Frangible Firearm Projectiles Using Compacted Metal Powders
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Solution Overview
Problem
There is a need for an effective and cost-efficient alternative to Sinterfire™ frangible firearm projectiles, as the copper and tin powders used in these projectiles are relatively expensive.
Innovation Solution
Frangible firearm projectiles are formed from compacted metal powders, including iron, zinc, copper, tungsten, and nickel, with an anti-sparking agent like boric acid, which are heat-treated to create discrete alloy domains without forming a liquid phase, providing strength and frangibility while avoiding the use of polymeric binders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper and tin powders are used to form frangible firearm projectiles, then the projectiles achieve the desired frangibility and effectiveness, but the manufacturing cost increases
Solution Approach 1:
The patent changes the material parameters by replacing expensive copper and tin powders with cheaper metal powders (iron, zinc, bismuth, copper, tungsten, nickel) while adjusting the powder composition ratios and heat treatment parameters to achieve the desired frangibility. The invention specifies that the compacted metal powders should contain 5-95% primary component and 5-95% secondary component by weight, with specific heat treatment conditions (temperature, time, atmosphere) to create discrete alloy domains that provide frangibility without requiring expensive materials.
Solution Approach 2:
The patent applies this principle by using cheaper metal powders instead of expensive copper and tin powders. The invention explicitly states that the compacted metal powders may include iron, zinc, bismuth, copper, tungsten, and nickel, which are generally less expensive than the traditional copper-tin combination, thereby reducing manufacturing cost while maintaining the frangible characteristic.
2Strength
If heat treatment is applied to compacted metal powders to create discrete alloy domains, then the projectiles gain strength and structural integrity, but the processing complexity increases
Solution Approach 1:
The patent specifies precise heat treatment parameters including temperature ranges (e.g., 200-400°C for certain metal combinations, or temperatures below the melting point of the lowest-melting metal in the mixture), holding times, and atmosphere conditions. These parameter specifications provide clear processing guidelines that achieve the desired discrete alloy domain formation and structural integrity without requiring overly complex processing procedures.
Solution Approach 2:
The patent replaces complex mechanical bonding methods with thermal field-based processes. Instead of using mechanical pressure or chemical binders to join metal powders, the invention uses controlled heat treatment to create discrete alloy domains through vapor-phase diffusion bonding and oxidation, simplifying the overall processing system while achieving the required structural integrity.
3Strength
If vapor-phase diffusion bonding and oxidation are used to create chemical bonds in the compacted mixture, then the projectiles achieve sufficient strength, but the heat treatment time increases
Solution Approach 1:
The patent optimizes heat treatment parameters by specifying temperature ranges, holding times, and atmosphere conditions that balance chemical bonding strength with processing time. For example, the invention mentions heating to specific temperatures for predetermined times to achieve the desired alloy domain formation and oxidation bonding, providing clear time parameters that prevent excessive processing duration while ensuring sufficient strength development.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting projectiles are cost-effective, maintain integrity during processing and assembly, and break into small particles upon impact, reducing the risk of ricochets and fire hazards while being non-toxic and lead-free.
Implementation Method 1
The heat treating is regulated to create chemical bonds within the compacted mixture via at least vapor-phase diffusion bonding and oxidation of the metal powders
Implementation Method 2
The heat treating is regulated to create chemical bonds within the compacted mixture via at least vapor-phase diffusion bonding and oxidation of the metal powders
Data Source
AI summary
Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from compacted metal powders that may include an anti-sparking agent. The compacted metal powders may be or include a compacted mixture of metal powders that may include powders of one or more of iron, zinc, bismuth, copper, tungsten, nickel, boron, and/or alloys thereof, and/or oxides thereof. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. The anti-sparking agent may include a borate, such as boric acid.