX-rayTests 52PerformanceAnalysisofLeMas(RBCD)Projectiles 57 AmmunitionPerformanceStatistics 57
SafetyandOperationalTests 62 AccuracyandDispersionTests 84 ArmorPenetrationTests 100 SoftTarget/TissueSimulant(BallisticGelatin)Tests 104HistoricalAnimalTestswithSoftPointProjectiles 127
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CONTENTS
PageReviewAvailableInformationonGovernmentTestsDoneonTrue(P/M)Type 129Projectiles
PowderMetallurgyIronFrangibleBulletTest 130 ControlledPenetration(PressedMetalPowder)ProjectileTest 130 ARDEC2002TerminalBallisticsEffort 131ComparisonofLeMasProjectilePerformanceand(P/M)ProjectilePerformance 132AssessmentofLeMasMarketingClaims 132 MostSignificantTechnologicalAdvancement 132 ProduceImmediateZeroMissionCapability 133 VariedPenetrationBasedonTarget 133
Non-comparablePerformanceinLivingTissue 134 ProducedEnhancedFragmentationPatterns 136 CauseHeatGeneratedBlisteringinSoftOrganStructures 137 UniqueManufacturingProcess 37 UseLeadFreeComponents 137 PatentedAmmunitionProducts 138Conclusions 138References 139Appendices ABasicWeaponStatistics 141 BIndependentTesting 147DistributionList 153
FIGURES1 LeMasUWandNoslerballistictipprojectilecrosssectionsandmoldnumber 42 LeMasUWcartridgewithNoslerballistictipbulletcoatedwithmolybdenumdisulfide 4
3 Sample7.62-mmhardtargetpenetrationphotographs 64 Cranehardtargettest 75 LeMasLtd.marketingpictureshowingarmorplatepenetration 13
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FIGURES(continued)
Page
6 PurportedeffectoftemperatureonBMTperformance 14
7 RoscoeStokerspatentedprojectilediagram 168 RoscoeStokerspatentedprojectiledesign 189 Breakoutofammunitionforthiseffort 19
10 LeMas5.56-mmblendedmetalprojectiles[UW(left)andLW(right) 1911 FBIvisualinspectionoftheLeMasUWcartridge 2012 InitialFIcomparisonofLeMas/RBCDUWtosimilarprojectiles 20
13 FBIweightcomparisonbetweenUWandNoslerprojectiles 2114 VisualcomparisonbetweenNoslerballistictipandLeMasUWdesign 2115 FBIphotographshowingNoslerstylemoldnumbersonLeMasUWprojectiles 2216 SidebysideNoslerandUWprojectilecrosssectionvisualinspection 2217 NoslerandLeMasblendedmetalUWprojectiles(moldnumbersfoundonboth 23 projectilestested)(ARDECphotograph)18 AsReceivedLeMasprojectilepictures 2419 SidebysideSierraandLWprojectileas-isvisualinspection 2520 SidebysideSierraandLWprojectilecrosssectionvisualinspection 2621 7.62-mmLeMasLWprojectile(ARDECasreceived) 2722 LeMasUW(left)andLeMasLW(right)jacketexamination 2723 Dimensionalmeasurementsofcrosssectioned5.56-mmprojectiles 2824 USSOCOM5.56-mmvisualinspectiontests 29
25 Basicdescriptionofthe7.62x51-mmtestammunition 3026 Basicdescriptionandphotographsofthe9x19-mmtestammunition 3127 Dimensionalmeasurementstakenontestammunition 32
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FIGURES(continued)
Page
28 UWcrosssectionimageshowinglocationsofmicrostructureanalyzed 36
29 LeMasUWleadcoremicrostructure 3630 UW(Nosler)copperjacketmicrostructureimages 3731 UWcartridgemicrostructure 3732 Noslerballistictipmicrostructure 3833 LWcrosssectionimageshowinglocationsofmicrostructureanalyzed 3934 LWleadcoremicrostructure 39
35 LW(Sierra)copperjacketmicrostructureimages 4036 LWcartridgemicrostructure 4037 SierraVarmintemicrostructure 4138 ResultsofthreeseparatemicrohardnessreadingsonNoslerandLeMas 43 ammunitionsamples39 Repeatabilityofmachinescriteriaformicrohardnesstests 4340 ResultsofthreeseparatemicrohardnessreadingsonSierraandLeMas 45 ammunitionsamples41 Bondedtestsamples(NoslerandUW) 4642 Bondedtestsamples(SierraandLW) 4743 LocationsforVickersDPNhardnessmeasurements5.56-mmcartridgecases 4844 LocationsforVickersDPNhardnessmeasurements7.62-mmcartridgecases 4945 LocationsforVickersDPNhardnessmeasurement9-mmcartridgecases 50
46 Illustrationofbulletcrimp 5147 ExampleUW(Nosler)corechemistryspectrumresult 5248 ExampleUWjacketchemistryspectrumresult 53
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FIGURES(continued)
Page
49 UWjacketcoatingchemistryspectrumresult 53
50 UWandNoslerballistictipcomparativechemicalanalysis 5451 LWcorechemistryspectrumresult 5452 LWjacketchemistryspectrumresult 5553 LWjacketcoatingchemistryspectrumresult 5554 LeMasLWandSierraVarmintercomparativechemicalanalysis 5655 Averagecasemouthpressureversustemperaturefor9-mmammunition 69
56 TestsheetshowingM9weapondamage 7057 BlownprimersandextrudedbulletcorematerialLeMas9-mmEPVATtest-40F 7158 SampleARDECEPVATcurvesforLeMasLW(Sierra)ammunition 7259 Additionalblownprimers(9-mmLeMas)observedduring-40Fvelocitytesting 7660 Bubbletestresults(5.56mm) 7861 Bubbletestresults(7.62mm) 79
62 Bubbletestresults(9mm) 7963 5.56-mmFNM16A4bulletbreak-upresults 8264 BulletRPMversustwistrate(M16A4andM4A1) 8265 Universalbondreceiver/Mann-typebarrel 8466 Dispersion/accuracyrelationship 8567 Definitionsofdispersionmeasurements 8568 5.56-mmextremespreadresults(100mand300m) 8769 7.62-mmextremespreadresults(100mand300m) 8870 9-mmextremespreadresults(25mand50m) 88
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FIGURES(continued)
Page
71 Pistolandrifleweaponmounts 89
72 Average5.56-mmextremespreadM4A1dataonscaledtargets 9273 7.62-mm(Mk11)extremespreadonscaledtargets 9574 9-mmextremespreadonscaledtargets(25m) 9875 Armorpenetrationtestsetup 10076 Cardboardwitnessmaterials 10077 Example5.56-mmshotsagainst3/8-in.AR-500(steelplate) 101
78 Example7.62-mmshotsagainst3/8-in.AR-500steelplate 10279 Example9-mmshotsagainst3/8-in.AR-500steelplate 10380 Cranehardtarget(R50)testdata 10481 Dziemanscomparisonofbulletwoundtractdimensions(ingoats)andenergy 106 absorptionfrombulletsby20%gelatintissuemodels82 Velocitydecaycurvedataformahistorical1960scomparativetest 10683 Historicalcomparisonsofgelatinandtissue 10784 Samplevelocitydecaycurves(m/s)versusdepthofpenetration(cm)forSierra 108 andM855projectilewhenfiredinto10%gelatinsimulant85 Sampleenergydepositcurves(J/cm)versusdepthofpenetration(cm)forSierra 109 andM855projectileswhenfiredinto10%gelatinsimulantattworanges86 Relevantgelatinblockfeatures 11187 SampleM4A15-mbaregelatinresults 11288 SampleM4A1100-mbaregelatinresults 113
89 SampleM4A1300-mbaregelatinresults 11490 SampleM16A4baregelatinshots 115
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FIGURES(continued)
Page
91 Theshotthatchangedlawenforcementammunitioncriteria 115
92 SampleMk115-mbaregelatin 11693 SampleMk11100-mbaregelatin 11694 SampleMk11300-mbaregelatin 11795 SampleM8pistol5-mbaregelatin 11896 SampleM9pistol25-mbaregelatin 11897 SampleM4A15-mautoglassresults 119
98 SampleM16A45-mautoglassresults 12099 SampleM4A1100-mautoglassresults 120100 SampleM16A4100-mautoglassresults 120101 SampleM4A1300-mautoglassresults 121102 SampleM16A4300-mautoglassresults 121103 Non-lethaldesignsthatdonotpenetrateskin,butdopenetrategelatin(about3in.) 122104 SampleMk115-mautoglasstarget 123105 SampleMk11100-mautoglasstarget 124106 SampleMk11300-mautoglasstarget 124107 SampleM9pistol5-mautoglasstarget 125108 SampleM9pistol25-mautoglasstarget 125109 .220Winchestersoftpoint 128
110 Sampledamagepictures 129111 Sample.220Winchestershotintogelatin 129112 SNCCPApenetrationresultsagainstvariousbarriersandgelatinat25and300m 131
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FIGURES(continued)
Page
113 JohnHamilton(right)talksafterdemonstratingablendedmetalroundagainstclay 134
114 SamplemaximumdynamiccavityimageM855andLeMasLW(Sierra)(5mtest 135 withM4)115 Easonsstrikingenergyversusenergyabsorbedforchromesteelspheres 135
TABLES1 CartridgedesignspurchasedfromLeMasLtd. 32 Costcomparisons 3
3 Projectilesurrogates 64 Proposedtestbreakdownbyorganization 105 QuantitiesandtypesofammunitionpurchasedfromLeMasLtd.withcomparisons 11 data6 Weightsanddimensions(NoslerballistictipandUWprojectiles) 257 Weightsanddimensions(SierraandLW) 268 Testammunitioncharacteristics 289 Summaryofmeasurementsfromthedimensionalinspectionof5.56x45mmtest 33 ammunition10 Summaryofmeasurementsfromthedimensionalinspectionof7.62x51mmtest 33 ammunition11 Summaryofmeasurementsfromthedimensionalinspectionof9x19mmtest 34 ammunition12 Samplemicro-hardnessvaluesobtainedforLeMasUWandNoslerballistictip 42 projectiles
13 Samplemicro-hardnessvaluedobtainedforLeMasLWandSierraprojectiles 4414 EstimatedmechanicalpropertiesofprojectilessuppliedbyLeMasLtd. 4615 AverageVickersDPNhardnessmeasurementsfor5.56x45-mmcartridgecases 48
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TABLES(continued)
Page
16 AverageVickersDPNhardnessmeasurementsfor7.62x51-mmcartridgescases 49
17 AverageVickershardnessmeasurementsfor9x19-mmcartridgecases 5018 Summaryofbullet(highlightedresultsareoutsideofspecification) 5119 Calculatedsectionaldensitiesoftestammunition 5820 EstimatedBCoftestprojectiles 5821 5.56-mmmuzzlevelocity 5922 7.62-mmmuzzlevelocitytest 59
23 9-mmmuzzlevelocitytest 6024 5.56-mmimpactenergyandmomentumstatistics 6025 7.62-mmimpactenergyandmomentumstatistics 6126 9-mmmuzzleenergyandmomentumstatistics 6127 5.56-mmrecoildatawithtestammunition 6228 7.62-mmrecoildatawithtestammunition 6329 9-mmrecoildatawithtestammunition 6330 MIL-STDpressurespecifications 6531 SAAMIpressurespecifications 6532 MIL-STDpressureresultsfor5.56-mmcartridgestested 6633 SAMMIpressureresultsfor5.56-mmcartridgestested 6634 MIL-STDpressureresultsfor7.62-mmcartridgestested 67
35 SAMMIpressureresultsfor7.62-mmcartridgestested 6736 MIL-STDpressureresultsfor9-mmcartridgestested 6837 SAMMIpressureresultsfor9-mmcartridgestested 6838 SummaryofLeMas9-mmpressureissues 69
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TABLES(continued)
Page
39 MIL-STD(left)andSAAMI(right)velocityspecifications 73
40 MIL-STD5.56-mmvelocitytestresults 7441 SAAMI5.56-mmvelocitytestresults 7442 MIL-STD7.62-mmvelocitytestresults 7543 SAAMI7.62-mmvelocitytestresults 7544 MIL-STD9-mmvelocitytestresults 7645 SAAMI9-mmvelocitytestresults 76
46 5.56-mmand7.62-mmWaterproofnesstestresults 7747 9-mmWaterproofnesstestresults 7848 9-mmmalfunctionchart(functionandcasualty) 8349 Testbarrelinformation 8650 Accuracydata(averageofthree10-shotgroups) 8651 Standarddeviationofdispersiontests 8752 Statisticalcomparisonoftestammunitionextremespread(Mannbarrel) 8953 100m5.56-mmM4A1dispersionresults(averageofthreeweapons) 9054 300m5.56-mmM4A1dispersiontestresults(averageofthreeweapons) 9155 Standarddeviationsof100mand300m5.56-mmM4A1dispersiontest 9156 100mANOVAresultsfor5.56-mmM4A1dispersiontest 9257 300mANOVAresultsfor5.56-mmM4A1dispersiontest 93
58 100m7.62-mmMk11dispersionresults(averageofthreeweapons) 9359 300m7.62-mmMk11dispersionresults(averageofthreeweapons) 9460 Standarddeviationsof7.62-mmMk11100mand300mdispersionresults 9461 Differencebetween100mMannbarreland100mMk11results(averageof 94 threeweapons)
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TABLES(continued)
Page
62 Differencebetween300mMannbarreland100mMk11results(averageof 95
threeweapons)63 100-mANOVAresultsfor7.62-mmMk11dispersiontest 9664 300mANOVAresultsfor7.62-mmMk11dispersiontest 9665 25m9-mmBerettadispersionresults(averageofthreeweapons) 9766 Standarddeviationsof9-mmM9Beretta25mdispersionresults 9767 Differencebetween25m9-mmMannbarrelandM9Berettadispersionresults 97 (averageofthreeweapons)
68 ANOVAresultsfor9-mmBerettadispersionresults 9869 Statisticalcomparisonoftestammunitionextremespread(fieldweapons) 9970 300-yarddispersiondata(Cranetest) 9971 5.56-mmpenetrationresultsagainst3/8-in.and5/8-in.steelplate(5and100m) 10172 7.62-mmpenetrationresultsagainst3/in.and5/8-in.AR-500(steelplate) 10273 9-mmpenetrationresultsagainst3/8-in.and5/8in.steelplate 10374 Criticaldimensionsofhumanmales 11075 5.56-mmbaregelatinresultsat5m 11376 5.56-mmbaregelatinresultsat100m 11377 5.56-mmbaregelatinresultsat300m 11478 7.62mm5-mbaregelatinresults 11679 7.62-mmbaregelatinresultsat100m 117
80 7.62-mmbaregelatinresultsat300m 11781 5.56-mm5-mautoglassresults 12082 5.56-mm100-mautoglassresults 12183 5.56mm300-mautoglassresults 122
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TABLES(continued)
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84 7.62mm5-mautoglassresults 123
85 7.62mm100-mautoglassresults 12486 7.62mm300-mautoglassresults 12487 ARDEC2004statictestdatavaluesonrelevanttesting 126
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BottomLineUpFront1.LeMasLtd.promotedaseriesofBlendedMetalTechnologyRBCDprojectilesandassertedthattheyareuniqueinconstructionandsuperiortocurrentmilitaryandlawenforcementalternatives.2.TestingrequestedbyCongressthrougha$1,050,000DefenseappropriationissuedforFiscalYear2003wasconductedbyUSSOCOMIPT.3.LeMasriflebulletswerefoundtobecomposedofroutineandcommonlyavailablecommercialprojectilesofothermanufacturersthathadbeencoatedwithadrylubricant(molybdenumdisulfide).4.AlloftheproductspurchasedfromLeMaswerefoundnottofulfillexistingDoDneeds,requirements,andspecifications.5.LeMasproductsaresignificantlymoreexpensivethanexistingmilitaryalternatives.6.Alegalreviewbasedonthisreportisinprogress.
EXECUTIVE SUMMARY
TheHouseofRepresentativesConferenceReporttotheFiscalYear2003DefenseAppropriationActcontaineda$1,050,000appropriationfortheDepartmentofDefense(DoD)totestblendedmetaltechnology(BMT)bulletstosupportgovernment-widetestingofrevolution-arysmallarmsammunitionwithfullspectrumoflethalandpenetratingeffects.Further
clarificationoftheappropriationrevealedthatthebulletstheDoDweretotestwerethoseproducedbyLawEnforcementMilitaryAmmunitionSales(LeMas)ofLittleRock,Arkansas. LeMashasbeenpromotingavarietyofBMTprojectilesthatitclaimstobesuperiortocurrentmilitaryandlawenforcementsmallarmsammunition.Theseblendedmetalprojectilesweredemonstratedatanumberofshootingcompetitions.Severalgovernmentagenciesevaluatedthemusingnationallyandinternationally(NATO)-acceptedevaluationprotocols 1.ThistestingdidnotsupportLeMasclaimsandthetechnologywasnotpursued.However,LeMasLtd.objectedtothemannerinwhichtheroundsweretested.
_______________________1BoththeArmyandtheNavylookedatseveralLeMascartridgesintheyearspriorto2003.
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Inresponse,theUnitedStatesSpecialOperationsCommand(USSOCOM)formedanintegratedproductteam(IPT)totestbulletsmarketedbyLeMasLtd.asBMT.TheIPTconsistedofrepresentativesfromtheNavalSurfaceWarfareCenter,CraneDivision(NSWCCrane);theU.S.ArmyArmamentsResearch,Development,andEngineeringCenter(ARDEC),PicatinnyArsenal,NewJersey;theFederalBureauofInvestigations(FBI);theOfficeoftheSecretaryofDefense(OSD),aswellassubjectmatterexpertsupportcontractors.
Thescopeoftheinvestigationwasfourfold.Inshortwhatisit,isitsafe,doesitwork,andcanweuseit?Thisreportdiscussesthetestresultsthatwereobtainedtoanswerthosequestions.Thelegal(lawofwar)reviewrequiredbyDoDInstruction5000.2(12May2003),ArmyRegulation27-53(1January1979),andUSSOCOMDirective525-27(14February2001)willbeperformedbytheOfficeofGeneralCounsel,DoD,basedonthetestresultscontainedwithinthisreport.Preliminary IPT Meeting with LeMas Ltd.
ThestudyoftheBMTstartedwithanIPTmeetingwithLeMasLtd.sPresident,JohnHamilton.Mr.HamiltonstatedthatitsammunitionwasmanufacturedbyRBCDPerformance
Plus,Inc.toLeMasLtd.sspecifications.HealsoclarifiedLeMasLtd.smarketingclaimssothattheIPTcouldaccuratelycomparethebulletsperformancetotheirassertions. FromtheLeMaspresentation,fourclaimsrequiredparticularattention:
1. LeMasmadetheassertionthatitsammunitionwasmadeusingBMT.2. LeMasclaimedthatitsroundsproduceimmediatezeromissioncapability, thatis,immediateincapacitation.3. LeMasLtd.claimedthatitsprojectileshadunusualpyrophoricproperties, whichworkedwellinwarm,oxygenated,tissue,butreacteddifferentlyin chilledballisticgelatin.4. LeMasclaimedthattheirbulletsfullypenetrateatargetbehindin.AR500 steelplate,butdonotoverpenetratehumantargets.
Mr.HamiltonshowedvideosofliveanimaltestsconductedbyLeMasLtd.2Infact;theLeMasvideoscontradictedHamiltonszeromissioncapabilityassertion,astheanimalsclearlywereobservedaliveandmovingforanextendedtimeafterbeingshot. Followingthisinitialmeeting,USSOCOMformulatedatestplantoassessLeMasassertions.USSOCOMpurchasedstocksofavarietyofLeMasammunitionfromLeMasLtd.(table1).
_______________________2LeMasLtd.sliveanimaltestingwasnotdoneatthebehestoftheU.S.GovernmentorbyanymemberoftheIPT.LeMasLtd.waslaterbroughttocourtandfinedfortheirtestingpractices.ReferenceUSDA,APHIS,IESCaseNumberAR5002-AC,whichlistednumerouscitationsincluding2.38(f)2(i)physicalabuse.
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Table1CartridgedesignspurchasedfromLeMasLtd.
Caliber(mm) Nomenclature Projectileweight
5.56 RBCD/LeMas"UrbanWarfare"cartridge 37grain
5.56 RBCD/LeMas"LandWarfare"cartridge 45grain
7.62 RBCD/LeMas"LandWarfare"cartridge 110grain
9 RBCD/LeMas"CQBSPLP(H)"cartridge 58grain
LeMasrecommendstheLandWarfare(LW)5.56-mmcartridgeformilitaryuseintheM4andthe5.56-mmUrbanWarfare(UW)cartridgeforlawenforcementuse 3.ThesecartridgesweresubstantiallymoreexpensivethantheM855cartridgethattheU.S.ArmycurrentlypurchasesforalloftheServices(table2).
Table2Costcomparisons
Nomenclature Individualcartridgeprice
Noslerballistictipcartridge(websurvey) $.50to$.79
Sierra1310cartridge(websurvey) $.50to$.80
MilitaryM855(withpackaging)estimated $.20to$.30
LeMasUWcartridge(actualcostpaid)
LeMasLWcartridge(actualcostpaid)
Initial Tests
Initialvisualanddimensionalinspections(fig.1)ledtheIPTtosuspectthattheriflebullets,providedbyLeMas,werenotmadeofblendedmetalsormadebyRBCD.TheriflebulletsthatLeMassoldUSSOCOMwerestandardcommercialprojectiles(ofothermanu-facturers4)thatweregivenathincoatingofmolybdenumdisulfide[adrylubricant(fig.2)].Theseconclusionswereverifiedbymetallurgical,visual,andspectrometricanalysisconductedatseveralindependenttestsites. _______________________3Militaryandlawenforcementammunitionmaydifferbecauseofdifferentrequirements,restrictions,andneeds.Inparticular,militaryammunitionmustadheretoU.S.Treatyobligations.4Threeprojectilemanufacturerswerepositivelyidentified:Speer,Nosler,andSierra.
3
(b) (4)
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Figure1LeMasUWandNoslerballistictipprojectilecrosssectionsandmoldnumber
Figure2LeMasUWcartridgewithNoslerballistictipbulletcoatedwithmolybdenumdisulfide
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Spectrometricanalysisrevealedthatthesebulletswerecomposedprimarilyofleadandantimony,likeordinarybullets.AftercuttingtheLeMasLtd.bulletsinhalf,ARDECmetallurgistsdeterminedthatthemicrostructuresoftheriflebulletswereconsistentwithswagingmanu-facturingtechniquesandnotwithpowdermetallurgytechniques.TheFBIsforensicanalysisrevealedthatthelistedprojectileweightsdifferedfromUWprojectileweightsandthattheseprojectilescontaineddistinctiveorangeNoslerstylemoldnumbersthatmatchedthosefoundon
Noslersballistictipprojectiledesign.TheactualweightoftheLeMasUWbulletsmatchedtheweightoftheNoslerballistictipbullets. Ogiveradius,thicknessofthebaseofthejacket,andthicknessofthejacketwallwerealsomeasuredonbothdesigns.Matchinganyofthesedimensionsisoftensufficienttoidentifythemanufacturerofabullet.Opticalcomparatormeasurementsrevealedthattheother5.56-mmsubmission,theLWbullet,wasamatchtotheSierra1310Varminterbulletonallthreedimensions. Whenaskeddirectly,LeMasLtddeniedthattheirprojectileswereanythingotherthanRBCDsownuniqueproprietaryblendedmetaldesign 5.RequestsbytheIPTtotourtheLeMas/RBCDmanufacturingfacilitywererefused.LeMasLtdinsistedthattheIPTcontinuetheir
effortstovalidatetherealworldoperationalcapabilityofBMT.Notwithstanding,LeMasdenialsandclaimstothecontrary,theIPTconcludedthatthe5.56-mmUWprojectileswereleadcoreNoslerballistictipprojectilesthatwerecoatedwithathinfilmofmolybdenumdisulfideandthatthe5.56-mmLWprojectileswereleadcoreSierraprojectilesthathadlikewisebeencoated. TheIPTinvestigationprovedscientificallythatthecartridgespurchasedfromLeMascontainedcommercially-availableprojectilesnotdesignedormanufacturedbyLeMasorRBCD.AsLeMas/RBCDneverclaimedtomanufacturethecartridgecase,primer,orpowder,theonlylogicalconclusionwasthatLeMas/RBCDassembledammunitionfrompartsitpurchasedtosellasitsowndesignandproduct.Prelude to Operational and Safety Tests
AfterdeterminingthattheLeMas5.56-mmprojectileswereordinaryleadcorebullets,theIPTconductedadditionaloperationalandsafetytestingtoevaluateoverallcartridgeperformancewiththe5.56mm,7.62mm,and9-mmLeMassubmissions.USSOCOMtestedandcomparedtheperformanceofthesecartridgeswithcurrentmilitaryalternatives,andwiththeanalogouscommercialbulletdesigns(Sierra,Nosler,andSpeer).TheseanalogouscommercialdesignswerethenloadedtothesamevelocitiesandchamberpressuresastheequivalentLeMascartridge.
_______________________5LeMasLtd.istheexclusivedistributorofRBCDBMTprojectiles.
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ItwasproposedthatifthecommercialbulletsdemonstratedthesameperformanceastheLeMasbullet,thenGovernmenttestinghadnotoverlookedanythingsignificant.Thesesurrogatebulletswereofknownorigin,notblendedmetals,andappearedidenticaltotheLeMas-furnishedbullets(table3)6.ThesesurrogatesservedasadirectgaugeoftheuniquenessoftheLeMasbullets.Testresultsshowedthatboththe5.56mmand7.62-mmsurrogatesperformancematchedtheLeMas-furnishedbulletsperformance.The9-mmpistolresultsdiffered,butnot
overwhelminglyandwerediscontinuedaftersafetyissueswhenthepressuretestsresultedindamagebeingdonetotwotestweapons.
Table3Projectilesurrogates
CaliberProjectileclass
5.56mm 7.62mm 9mm
Militarydesigntested M855 M118LR M882
LeMasproductstested UW,LW LW CQBSPLP
CommercialsurrogatestestedSierra"Varminter",
Nosler"BT"Speer Aguila
Operational and Safety Tests
Thissectionisnotmeanttobeallencompassing.Severalareasofthefollowingsectionareverycomplexandsimplificationsweremadetopromoteunderstanding.Additionaldetailsarefoundinthebodyofthereportandinthesupportingmaterial. ThehardtargetpenetrationtestsconductedaspartofthisinvestigationshowedthatsomeoftheLeMasammunitionismoreeffectivethanthetestedmilitaryalternativesagainstthinsteelbarriersatshortranges.Forexample,the7.62-mmLeMascartridgeperformedbetterinthistestthantheM118LRagainst3/8in.AR500steelplateat5m(fig.3).
Figure3Sample7.62-mmhardtargetpenetrationphotographs 7
_______________________6Therifleprojectileswereexactlyanalogous.The9-mmprojectilewasnot.Referencelatersectionsfordetails.7DODIC:DoDIdentificationcode,OTM:Opentipmatch,SP:Softpoint,LCAAP:LakeCityArmyAmmunitionPlant,BRC:n/a
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However,thetestingalsoshowedthattheLeMasalternativeslostvelocityquicklyandwerenoteffectiveagainstthesametargetsatlongerranges.Inshort,theLeMasalternativeshaveanarroweroveralloperationalband.Additionally,theLeMasprojectileswerelesseffectiveagainstthickertargetsandbehindwindshieldsthatwereslopedtoanobliquityof45deg.
Figure4Cranehardtargettest
LeMasclaimthatitsbulletpenetratesarmorbutdoesnotover-penetratesofttargetsisnotcontested.Thisisbecauseofthebulletdesign(lightweightandexposedsoftleadorpolymertip)andbecauseofitsimpactvelocity,notbecauseofanyuniqueconstructionofthebullet. Lastly,theIPTaddressedthequestion,isitsafeanddoesLeMasammunitionfulfillDoDneeds,requirements,andspecifications?Inshort,theanswerisno.Functiontestsconductedwiththe9-mmLeMaspistolcartridgesresultedinnumeroushighpressureproblems(observedduringcoldtemperaturetests).Thesetestseventuallydamagedtwotestweaponsandhalted
additionalpressuretestswiththatdesign.AccuracytestsonthesamecartridgeshowedthattheLeMasproductwasnotablylessaccuratethancurrentoptions. Additionally,bulletintegritytestsconductedwiththe5.56-mmLW(Sierra)cartridgeandtheM16showedthattheLeMasalternativebroke-upafterlaunch.Bulletbreak-updegradesaccuracy.WaterproofnessfailuresonmultipledesignsfurtherreinforcedthepositionthatnumerousmodificationswouldhavetobemadebeforeaLeMasroundfieldingcouldevenbeconsidered.Thesubstantialcostpercartridgeincreaseisalsonoted.Executive Summary Conclusions
Periodically,theGovernmentreceivesclaimsofrevolutionarybulletdesigns.Theseare
frequentlylightweightdesignswithsofttips,firedathighvelocities.Thesedesigncharacteristicstypicallyyieldimpressiveresultsinspecifictestscenarios,normallyatshorterranges;however,comprehensivetestinginevitablydemonstratesthattheirperformanceistoonarrowlyfocusedandnoteffectiveacrossthebroadspectrumofmilitaryrequirementsthatmustbemet.LeMassubmissionfallsintothisgeneralcategory.
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INTRODUCTION
LeMasLtd,ismarketingseveraltypesofcartridges.Inmarketingbrochures,developedbyLeMasLtd,theseproductsaredescribedasusingBMT,whichispurportedbyLeMasLtd.to:
Produceimmediatezeromissioncapabilitywithrapidterminalresults(ref.1)
Notexhibitover-penetration8inwarm,soft,oxygenatedtissue(ref.1) Produceenhancedfragmentationpatterns(ref.1) Causeheatgeneratedblisteringinsoftorganstructures(ref.2)
In2002,CongressmandatedthattheDODtestBMTSmallArmsAmmunition.Asaresult,USSOCOMputtogetheraJointServiceIPT(JS-IPT)tocarryoutthedirective.ThisIPThadparticipationandinputfrommultiplesourcesincluding:USSOCOM,U.S.Army,U.S.Navy,FederalBureauofInvestigation(FBI),andtheOfficeoftheSecretaryofDefense(OSD).Thisjointservice,jointagency,approachwasdeemeddesirable,as:
Suchapanelofdiverseballisticexpertswouldbringskills,knowledge, experience,andresourcesthatwouldenhancetheeffortandotherwisebe unobtainable. Testcredibilityandobjectivitywereconsideredkeyandessential BMTprojectilesmightbeprohibitedformilitaryuseunderU.S.treaty obligations.Thelegal(lawofwar)reviewrequiredbyDoDInstruction5000.2 (12May2003),ArmyRegulation27-53(1January1979),andUSSOCOM Directive525-27(14February2001)willbeperformedbytheOfficeof GeneralCounsel,DoD,basedonthisreport.
Initial IPT Meeting February 2004)
TheIPTmetinitiallyon19February2004to:
DiscussBMTprojectileswithLeMasPresidentJohnHamilton DiscussUSSOCOMtestersandprocedures
_______________________8Projectiledoesnotexitthetarget.
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Mr.HamiltonpresentedseveralvideoclipsandphotographsshowingvariousteststhatwereconductedbyLeMasLtd.IncludedinthevideoclipswereaseriesofliveanimalteststhatwereconductedbyLeMasLtd.topromotetheirproduct. LeMasconductedtheseliveanimaltestsindependently,withoutanygovernmentrequestoroversight.ItistheopinionoftheIPTthatLeMasdidnotadheretocurrentorhistoricalanimal
testingprotocols,andconductedthesetestsinanunethicalmanner 9,10,11,12(refs.1,3,and4). Followingthevideoclips,Mr.HamiltonpresentedtheIPTwithtestimonialsfromthetwoattendingphysicianswhoperformednecropsiesonfourofthepigsdestroyed.2004 JS-IPT Proposed Plan
FollowingthemeetingwithLeMasLtd.,apathforwardwasoutlinedbytheIPT.
ReviewanddiscussLeMasLtd.marketingclaims(referenceLeMasLtd. MarketingClaimssection)
DeterminewhatconstitutesBMTasitpertainstotheCongressionalmandate (referenceWhatisBMT?section) ReviewanddiscusshowBMTpertainstoLeMasammunition(reference AnalysisofLeMas(RBCD)Projectilessection) ReviewavailableinformationongovernmenttestsdonewithLeMasprojectiles (referencePerformanceAnalysisofLeMas(RBCD)Projectilessection6)
_______________________9LegalactionwastakenagainstLeMasLtd.byPETA.ReferenceUSDA,APHIS,IESCaseNumberAR5002-AC,whichlistednumerouscitationsincluding2.38(f)2(i)physicalabuse.ReferencethenotedPETAwebsiteforadditionalinformation.10Currenttestprotocolstypicallyusetissuesimulantssuchasballisticgelatintomeasureterminaleffectiveness.TheseprotocolswereextensivelyrefinedandvalidatedinthedecadesfollowingWorldWarIIandminimizetheneedforadditionalanimaltesting.11LegalactionwastakenagainstLeMasLtd.byPETA.ReferenceUSDA,APHIS,IESCaseNumberAR5002-AC,whichlistednumerouscitationsincluding2.38(f)2(i)physicalabuse.ReferencethenotedPETAwebsiteforadditionalinformation.12LeMasLtd.objectstootherthanliveanimalorwarmoxygenatedtissuetesting,statingthattheirprojectilesonlyreactwhenimpactingthatmedium(asopposedtoballisticgelatin).
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ReviewanddiscusshistoricaltestsconductedonotherBMTtypeprojectiles (referenceHistoricalAnimalTestswithSoftPointProjectilessection) Research,review,andevaluatecurrentlyavailableBMT)typeprojectiles (formand/orfunction)(referencePerformanceAnalysisofLeMas(RBCD) Projectilessection).
BenchmarkBMT(referencePerformanceAnalysisofLeMas(RBCD) Projectilessection):
Tocurrentmilitarycartridgeperformance Tomilitaryrequirements Costconsiderations(referenceIntroductionsection)
ConducttestsonotherprojectilessimilartoLeMasLtd.BMTprojectilestosee ifBMTammunitionperformanceisuniquetoLeMasLtd.designs(reference PerformanceAnalysisofLeMas(RBCD)Projectilessection). EvaluatepossibleprosandconsofBMTtocurrentmilitaryalternatives (referenceAssessmentofLeMasMarketingClaimsandConclusions sections) ReportResults(thisreport)
Task Distribution
Thetasksjustoutlinedweredistributedappropriatelyacrossmultipletestcenters,withtheideabeingthataparallelapproachwouldbemorecomprehensiveandmorethoroughthanaserialone.13Asaresult,theArmy,Navy,andFBItestedLeMasammunitionintheirinternalfacilities,whileUSSOCOMcontractedanindependentorganizationtotesttheLeMasammuni-
tion(table4).
Table4Proposedtestbreakdownbyorganization
_______________________13Inadditiontosomespecifictestsets,ARDECwastaskedwithwritingthefinalreportfromthedatathatwasgatheredfromtheotherservices.
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Uponconclusionofthisstudy,alegalreviewofsubjectammunitionwillbeconductedbytheOfficeofGeneralCounsel,DoD,todeterminecomplianceofsubjectammunitionwiththelawofwarobligationsoftheUnitedStates.
Funding and Costs
Aformal$1,050,000CongressionalappropriationtotestBMTsmallarmsammunitionwasissuedbytheHouseofRepresentatives107 thCongress2dSessionattheendof2002.ThisfundingwasthenissuedtothevariousgovernmenttestcenterstocoordinateandperformtestsonBMTsmallarmsammunition.Inmostcases,contractualagreementswereinitiatedandfundswereobligatedearlyintheeffort 14(table5).
Table5QuantitiesandtypesofammunitionpurchasedfromLeMasLtd.withcomparativedata 1516
LEMAS LTD. MARKETING CLAIMS
LeMasLtd.istheexclusivelawenforcementandmilitarydistributorofRBCDBMTsmallarmsammunition(ref.5).AstheexclusivedistributorofRBCDBMT,LeMasammunitionhas
madeanumberofclaimsadvancingtheirproduct.Theseclaims(outlinednext)areinitiallylistedheretoprovidethereaderwithinsightintotheexpectedperformancethatwasadvancedbyLeMas.Followingthetestresults,anassessmentoftheseclaimswillbeperformedbasedonthedataandinformationtodate.
Most Significant Technological Advancement
Claim:LeMasLtd.claimsthatitsBMTisthemostsignificanttechnologicaladvancementinsmallarmssincetheadventofthe20 thcentury(ref.5).
Thesenewblendedmetalspayloadsdepartradicallybothinconstructionandcapability,fromthehistoricallymanufacturedleadbulletammunitionsofthelast100years(ref.5).
_______________________14Forthisreason,alloftheindividualtestswerecontinuedtocompletion,eventhoughvalidquestionsandconcernswereraisedaboutwhetheradditionalinformationwasnecessary.15Aspartoftheprocurementprocess,newammunitionDODICsweregenerated.16Commercialcalibernomenclaturesarenotthesameasthemilitary.SAAMIusesthefollowing:.223Remingtoninsteadof5.56mmx45mm,.308Winchesterinsteadof7.62x51mm,and9-mmLugerinsteadof9x19mm.
11
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TheRBCD.223StateDepartment39grainSpecialPurposeLimitedPenetration(SPLP)armorpenetratingroundoffersexceptionalincapacitationterminalperformanceinrealtissue,defyingtheconventionalmaximumwound/minimumvelocityrequirementsoftraditional.223bulletdesigns(ref.5).
Reference:AssessmentofLeMasMarketingClaimssection.Produce Immediate Zero Mission Capability
Claim:LeMasLtd.claimsthatitsammunitionproducesimmediatezeromission capability,whichrapidlyleadstoterminalresults(ref.1).
Basedonvarioustestsinlivingandnon-livingtissue,webelievethatanyimpacttothetorsowithanySPLPbulletdesignwillproduce"zeromissioncapabilityinthattarget.Wealsobelievethatanyhittoanappendagewillcauseanincapacitatingwoundresultinginthethreattargetsinabilitytocontinuehismission(ref.5).
Reference:AssessmentofLeMasMarketingClaimssection.Varied Penetration Based on Target
Claim:LeMasLtd.claimsthatitsammunitionwilldefeatavarietyofbarrierobstaclessuch asglass,bodyarmor,andin.AR500steelplate(fig.5),butnotoverpenetratewarm, soft,oxygenatedtargets(ref.5).17
WhatmakesLeMasammospecialisitsabilitytopenetratehardbarriers,suchasbodyarmorandsteelplate,yetnotpassthroughasoftmedium,suchasahumantorso(ref.6).TheSpecialPurposeLimitedPenetration9mmLE-HwhenfiredfromaGlock-17willpenetrate5mmofheattreatedhardenedaluminumarmor,thecurrentM882willnotpenetratethisarmorwhenfiredfromaMP-5platform.ThesameSPLP9mmLE-Hwillinflicttraumaticlivetissuedestruction,deployingasafrangiblebulletwithlimitedpenetration,afterdefeatingthishardenedaluminumarmorbarrier(ref.7) 18
_______________________17LeMasisinferringthattheoxygencontentthatispresentwithinalivinganimalisdifferentthantheoxygencontentthatispresentinagelatinblock.18TheHeckler&Koch(HK)MP5isafamilyofclosedboltsubmachinegunsdevelopedbyHKinthe1960s.
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Figure5LeMasLtd.marketingpictureshowingarmorplatepenetration(ref.8)
IamattachingsomehardbarrierteststhatwereconductedinthePhilippinesrecentlywithourammunition.Theyhavepromisedsome2leggedlivetissuenecropsieswithawidevarietyofourAPLPproducts.Iwillforwardthoseto
youiftheycometome.WehaveyettoseeanycurrentlyusednondedicatedAPammunitionthatwillpenetratethesetypesofbarriers,andcertainlynoammunitiontodatethatwilloptimizelivetissuedestruction's(sic)aswellaspenetratethesetypesofhardarmors(ref.8).
Reference:AssessmentofLeMasMarketingClaimssection.Non-comparable Performance in Living Tissue
Claim:LeMasLtd.claimsthatballisticgelatintestsarenotrepresentativeoftheresults thattheyhaveseenintheirliveanimaltests(fig.6).
The5.56mmLandWarfarebulletwhenimpactingcalibrated10%ballisticgelatindemonstratesshallowpenetration,smallpermanentwoundchannel,andverylittlefragmentation.However,whenimpactinglivetissue,thesamelandwarfarebulletdeployswithdramaticdimensionsoffragmentation,largepermanentwoundchannelandgreaterdepthofpenetration(ref.1)
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TheseSPLPBMTmunitionsweredesignedtodeployinrealtissuemediums.Optimalperformancecanonlyberealizedinlivingtemperaturetissue.Coldgelatinblocksortissue,farbelowlivingtemperatures,isnotadesignparameterofthesemunitions(ref.5)
Ourpositionisthatthenewtechnologyofourproductsperformanceisnot
completelyaccurateunlessevaluatedintissue(ref.5) Reference:AssessmentofLeMasMarketingClaimssection.
Figure6PurportedeffectoftemperatureonBMTperformance
Produce Enhanced Fragmentation Patterns
Claim:LeMasLtd.claimsthatthehighrotationalvelocityofitsammunitionenhancesthe fragmentationpatternandgivestheadvantagebacktothemarksman(ref.1).
Thisproductsneteffectistoenhancetheoperationalcapabilitiesofcurrentplatforms,totheperformancelevelsofthenextheavierweaponsplatform(ref.5)
Reference:AssessmentofLeMasMarketingClaimssection.Cause Heat Generated Blistering in Soft Organ Structures
Claim:LeMasLtd.claimsthatitsammunitionproducesblistersandthirddegreeburnson
interiororganswithinthetarget(ref.1). Reference:AssessmentofLeMasMarketingClaimssection.
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Unique Manufacturing Process
Claim:LeMasLtd.claimsthat:
Ouruniquemanufacturingprocessallowsustheabilitytorapidlyrespondtoemergentmissionrequirements.Ifwecurrentlydonotstockamunitionthat
specificallymeetsyourrequirements,wecanprovide,inaveryshorttime,missionspecificmunitions,necessarytosatisfyemergentcommandmissionassignments,usuallyeightweeksorless(ref.5)
Reference:AssessmentofLeMasMarketingClaimssection.Use Lead Free Components
Claim:LeMasLtd.claimsthat:AllRBCDmunitionsuseleadfreecomponents(ref.5)19
Reference:AssessmentofLeMasMarketingClaimssection.
Patented Ammunition Products Claim:LeMasLtd.claimsthat:
Allofourproductsarepatentedorpatentpending.Weareahightechnologycompanythathastheproductioncapacitytogenerate1,000,000rounds,inmostofourproductline,withinthreeweeksofnotification(ref.5)
Reference:AssessmentofLeMasMarketingClaimssection.
WHAT IS BLENDED METAL TECHNOLOGY BMT)
BlendedMetalTechnology(BMT)offersthemostsignificantadvancementinbulletcapabilitiessincetheadventofsmokelesspowderinthe20 thcentury.BlendedMetalspatentedproductionprocessesfacilitatethehomogeneousblendingofmultiplemetalcompositions.LeMasadvertisement
LeMas Ltd. Definition of BMT
20
ThedefinitionofBMTisdeemedproprietarybyLeMasLtd.InresponsetoIPTrequests,LeMasLtd.gavethefollowingdefinitionforblendedmetal:
ThetermBlendedMetalisbothamarketingacronymandnomenclaturewhichreferstothemanufacturingprocessusedtoassemblethecorebullet
constructionmaterialswhichprovidethespecificoperationalcapabilitieswithrespecttoeachbulletdesign.(ref.9)
_______________________19LeMasLtdmadethisclaiminreferencetotheirproduct.ItisunderstoodthatRBCD,whichisthesourceofLeMasammunition,wasnotpartytothisclaim.
20ThemetallurgicalanalysisportionsofthisreportwereconductedbytheMetallicMaterialsTechnologyTeamatARDEC.Amoreindepthdiscussionofthosetopicsarecoveredinadditionalreportsthatareavailableuponrequest.
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TheIPTdeterminedthatthisdefinitiondoesnotuseinternationallyrecognizedtermsthatdefinethemetallurgical,mechanical,orphysicalpropertiesoftheLeMasbullets.American Society of Metals ASM) Definition of Blending Metals
AccordingtotheAmericanSocietyofMetals(ASM)andASTMStd.B243-04a,Standard
TechnologyofPowderMetallurgy,thereisnospecificationforthetermblendedmetalorblendedmetaltechnology.Additionally,asearchofinternationaldatabases,suchasInfonormeLondonInformation(il.co.uk/en/)hasnotrevealedaspecificationforthetermblendedmetalorblendedmetaltechnology. Aftercombingseveralnationalandinternationalmaterialsdatabases,theclosestmetallurgicaltermthatcouldbefoundwasblendingmetals.Thistermisapowdermetallurgytermmeaning,thethoroughinterminglingofpowdersofthesamenominalcomposition,forexample,combiningtungstenpowderstogetherthathavedifferentparticlesizesbuthavethesamechemistry. TheIPTsinitialpremisewasthatBMTwassimilartopowdermetallurgytechniques.A
patentsearchwasconductedtoverifythispremise21
.United States Patent No. US 6,363,856 B1
RBCDPerformancePlusInc.providesLeMasLtd.withtheirpatentedorpatentpendingprojectiles(refs.1and5).Assuch,theIPTconductedapatentsearchtoreviewanyandallpatentsthatwereheldbyLeMasLtd.,RBCD,oranyofitsknownassociates.Onlyonesuchpatentwasfound(fig.7).
Figure7RoscoeStokerspatentedprojectilediagram(ref.10)
_______________________21Thisinitialpremisewasoverturnedasaresultofadditionaltesting.22Reminder,RBCDprovidesLeMasLtd.withtheirpatentedorpatentpendingprojectiles(refs.1and5).
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RoscoeR.Stoker,Jr.,ownerofRBCD22andinventor,filedpatentnumberU.S.6,363,856B1on2April2002.Thepatentbackgroundreadsasfollows:
Applicantsinventionrelatestoaprojectile;andmoreparticularly,toaprojectilehavingalowdensitycoredesignedtotravelatanincreasedmuzzlevelocityascomparedtoconventionalbulletdesignswhenfiredfromconven-
tionalsmallarmsunderthesameconditions.Thelighterweightoftheprojectile,duetothelowdensitycore,actstoquicklyreducethevelocityoftheprojectileafterfiring.Thehighmuzzlevelocityoftheprojectileallowstheprojectiletomoreeffectivelypenetratebodyarmor,andothersolidobjectsatshortranges,generallyunderfifty(50)yards,whiletherapidvelocitylossmakestheprojectilelessdangeroustoinnocentbystandersifthetargetismissed,orduetooverpenetration(ref.10).
Thisquote,takendirectlyfromthepatent,providesinsightintothedesignphilosophythatMr.Stokerbelievedwasadvantageous.Hisgoalwastopatentalight,fast,projectilethatwascapableofpenetratingbodyarmoratcloserangewithoutoverpenetration.
ThepatentsdetailsoutlineMr.Stokersprojectiledesign,whichiscomposedofajacket(firstmetallicalloy),alightweightcorematerial,andaslug(secondmetallicalloy). Forthejacket,ametallicalloycomposedofcopper,molybdenum,zinc,nickel,andsiliconisspecifiedasthepreferredcomposition.Thisjacketalloyactstoreducefrictionoftheprojectileagainstthebarrelasittravelsthroughthebarrelascomparedtoaconventionalprojectile(ref.10). Thecorematerialcompositionisnotspecifieddirectlyinthepatent;however,thepatentindicatesthatthecorematerialshouldhaveadensityoflessthantheslugandpreferablywithavalueoflessthan7g/cm3.Additionally,thecorematerialshouldbemalleableduringacuringperiod,andhaveelasticpropertiesaftercuring(refs.10and11). 23,24
Thecorecanbemadefromvariouslightweightsubstancesthathavetherequiredphysicalpropertyofbeinglessdensethantheslug;howeverpolymers,epoxies,andplasticsarewellsuitedforuseascorematerials.(ref.10)
Fortheslug,Mr.Stokeroutlined:
Theslugismadefromasecondmetallicalloy.Apreferredcompositionoftheslugis30-50%bismuth,upto40%lead,upto20%molybdenum,upto40%epoxysuchasScotch-WeldTMgreyorScotch-WeldTMtranslucent,upto15%aluminum,andupto15%zinc.Theepoxy,suchasScotch-Weld TMgreyorScotch-WeldTMtranslucentisusedtobindthepowderstogether(ref.10).
_________________________23Tyically,asthedensityofthematerialgetsclosertothehumantissue(about1g/cm3)theamountofx-rayabsorptionfromthatmaterialdecreasesproportionallyassumingthatthereisnochangeinthickness(consultBeersLaw).Thishasdirectimplicationsonhowwellthatmaterialwillshowuponamedicalx-ray,whichgenerallyusesdifferencesinabsorptioncharacteristicstodistinguishfeaturesandstructures.24Forreferencepurposes,thedensityofleadistypicallytakenas11.34g/cm3,copperisabout8.92g/cm3,andnylonisroughly1.15g/cm3.
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Mr.Stokerstated,inthispatent(ref.10),thatthispatenteddesignwasnotmaterielorcaliberspecific(fig.8).
Itshouldbeunderstoodthatthematerialsofthecorecompositionandthemetallicalloysmaybealteredorsubstitutedforwithothermaterialshavingsimilarphysicalproperties.Additionally,thesize(orvolume)oftheprojectiles
coremaybeincreasedordecreasedrelativetothesize(orvolume)oftheslug.Theprojectilesotherattributesmayalsobechangeddependinguponuse.Forexample,thesizeoftheprojectilemaybealteredbaseduponthecaliberofthefirearmthatistobeused(ref.10).
Figure8
RoscoeStoker'spatentedprojectiledesign(ref.10) AsfarastheIPTcandetermine,thisistheonlypatentonfileforMr.StokerandforRBCD.
ANALYSIS OF LEMAS RBCD) PROJECTILES
25
Aspreviouslymentioned,BMTcartridgeswerepurchaseddirectlyfromLeMasLtd.usingstandardDODcontractualprocedures. 26Thatsingleammunitionpurchasewasthendistributedtomultiplegovernmentlabsforindependentanalysis(fig.9).
_______________________25Thissectionofthereportcontainsinformationthatmaybeconsideredproprietaryinnature.ThisindepthanalysisintothecharacteristicsofLeMasammunitionwasinitiatedasaresultofrangesafetyconcernsthatweregeneratedasaresultofearliertestingandcorrespondencewithLeMas.Astheanalysisproceeded,itwasexpandedasaresultofotherconcerns.26ThepurchaseisfullydocumentedbySOCOM(ContractagreementH92236-04-P-3245)andisavailableuponrequest.
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Figure9
Breakoutofammunitionforthiseffort 27
Visual Tests
ThreeindependentgovernmentagenciesperformedvisualanddimensionaltestsonLeMasprojectiles(fig.10).Thesetestswereconductedtodetermineiftheprojectileshadasatisfactorylevelofproductionconsistencyandiftheprojectileswereincompliancewith
applicabledrawings,weapontolerances,performancespecifications,andotherrequirements.Theresultssuggestthatalthoughconsistencyissatisfactory,therearemorequestionsabouttheoriginsoftheprojectiles(discussedlater).
Figure10LeMas5.56-mmblendedmetalprojectiles[UW(left)andLW(right)]
FBI UW Analysis The5.56-mm37-grainLeMas/RBCDUWcartridge(lot03020113)wasacquiredbytheFBIfromUSSOCOM(fig.11). 28InitialinspectionoftheprojectilerevealedittobesimilartotheNosler40-grainballistictip.Followingtheprocurementofadditional40-grainballistictipNoslerprojectiles,theFBIconductedacomparisonanalysisofthetwoprojectiles(figs.12through14).The37-graintestprojectiles(sentbyLeMas)werefoundtoweigh40grains._______________________27ItisnotedthatbothARDECandCranehaveacquiredandtestedLeMasammunitionforotherprograms.28Ashasbeenpreviouslymentioned,LeMasmarketsRBCDprojectiles.
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Figure11FBIvisualinspectionoftheLeMasUWcartridge
Figure12InitialFBIcomparisonofLeMas/RBCDUWtosimilarprojectiles
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Figure13FBIweightcomparisonbetweenUWandNoslerprojectiles
Figure14
VisualcomparisonbetweenNoslerballistictipandLeMasUWdesign Noslerwastelephonicallycontactedandaskediftherewereanyidentifyingmarksontheir40-grainballistictipprojectiles.AseniormanageratNosleradvisedthattheycouldpositivelyidentifyanyprojectilesthatweremanufacturedbyNosler. 29 NoslersresponserevealedthattherewerethreemajormanufacturerswhoproduceprojectilessimilartotheNoslerballistictip.However,Noslerballistictipprojectilesaretheonlyplastictipprojectilesthathaveathickbase.Bothoftheothercompaniesuseadrawncup. 30_______________________29NoslerwasnotadvisedoftheinvestigationbeyondthefactthattheFBIwasattemptingtoproveordisprovetheoriginoftheprojectile,andatnotimewastheoriginoftheprojectilerevealedtoNosler.30Bulletjacketsproducedusingadrawncupapproachacquiredtheirfinalshapebystretchingacupshapedpieceofjacketmaterialintoitsfinalform.
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Noslerballistictipprojectilesaremoldedinagangmold.31Consequently,eachprojectilehasamoldnumberimprintedonitsbase.IfaNoslerprojectileiscarefullydisassembled,thenthisnumbershouldbecomevisiblewithamagnifyingglass. TheFBIcarefullyremovedtheplastictipsfromthreeoftheLeMastestprojectilesandexaminedwhetheraNoslerstylemoldnumberwaspresent.Theiranalysisshowedthat
numbersthatwereconsistentwithNoslersfont,numbersystem,color,andplacementwereonallthreeRBCDproprietaryprojectiles(figs.15and16).
Figure15
FBIphotographshowingNoslerstylemoldnumbersonLeMasUWprojectiles
Figure16
SidebysideNoslerandUWprojectilecrosssectionvisualinspection
LeMaswasaskedviaemailiftheUWprojectileswereNoslersdesignandtheresponsefromStanBulmerwasanunequivocalno(refs.12and13)._______________________31Asinglemoldhavingmultipleshapingcompartmentsinwhichmultiplearticlesareformedbyoneoperation.
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AdditionalphotographsweretakenatARDECtosupporttheFBIpositionthatUWprojectileswereNoslerballistictipprojectilesthathadbeencoatedwithmolybdenumdisulfide(fig.17).
Figure17NoslerandLeMasblendedmetalUWprojectiles(moldnumbersfoundonbothprojectiles
tested)(ARDECphotograph) NoslerlaterconfirmedthattheprojectilesthattheFBItestedwere,infact,molybdenumcoatedNosler40-grainballistictipprojectiles. FBI LW Analysis AsaresultofthedisturbinganalysisresultsoftheUW(Nosler)design,andafterrecognizingthesimilaritiesbetweentheLWandtheSierrabullet1310,theFBIinitiatedcorrespondencewithSierratodetermineiftheLWdesignwasinessence,andinfact,aSierraprojectile.Bulletsamples,withnosourcedata,wereeventuallyprovidedtoSierrawhoconfirmedthattheproprietaryLeMas(RBCD)LWprojectilesweremolybdenumcoatedSierra
projectiles.
Sierrahascarefullyexaminedthebulletsamplesyousent.WearecertainthattheseareinfactSierraBullets,stocknumber1310.Thereareseveralreasonswhywebelievethistobetrue.Firstistheogiveradius.Whenmeasuredonanopticalcomparator,thesamplesyousentpreciselymatchSierrasprofile.Secondisthejacketsconstruction.Whenmeasuredonatoolmakersmicroscope,thethicknessofthebaseofthejacketusedtoconstructthisprojectileisexactlythesameasSierras.Additionallythejacketwallthickness(measured0.120fromthebase)isalsoidentical.Third,thesebulletsfallwithinSierrasverytightinhousediametertoleranceof 32.Finally,everyotherphysicaldimensionisidenticaltoSierrasbullet.Individually,any
ofthesethreedimensionsbeingidenticaltoSierraswouldbeunusual.Whencombined,thepreciseduplicationofSierrasdimensionsremovesanyreasonabledoubtthatthesesamplesyousentareSierrabullets.
_______________________32Sierrasexacttolerancevaluewasremovedfromthequoteforproprietaryreasons.
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However,ifthereisanyfurtherquestion,aspectrographofthejacketmaterialandleadalloywouldprovebeyondanydoubtthatthisisaSierraproduct.Onewouldexaminetheantimonialcontentoftheleadandthecompositionofthejacket.SierrausesC210(5%zinc,not10%)initsproduct.Itismostlikelythatthematerialcompositioncouldnotbetraceddirectlytoaspecificmaterialcertification,butitmaybepossible(ref.14). 33,34
ARDEC Dimensional Analysis Tests The5.56-mmUW[Nosler(left)]and5.56-mmLW[Sierra(right)]projectileswereremovedfromtheircartridgesandwerephotographedintheasreceivedcondition(fig.18).SlightdifferencesinthenoseshapesoftheLW(Sierra)bulletswereattributedtotheeasilydeformedtip.
Figure18"Asreceived"LeMasprojectilepictures
_______________________33NotethattheARDECchemicalanalysisoftheLWprojectilerevealedthatthejacketcompositionoftheLWprojectilecontainedabout5wt%zinc.34Theefforttotracethematerialcompositiondirectlytoaspecificmaterialcertificationwasnotrequestedandwasnotconducted.
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Table6showstheresultsofdimensionaltestsdoneontwoLeMasLtd.UW(AandB)andonfiveNoslerballistictipprojectiles(AthroughE)(fig.12).
Table6Weightsanddimensions(NoslerballistictipandUWprojectiles)
ProjectiletypeSamplenumber
Weight(gm)
Weight(gr)
Length(in.)
Borediameter(in.)
A 2.593 40.0 0.701 0.225LeMasUWprojectile
B 2.589 39.9 0.702 0.225
A 2.594 40.0 0.702 0.225
B 2.593 40.0 0.703 0.225
C 2.592 40.0 0.703 0.225
D 2.591 40.0 0.704 0.225
Noslerballistictip
E 2.592 40.0 0.702 0.225
Inthistest,theLeMasUWsubmissionandtheNoslerbulletdifferedbynomorethan0.1grainsinweightand0.02in.inlength.Theborediameterswerevirtuallyidenticalforbothprojectiletypes(fig.19). 35
Figure19SidebySideSierraandLWprojectileas-isvisualinspection
_______________________35NotethattheminordifferencesbetweentheUWprojectilesandNoslerprojectilesareattributabletothestandardmanufacturingvariationsthatroutinelyoccurondifferentproductionlots.
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TwoLW(AandB)andfiveSierra(AthroughE)projectileswerealsotested(fig.20andtable7).
Figure20SidebysideSierraandLWprojectilecross-sectionvisualinspection
Table7
Weightsanddimensions(SierraandLW)
ProjectiletypeSamplenumber
Weight(gm)
Weight(gr)
Length(in.)
Borediameter(in.)
A 2.909 44.9 0.605 0.225LeMasLWprojectile
B 2.911 44.9 0.605 0.225
A 2.916 45.0 0.630 0.225B 2.926 45.1 0.625 0.225C 2.911 44.9 0.625 0.225D 2.916 45.0 0.626 0.225
Sierra1310
E 2.903 44.8 0.631 0.225
TheLeMasLW(Sierra)designandtheSierrabulletdifferedbynomorethan0.2grainsinweightandby0.026in.inlength. 36Borediameterswereidentical._______________________36Thedifferenceinlengthisprimarilyduetodifferencesindeformationintheexposedleadtip.Sinceleadisarelativelysoftalloy,materialcompressioncaneasilyoccur.Differencesintheassemblyprocess,suchastheadditionofthemolycoatingstep,(aswellaslottolotdifferences)mayaccountfortheslightdifferenceinlengthaswell.
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TheLeMas7.62-mmLWprojectilewasalsoexaminedbyARDEC,butonlyonalimitedandpreliminarybasis(fig.21).
Figure217.62-mmLeMasLWprojectile(ARDECasreceived)
ARDEC Cross-Section Visual Inspection Tests Boththe5.56-mmUW(Nosler)andLW(Sierra)projectileswerecrosssectionedandmeasured.Bothdesignshavejacketsthatbeartoolmarks.Thisindicatesthatthejacket
wasstretchedorswagedinadietoachieveitsfinalshape.Thisindicatesthatthejacketswerenotproducedusingpowdermetallurgy(P/M)techniquesasa(P/M)partisusuallyproducedinitsfinalshapeanddoesnothavethetoolingmarksandwrinklesthatwereobservedonthejacketsofbothdesigns(figs.22and23).
Figure22LeMasUW(left)andLeMasLW(right)jacketexamination
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Figure23
Dimensionalmeasurementsofcrosssectioned5.56-mmprojectiles
USSOCOM Physical Inspection of Test Ammunition AsdidtheFBIandARDEC,USSOCOMperformedasetofroutinevisualanddimensionaltestspriortoconductingafullsuiteofperformancetests.Theresultsareoutlinedinthefollowingsectionsandreinforcetheconclusionthatthetestedprojectilesaresimilartoothercommercialprojectiles. Table8documentsthephysicalcharacteristicsofthetestammunition.
Table8Testammunitioncharacteristics
Caliber DODIC Model Manufacturer LotNumber
A059 M855LakeCityAmmunitionPlant
(LCAA) LC-90J082-629
W105 LandWarfare LeMasLtd./RBCD 040401-025.56x45mma.k.a.
.223RemingtonW141
Sierra"Varminter" B.R.Consulting(BRC) BRC-May-2005-556mm
AA11 M118LR LakeCityAmmunitionPlantLC-03D271-012(SubLot
G)
W106 LandWarfare LeMasLtd./RBCD 04041401-027.62x51mma.k.a..308Winchester
W142 Speer"Hot-Cor" B.R.Consulting(BRC) BRC-May-2005-762mm
A363 M882WinchesterCartridge
Company WCC03G037-012
W107 CQBSPLP(H) LeMasLtd./RBCD 03013-49x19mma.k.a.9mmLuger
W143 IQ Aguila n/a
Figures24through26documenttheinitialphotographsthatweretakenofthetest
ammunition.Ineachphotograph,theLeMasLtd.ammunitioncartridgescontainaheadstamp,whichshowsthatthebrasscasewaspurchasedfromanoutsidesource.Itisalsonotedthatthephotographsalsoshowthebulletsurrogates,whichweredevelopedaspartoftheoperationaltestphase.Thiswillbediscussedinlatersections.
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USSOCOM 5.56-mm Test Ammunition Visual Inspection Photographs.
Figure24USSOCOM5.56-mmvisualinspectiontests 37,38,39
_______________________37Photographsarenottoscaleortosize.38LeMasLtd.ammunitionislistedasthemanufacturer,butisactuallythemarketerforRBCDPerformancePlus,Inc.39DODICW141(bottomprojectile)arenotcommerciallyavailable.TheyweredevelopedandmanufacturedforthistestbyBRC(undergovernmentguidance)toprovidetestammunitionofsimilardesignasLeMasLtd.
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USSOCOM 7.62-mm Test Ammunition Visual Inspection Photographs.
Figure25Basicdescriptionofthe7.62x51-mmtestammunition 40,41,42
_______________________40Photographsarenottoscaleoractualsize.41NotethattheLeMasLtd.cartridgehasaWinchesterheadstamp.ThissuggeststhatWinchestercartridgecomponentswereusedintheLeMasproduct.42DODICW142(bottomprojectile)arenotcommerciallyavailable.TheyweredevelopedandmanufacturedforthistestbyBRC(undergovernmentguidance)toprovidetestammunitionofsimilardesignasLeMasLtd.
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USSOCOM 9-mm Test Ammunition Visual Inspection Photographs.
Figure26Basicdescriptionandphotographsofthe9x19mmtestammunition 43,44,45
_______________________43NotethatW107(LeMas)projectileshownissimilarinnappearancetothedesigndescribedintheRBCDpatent.44NotethattheLeMascartridgehasaLugerheadstamp.ThissuggeststhatLugercartridgecomponentswereusedintheLeMasproduct.45DODICW143AguilawasusedintheSOCOM9-mmtests.Fromthecrosssection,itisclearthattherearesomedifferencesinthedesignsofthethree9-mmprojectiles.
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USSOCOM DimensionalAnalysisTests. Whileavisualinspectionwasperformedtodeterminethatthecartridgesareincompliancewithapplicabledrawings,adimensionalinspectiondeterminesthemanufacturersqualitycontrolandconsistencyatmanufacturingammunition(fig.27). References:
MIL-STD-636(VisualInspectionStandards)ANSI/SAAMIZ299.4-1992(CenterfireRifleSportingAmmunition)ANSI/SAAMIZ299.3-1993(CenterfirePistolandRevolverAmmunition)SOP/BRC/2004StandardOperatingProcedure(DimensionalInspectionofSmallArmsAmmunition)ARDECDrawing7643674(ClassificationofCartridgeDefects)
Toaccomplishthisrequirement,asampleof40cartridgesofeachammunitiontypewasrandomlyselectedforvisualanddimensionalinspection.Eachdimensionwasmeasuredtothenearest0.001in.orweighedtothenearest0.1grain(tables9through11).
Observations:Dimensionalmeasurementscaninfluencetheoverallperformanceoftheweaponsystem.Forexample:
Acartridge,whichistoolongmaynotfitinastandardmagazine Acartridge,whichistoolongortooshortmaynotfeedproperly. Arimdiameter,whichissmallerthanthespecificationcanresultina failuretoextract Acartridgewithamouthdiametergreaterthanthespecificationmay resultinafailuretochamber.
Figure27
Dimensionalmeasurementstakenontestammunition
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Table9Summaryofmeasurementsfromthedimensionalinspectionof5.56x45mmtestammunition 46,47
Table10Summaryofmeasurementsfromthedimensionalinspectionof7.62x51mmtestammunition
_______________________46O.A.L.=Overalllength.47SAAMI:SportingArmsandAmmunitionManufacturersInstitute,Inc.
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Table11Summaryofmeasurementsfromthedimensionalinspectionof9x19mmtestammunition
Conclusions:
1. Novisualdefectswerenotedonanyofthetestammunition2. Everycartridgecompliedwithtolerancelimitsestablishedfor commercialindustry3. Thesoftpointdesignswereeasilydeformed.Variationsinnoseshape
canpotentiallyhaveaneffectonvariousperformanceparameterssuch asdispersionandpenetration.Inaddition,itisnotedthatexposedlead tipsdonotfeedintoweaponsaswellasotherdesigns.
GeneralizedSummaryofARDEC,FBI,andUSSOCOMTests . Uponfurtherinspectionofthecommonbrass,propellant,andprimercomponents,itisdifficulttodeterminewhat(ifanything)makestheoverallLeMasrifleproductdifferentfromsimilarlyloadedNoslerandSierrariflecartridges.ItdoesnotseemlikelythatasupposedproprietaryLeMas(RBCD)projectiledesignwouldduplicateotherproprietaryprojectilessoprecisely,andyetproduceanextraordinaryincapacitationresultwhenfiredagainstlivingtissue. 48 LeMass9-mmpistolcartridgewasnotpositivelyidentified,andcouldhave
warrantedfurtherscrutiny;however,theresultsoftheoperationalandsafetytestsshowedthatthecartridgehasotherissues(discussedlater)._______________________48ThisspeculationwaslatertestedbyoneoftheFBIinvestigatorswhousedseveralroundsofLeMasammunitionduringanauthorizedandsuperviseddeerhunt.Twosolidhits(under100yards)wereobservedbytheinvestigatorandbyawitnessinggamewarden.Noinstantincapacitationswereobserved.
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Recommendations TheFBIexaminersrecommendedthefollowingcourseofaction:
1. Ceasealleffortsassociatedwiththistestinguntiltheoriginofthe projectileswaspositivelyestablished.
2. AdviseRBCDthattheIPTrequeststoviewtheirmanufacturingprocess3. DonotprovidefurtherinformationtoRBCDuntiltheyhaveproventhat theymanufacturetheprojectiles.4. ForwardasampleoftheRBCDprojectilestoNoslerandSierrafor examination.(Donotindicatethesourceoftheprojectiles.)5. HaveARDECsmetallurgistteamconductlogical,side-by-side examinationsoftheRBCDandNosler40-grainballistictipprojectiles.49
AnIPTsitevisittoLeMaswasrequestedbytheSOCOMlead(viaemail)on16August2004.LeMasrespondedasfollows:
Therequesttoobserveboththemanufacturingandloadingprocessforthesebulletdesignsisrespectfullydeclinedatthispointinourrelationship.BothLeMasLtd.andRBCDconsiderthisinformationmosthighlyproprietary.LeMasLtd.completelyfailstograspthisrequirementasanelementforanyoperationalevaluation,aspromisedbyCol.Spellissy,todeliveratesttogiveusconclusiveevidenceofthesuitabilityandeffectivenessofthisammunitionformilitaryuse(intheArmedForcesJournalMay04letterspage6)Accesstothemanufacturingfacility,manufacturingprocess,andloadingprocesswillnotbeprovidedtotheUSgovernmentoranyotherentitywithoutcontractualcommitmentsforsustainedprocurement,insubstantivequantitiesIfyoufeelthatbeingdeniedaccesstothemanufacturingfacilityandproprietarydesignconstructioninformation,willprohibittheTIPTteamfromobjectivelyproceedingwitheffortstovalidateandevaluaterealworldoperationalcapabilityfortheBMTammunition,pleaseletusknownow.LeMasLtd.willforwardthisimpassetoourCongressionalrepresentatives. 50
Metallurgical and Structural Tests
MetallurgicaltestswereconductedonLeMasprojectilesatARDEC.Thesetestsuse
visualcuesinthemicrostructureofthematerialtoderiveprobableanswerstothequestionofhowtheprojectilewaslikelymanufactured.Inthisinstance,thesetestswereabletoshowthatLeMasbulletshaveamicrostructurethatisconsistentwithcommon,unbonded,swagedbullets._______________________49Tothisend,ammunitionfromtheSOCOMprocurementwassenttoARDEC.50Emailavailableuponrequest.
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ARDEC Microstructure and Mechanical Property Tests Examiningthemicrostructuresofthematerialspresentprovidesinsightintohowtheprojectilesweremanufacturedandwhether,specifically,theLeMassubmissionswereproducedusing(P/M)techniques.
Urban Warfare Microstructure.Figure28showstheUWcross-sectionimageofthelocationsofmicrostructurethatwereanalyzed.
Figure28
UWcross-sectionimageshowinglocationsofmicrostructureanalyzed Urban Warfare Nosler) Lead Core:Themicrostructureoftheleadcore(fig.29)containsrecrystallized,equiaxedgrainsthataretypicalofextrudedorswagedlead.Theleadcoremicrostructureisnotconsistentwith(P/M)techniques.Morelikely,thecoreswereformedbyplacingasmallpieceofleadintoadieandsqueezedintoitsfinalshape(swaging).Thisisaverycommonpracticeforprojectilecores.
Figure29LeMasUWleadcoremicrostructure 51
Urban Warfare Nosler) Copper Jacket(fig.30):Themicrostructureofthejacketwasexaminedatdifferentlocationsofthebullet(fig.28).Fromtheresults,itwasdeterminedthatthecopperjacketwasformedbyswaging(i.e.,astartingcupwasplacedintoadieandsqueezedintoitsfinalshape).Theelongatedgrainsinthesidewallsofthecupsupporttheideathatthejacketwasformedthroughsomesortofswagingoperation(figs.31and32). 52,53_______________________51Thecolorsshownareattributedtothetestprocessandareforillustrativepurposesonly.52Therewasaconcernthatthemarkingsmightbemistakenassawmarksfromtheactofcuttingtheprojectile.Thisisnotthecase.Foronething,thedirectionofthestretchedgrainsisnotconsistentovertheentirelengthoftheprojectile.Foranother,thesizesvary.Consequently,thisexplanationcanberuledout.53Althoughnotuncommon,bulletjacketsaregenerallydrawnandnotswaged.
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Figure30UW(Nosler)copperjacketmicrostructureimages 54
UW Microstructure
Figure31UWcartridgemicrostructure
_______________________54Thelinetypeformationsonthefirsttwopicturesareelongatedgrainsandareessentiallystretchmarks.
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Nosler Microstructure.
Figure32Noslerballistictipmicrostructure
Note:Theminordifferencesinthetwoimages(figs.31and32)areexpectedandarenotconsideredtobesignificant.Therefore,itcanbeconcludedthatthesearethesamebulletdesign. Land Warfare Sierra) Microstructure.TheLWcross-sectionimageshowing
locationswheremicrostructureswereanalyzedcanbeseeninfigure33.
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Figure33LWcross-sectionimageshowinglocationsofmicrostructureanalyzed
Land Warfare Sierra) Lead Core:Themicrostructure(fig.34)oftheleadcorecontainsgrainsthataredark(lead-rich)andwhite(antimony-rich)andisdeemednormalforantimoniallead96Pb-4Sb.Theseleadcoreimagesarenotconsistentwithwhatwouldbeexpectedif(P/M)techniqueshadbeenused.
Figure31LWleadcoremicrostructure 55
Land Warfare Sierra) Copper Jacket:Themicrostructureofthejacketwasexaminedatdifferentlocationsonthebullet(fig.35).Themicrostructurenearthebasedoesnotshowsubstantialgraindeformation.However,thesidewallofthejacketdoesshowelongateddeformedgrains(fig.35).Basedontheseobservations,theLWjacketisconsistentwithajacketthatwasformedfromastartingcup,whichwassqueezedintoitsfinalshape[swaging(figs.36and37)].
_______________________55Reminder:Thecolorsshownareattributedtothetestprocessandareforillustrativepurposesonly.
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Figure35LW(Sierra)copperjacketmicrostructureimages
LW Microstructure.
Figure36LWcartridgemicrostructure
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Sierra Microstructure.
Figure37
Sierra"Varminter"microstructureNote:Theminordifferencesinthetwoimages(figs.36and37)areexpectedandarenotconsideredtobesignificant.Therefore,itcanbeconcludedthatthesearethesamebulletdesign.
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Microstructure Summary.BoththeLeMassubmissionmicrostructuressuggestthatthejacketsandcorewerenotformedusing(P/M)techniques.Thisisreinforcedbythefactthatthejacketsonbothprojectiledesignsshowevidence(elongatedgrains)ofswaging.Con-sequently,theresultsofthesetestsconclusivelysupporttheFBIspositionthattheLeMasprojectilessoldtothegovernmentwerenotbasedon(P/M)technology. 56
Micro-hardnessData. Thecombinationofmicrostructurephotographsandmicro-hardnessvaluescanbeusedtoprovideanestimationofthemechanicalpropertiesofthematerial.FourteenidenticallocationsonboththeLeMasUWbulletandtheNoslerballistictipbulletwereidentifiedforanalysis(table12).Threemeasurementsweretakenoneachlocation.Hardnessvalues(VickersHardnessscale)forlocations12through14aresignificantlylowersincetheyareontheleadportionofthebullet.
Table12Samplemicro-hardnessvaluesobtainedforLeMasUWandNoslerballistictipprojectiles
_______________________56ItalsosupportedtheassertionthatLeMasacquiredprojectilesfromNoslerandSierra.
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Differencesbetweenthemicro-hardnessvalues(figs.38and39)fortheLeMasandNoslerprojectilesfallwithintheexpectedbandofvariationanddonotsuggestanymechanicalpropertydifferencesbetweenthetwodesigns.ThissuggeststhatthereisnomeasurabledifferencebetweentheLeMasprojectileandtheNoslercontrol.
Hardness Values by Location
0
20
40
60
80
100
120
140
160
180
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Location
VickersHardnessValue(DPH)
LeMas Urban Warfare Reading 1 LeMas Urban Warfare Reading 2 LeMas Urban Warfare Reading 3
Nosler "Bal list ic Tip" Reading 1 Nosler "Bal list ic Tip" Reading 2 Nosler "Bal list ic Tip" Reading 3
Figure38
ResultsofthreeseparatemicrohardnessreadingsonNoslerandLeMasammunitionsamples
Figure39Repeatabilityofmachinescriteriaformicrohardnesstests(ref.15)
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Themicro-hardnessvaluesshownintable13andfigure40aremeasuredontheVickersscale57andareconsideredtobesimilar.Asaresult,theLeMasLWblendedmetalprojectileandtheSierracontrolwerealsoshowntobeequivalentbythistest.
Table13Samplemicro-hardnessvaluesobtainedforLeMasLWandSierraprojectiles
_______________________57ASTMMethodE384.
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Hardness Values by Location
0
20
40
60
80
100
120
140
160
180
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Location
VickersHardnessValue(DPH)
LeMas Land Warfare Reading 1 LeMas Land Warfare Reading 2 LeMas Land Warfare Reading 3
Sierra "Varminter" Reading 1 Sierra "Varminter" Reading 2 Sierra "Varminter" Reading 3
Figure40
Resultsofthreeseparatemicro-hardnessreadingsonSierraandLeMasammunitionsamples Hardnessvaluesatvariouslocationswerealsousedtoestimatesomeofthemechanicalpropertiesoftheprojectiles.Thesepropertiesareanindicationoftheruggednessoftheprojectileandareausefulpartoftheprocessforgauginghoweffectivetheprojectilemightbeagainstvariousintermediatebarriers(cardoors,sand,windows,etc). Theresultsoutlinedintable14areconsistentwithotherleadbulletsofthistype.
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Table14EstimatedmechanicalpropertiesofprojectilessuppliedbyLeMasLtd. 58
ARDEC Bonded Projectile Test
TheLeMas5.56-mmsubmissionswerebothtestedtoseeiftheleadcoreswerechemicallybondedtothecopperjackets.Chemicallybondedbulletsaremoreruggedandare
betterpenetratorsthannon-bondedbullets(fig.41). Bondingtestscanbeconductedby:
Physicallyattemptingtopulltheleadoutofthecopperjacket Examiningtheinterfacebetweenthecopperjacketandtheleadcore materialunderamicroscopetoascertainifleadhaspenetratedthe copperjacket.
Figure41Bondedtestsamples(NoslerandUW)
BoththeLeMas(labeledasblendedmetalinfig.42)andNoslerbulletswereeasilyseparatedanditwasdeterminedthatthebulletswerenotbonded. 59_______________________58Note:Hardnessvaluesweremeasuredinalaboratoryandusedtoobtainestimatedmechanicalpropertiesfromhandbookdata.59Thiswasnotunexpectedasammunitionmanufacturersgenerallyhighlightandadvertisewhichoftheirbulletsarebonded.
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Figure42
Bondedtestsamples(SierraandLW) Insummary,bothoftheLeMassubmissionsshowednoevidenceofbeingbonded. USSOCOM Cartridge Case Hardness Test Thecartridgecaseisrequiredtodoavarietyoftasks.Itmustcontainthepropellantchargeandprimer.Itmustsealofftherearofthechamberwhenfiredandsafelycontaintheimmensepressureinside,yetpermitthecasetoberemovedwitheaseafterfiring.Itmustholdthebulletinplacetightlyenoughtokeepatmosphericdampnessout,yetreleasethebullettotraveldowntheboreunderpressureoftheignitedpowder.Itmustholdtheprimertightlyinplaceduringfiring,sothatitdoesntfallouttojamthefiringmechanism.Figures43through45andtables15to17showwherethehardnessmeasurementsweretakenandtheresults. Reference:
1. ARDECDrawing11820451(Caliber5.56mmCaseHardnessGradient)
2. ARDECDrawing12977196(Caliber7.62mmHardnessGradient)3. DTL85797555(MilitarySpecificationfor7.62mm,SpecialBall,Long Range)4. MIL-C-63989C(MilitarySpecificationfor5.56mm,M855)5. SOP/BRC/2004StandardOperatingProcedure(CaseHardnessTestof 9x19mmSmallArmsAmmunition)6. ASRMMethodE92-82R92(MethodofTestforVickersHardnessof MetallicMaterials)
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Figure43LocationsforVickersDPNhardnessmeasurements5.56-mmcartridgecases
Table15
AverageVickersDPNhardnessmeasurementsfor5.56x45-mmcartridgecases 60,61
Note1:M855s(DODICA059)requirementwasusedasthehardnessrequirement. Allthree5.56x45-mmammunitiontypesfailedtomeetthehardnessrequirement,asspecifiedinthemilitaryspecification. 62
_______________________60Note:DPNvaluesinredfailedtomeetM855(A059)specifications.61DODICA059istheM855,DODICW105istheLeMasLWsubmission,DODICW141isaSierra1310Varminter.
62Whythetestedmilitarycartridgefailedtomeetthehardnessrequirementisunclear,butrupturesgenerallyoccurrednearoneoftheends,notinthemiddlesoitisquitepossiblethatthislotreceivedawaiverwhichwentunnoticed.
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Figure44
LocationsforVickersDPNhardnessmeasurements7.62-mmcartridgecases
Table16AverageVickersDPNhardnessmeasurementsfor7.62x51-mmcartridgecases 63
Note2:M118LRs(DODICAA11)requirementwasusedasthehardnessrequirement.
Bothcommercialammunitiontypesfailedtomeetthehardnessrequirement(inmultipleareas),asspecifiedinthemilitaryspecification._______________________63DODICAA11istheM118LR,DODICW106isthe7.62-mmLeMasLWsubmission,andDODICW142istheSpeerHot-Corprojectile.
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Figure45LocationsforVickersDPNhardnessmeasurements9-mmcartridgecases
Table17
AverageVickershardnessmeasurementsfor9x19-mmcartridgecases 64
Note3:M882(DODICA363)waschosenasthebaseline9x19mmammunitionforthistest;however,therearenoestablishedcasehardnessspecificationsfortheM882.Sincetheobjectiveofthistestwastodevelopadatasetforfuturecomparisons,ahybridrequirementusingtheaveragecasesidewallhardnessresultsfortheM882(+/-3standarddeviations)andthecaseheadhardnessrequirementsfortheM855wasusedasaguide.Note4:TheminimumspecificationisbasedontheaveragehardnesslevelforM882(DODICA363)minus3standarddeviations.
Note5:ThemaximumspecificationisbasedontheaveragehardnesslevelforM882(DODICA363)plus3standarddeviations. Bothcommercialammunitiontypesfailedtomeettheproposedrequirement._______________________64DODICA363istheM882,DODICW107isLeMasCQBSPLP(H)andW143isa65-grainnAguilaprojectile.
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USSOCOM Bullet Pull Extraction) Test Anotherphysicaltestisthebulletpulltest.Thistestdetermines,undercontrolledconditions,theforcerequiredtoremovetheprojectilefromthecaseofanassembledcartridge(fig.46).Bulletpulldata(table18)isusedasameasureofuniformityandefficiencyinwhichthebulletsaresecuredinthecartridgecases.Consistentbulletpullisnecessaryformaintaining
uniformperformance(velocity,pressure,dispersion,reliability,etc.)fromroundtoround.Bulletpullisalsoimportanttoensurethatthebulletdoesnotcomeoutofthecasemouth(de-bullet)whenchambered;orgetpushedintothecaseduringroughhandlingorfeeding.
Figure46Illustrationofbulletcrimp
Reference:
1. MIL-STD-6362. AmmunitionBallisticAcceptanceTestMethods,forcaliber5.56-mm ammunitionandforcaliber7.62-mmammunition.3. DOD-STD-1468(SmallCaliberAmmunitionTestProcedures,9-mm Cartridges)4. MIL-C-63989(Specificationfor5.56mm,BallM855).5. DTL-85975556. MIL-C-70508(Specificationfor9mm,Ball,M882)
Table18Summaryofbulletpullresults(highlightedresultsareoutsideofspecification)
Note:Minimumbullet-pullrequirementsforbaselinesystems:
1. A059(M855)greaterthanorequalto45lb2. AA11(M118LR)greaterthanorequalto20lb3. A363(M882)greaterthanorequalto60lb(individual)and80lb(average)
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Conclusions:SeveraloftheLeMasdesignstestedeitherfailedtomeetexistingstandardsorbarelymetexistingstandards.However,itisnotedthatdifferencesinbulletdesign,waterproofingcompound,andamountofcrimpmayhavecontributedtotheseresults,andthatsomeofthespecificationsarenotabsolutes. 65Spectrometry and X-ray Tests
Semi-quantitativealloyidentificationanalyseswereperformedonthecommercial5.56-mmprojectiles.66Thetestchosen,EnergyDispersiveSpectroscopy(EDS),wasdoneinaccordancewithASTME1508,andenablesidentificationofelementsalongwiththeirrelativeproportions.Severalrunsweredoneoneachsample.TheresultsofthisparticulartestingseriesconfirmedthattheLeMas5.56-mmriflesubmissionscontainedasubstantialquantityoflead. 5.56mm Component Testing Urban Warfare Nosler) Core:Thechemistryofthecore(fig.47)materialisaclosematchtoalloyscontaining96to99weight%leadand1to4weight%antimony(ref.16).Thischemicalrangeencompassestwoantimonialleadalloyscalled:99Pb-1Sband96Pb-4Sb
(whichisalsocalledHardLead96-4).
Figure47ExampleUW(Nosler)corechemistryspectrumresult 67
_______________________
65LeMasammunitionisnotmanufacturedtomeetM855requirementsandspecifications.Consequently,failuretomeetunknownrequirementsandqualificationsisnotunexpectedandcouldpossiblybefixed.66Specifically,theLeMasUW,LeMasLW,Noslerballistictip,andSierraVarmintercartridgesweretested.67Multipleanalyseswereconductedbeforeafinaloveralldeterminationwasmade.Thispictureisanexampleofoneoftherunsthatwasconducted.
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Urban Warfare Nosler) Jacket:Thechemistryofthejacket(fig.48)isaclosematchtowhatwouldbeexpectedforcopperalloy21000(gildingmetal)(ref.?). 68,69
Figure48
ExampleUWjacketchemistryspectrumresult69
Urban Warfare Nosler) Jacket Coating:Thechemistryofthejacketcoating(fig.49)ismolybdenumdisulfidewhichiscommonlyusedasadrylubricant.
Figure49UWjacketcoatingchemistryspectrumresult 71
_______________________6895%copper5%zinc.69Thisisacommonbulletjacketmaterial.70Multipleanalyseswereconductedbeforeafinaloveralldeterminationwasmade.Thispictureisjustanexampleofoneoftherunsthatwasconducted.71Ibid.
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Urban Warfare and Nosler Comparison.Side-by-sideresultsshowthatthechemicalcompositiondifferencesareminimal(fig.50). 72
Figure50UWandNoslerballistictipcomparativechemicalanalysis
Land Warfare Sierra) Core:Thechemistryofthecorematerial(fig.51)isaclosematchtoliteraturereferencesthatcontain96weight%leadand4weight%antimony.Thischemicalrangeencompassesoneantimonialleadalloycalled:96Pb-4Sb(alsoknownasHardLead96-4)(ref.16).
Figure51
LWcorechemistryspectrumresult 73
_______________________72Foragivenprojectiledesigntherewillbearangeofresultsthatreflectlottolotproductionvariances.Additionally,aswithalltests,thereissomeamountofsystemicerrorthatwillresultinminorexperimentaldifferences.Thisisnotsignificant,butisnoted.73Multipleanalyseswereconductedbeforeafinaloveralldeterminationwasmade.Thispictureisanexampleofoneoftherunsthatwasconducted.
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Land Warfare Sierra) Jacket:Thejacketmaterial(fig.52)isaclosematchtotheliteraturereferencefor95%copper5%zincorgildingmetal(ref.16).
Figure52LWjacketchemistryspectrumresult 74
Land Warfare Jacket Coating:Thejacketcoating(fig.53)ismolybdenumdisulfidewhichisacommondrylubricant.
Figure53LWjacketcoatingchemistryspectrumresult 75
_______________________74Ibid.
75Ibid.
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Land Warfare and Sierra Comparison.Aswiththeprevioussetoftests,thesidebysideresults(fig.54)showthatthechemicalcompositiondifferencesbetweenthetwoprojectilesarewithintheexpectedrangeofmanufacturingvariation.
Figure54
LeMasLWandSierraVarmintercomparativechemicalanal