The firing of small arms ammunition is a significant environmental and health problem. The ammunition's projectile which is traditionally composed of lead and copper, is the principal source of pollution. Rifle, pistol, and shotgun projectiles composed of materials which are not significant environmental or health hazards, and that are economically recyclable are being developed. The primary objective is to develop high density, non-toxic bullets. The projectiles must meet all performance specifications of current bullets, but must significantly reduce or eliminate exposure of the shooter to hazardous materials and reduce environmental contamination. Controlled impact behavior and penetration are additional considerations for the use of a fragile projectile that disintegrates upon impact, reduces damage to training facilities, lowers the risk of ricochet and thus personal injury, and permits the use of a broader range of weapons in situations where overpenetration is a problem (e.g. inside a nuclear reactor facility or a hazardous waste storage area).

Non-Lead bullets with controlled impact properties are of great interest to DOE
 

• 10 million rounds of ammunition are expended each year
• Removal of health hazards and exposure
• Reduced waste generation and environmental impact
• reduced risk in unique HAZ or RAD area force scenarios

The non-lead bullets must exhibit similar performance and function to lead to maintain the high level of training required by the user.

Powdered metals can be combined to produce metal-matrix composite simulants to lead
 

9mm FMJ with  tin-tungsten composite core   9mm FMJ with  zinc-tungsten composite core

Light, soft metals such as tin or zinc are blended with hard, high density metals such as tungsten and compressed at room temperature to form a dense component. The properties of the composite have been designed to mimic the ballistic performance of  lead. The process of mechanical interlocking and cold welding are used to bond the metals together and control impact behavior of the material. The powder metallurgy compact simply replaces the the lead in the bullet. Existing equipment and techniques can be used for rapid insertion of the technology into the market.

The Technology can be applied to most any caliber and bullet design
 

The bullets are a one-to-one replacement for their lead analogs

However, powder metallurgy adds a new level of flexibility. Performance can be improved by manipulating core density and weight distribution.

Impact behavior can be controlled through composition, processing, and construction.

Click on the image to see a movie

The quest for "non-toxic" small arms ammunition is a team effort

The technology has been licensed, and is being evaluated as part of a SERDP project. An interagency working group for Non-Toxic Small Arms Ammunition has been formed. ("The Green Bullet Team"). This technology is a leading candidate for use in all military small arms ammunition.

Summary

Powder metallurgy is a viable approach for the fabrication of functional replacements for lead-containing bullets. Excellent results have been achieved using metal matrix composites composed of tungsten bonded with softer metals fabricated employing a sinterless process. The powder metallurgy approach permits significant control of ballistic and terminal properties, thus offering not only a direct replacement for lead, but a better one.
 
 

Research sponsored by the U.S. Department of Energy,  Office of Safeguards and Security

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