Sinter-Bonded Projectile Structure to Eliminate Core-Jacket Voids
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Solution Overview
Problem
Existing bullets face issues with lead toxicity, void formation between the lead core and copper jacket, leading to decreased velocity, accuracy, and penetrating power, and the need for a non-jacketed, lead-free alternative with improved performance.
Innovation Solution
A sinter bonded projectile is created by sintering a core component, such as tungsten carbide, with a copper component to form a tightly bonded solid mass without voids, using thermal shrinkage to integrate the copper into the core's pores and geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a copper jacket is wrapped around a lead core, then the rifling of the barrel is ensured and lead deposits are reduced, but voids are created between the lead core and jacket which decrease velocity, accuracy, and penetrating power
Solution Approach 1:
The patent combines the lead core and copper jacket into a single integrated sintered mass, eliminating the interface between them. The copper and lead particles are uniformly distributed throughout the projectile body through the sintering process, removing the voids that would otherwise form at the junction between separate components.
Solution Approach 2:
The patent creates a composite material by sintering a mixture of copper particles and lead particles together. This composite structure allows the projectile to simultaneously achieve the rifling benefits of copper and the density/velocity benefits of lead, while the sintering process eliminates internal voids by fusing the particles into a dense monolithic structure.
2Object-affected harmful factors
If a copper jacket is used to replace lead core, then lead toxicity is reduced, but the projectile becomes frangible and loses penetrating power
Solution Approach 1:
The patent uses a composite material consisting of copper particles and lead particles sintered together. The lead component provides density and penetrating power, while the copper component reduces toxicity concerns. The composite structure achieves both goals simultaneously rather than requiring a complete material replacement.
Solution Approach 2:
The patent changes the physical state and distribution parameters of the materials by using sintering instead of traditional jacketing. The sintering process creates a dense, non-frangible structure by fusing particles at their contact points, transforming the mechanical properties from frangible (in pressed copper) to solid and penetrating.
3Speed
If lead core is used for high velocity, then velocity and density are improved, but lead melts and vaporizes causing deposits in the barrel
Solution Approach 1:
The patent creates a composite projectile where copper particles are distributed throughout the lead-based sintered mass. The copper component has a higher melting point than lead, so when the projectile reaches high velocities, the copper reinforces the structure and prevents the lead from melting and vaporizing, thereby reducing barrel deposits while maintaining velocity capability.
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 solution results in a non-frangible projectile with enhanced accuracy, higher penetration, and improved centering, achieving greater force and velocity without the drawbacks of traditional lead-based bullets.
Implementation Method 1
melted at a temperature sufficient the it penetrates into the pores and geometry of the core component under compression due to thermal shrinkage
Implementation Method 2
the sintered metal powder surface of the projectile have a porosity of 5 to 25% to restrict friction of the projectile through the bore of the barrel
Data Source
AI summary
The invention of the present subject matter relates to a sinter bonded projectile comprising a core component and a copper component which has been sintered in such a manner to form a solid mass over the core. More particularly, the invention of the present subject matter provides a core component to which a copper component is melted at a temperature sufficient that it penetrates into the pores and geometry of the core component under compression due to thermal shrinkage, resulting in a tightly bonded solid mass containing no voids. The invention of the present subject matter also provides a process for manufacturing the projectile.