U.S. patent application number 14/332160 was filed with the patent office on 2015-04-23 for firearm projectiles and cartridges and methods of manufacturing the same.
The applicant listed for this patent is AMICK FAMILY REVOCABLE LIVING TRUST. Invention is credited to Darryl D. Amick.
Application Number | 20150107479 14/332160 |
Document ID | / |
Family ID | 44475386 |
Filed Date | 2015-04-23 |
United States Patent
Application |
20150107479 |
Kind Code |
A1 |
Amick; Darryl D. |
April 23, 2015 |
FIREARM PROJECTILES AND CARTRIDGES AND METHODS OF MANUFACTURING THE
SAME
Abstract
Firearm projectiles and methods of manufacturing firearm
projectiles from a supply of clad wire. In some embodiments, the
clad wire is manufactured as electrical wire, such as copper-clad
steel wire. Bullets and shot, as well as methods of forming bullets
and shot, from clad wire are disclosed.
Inventors: |
Amick; Darryl D.; (Albany,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
AMICK FAMILY REVOCABLE LIVING TRUST |
Albany |
OR |
US |
|
|
Family ID: |
44475386 |
Appl. No.: |
14/332160 |
Filed: |
July 15, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13023727 |
Feb 9, 2011 |
8783187 |
|
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14332160 |
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61440572 |
Feb 8, 2011 |
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61337614 |
Feb 9, 2010 |
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Current U.S.
Class: |
102/448 ;
86/57 |
Current CPC
Class: |
F42B 30/02 20130101;
F42B 33/00 20130101; Y10T 29/49712 20150115; F42B 7/046
20130101 |
Class at
Publication: |
102/448 ;
86/57 |
International
Class: |
F42B 33/00 20060101
F42B033/00; F42B 7/04 20060101 F42B007/04 |
Claims
1. A method of forming ammunition shot from a length of clad wire,
the clad wire including an inner core and a cladding surrounding
the inner core, the method comprising: obtaining a supply of
copper-clad steel wire, wherein the copper-clad steel wire was
manufactured as a standard gauge electrical wire; performing at
least one of: working the copper-clad steel wire into a plurality
of interconnected pellets, wherein each pellet has a dimension
generally corresponding to a desired diameter of the ammunition
shot, and separating the plurality of interconnected pellets into
individual pellets; cutting individual pellets from the supply of
the copper-clad steel wire, wherein each pellet has a dimension
generally corresponding to a desired diameter of the ammunition
shot; and pinching the clad wire to form individual pellets so that
the cladding of the clad wire wraps around the metal from the inner
core of the clad wire, and wherein the individual pellets
substantially do not include exposed metal from the inner core of
the clad wire; and rounding the individual pellets into generally
spherical pellets.
2. The method of claim 1, wherein the desired diameter corresponds
to a standard ammunition shot diameter.
3. The method of claim 1, wherein prior to the performing, the
method includes cutting the supply into lengths of copper-clad
steel wire and straightening the lengths of copper-clad steel
wire.
4. The method of claim 1, wherein the rounding includes refining
the plurality of pellets to make the plurality of pellets more
spherical in shape than prior to the refining.
5. The method of claim 1, wherein the method further includes
passivating the cladding of the plurality of pellets.
6. The method of claim 1, wherein the method further includes at
least one of electroplating, painting, and plastic coating the
plurality of pellets.
7. The method of claim 1, wherein the method further includes
loading a plurality of the ammunition shot into a shotgun
cartridge.
8. Ammunition shot manufactured according to the method of claim
1.
9. A shot shell comprising a plurality of ammunition shot according
to claim 8.
10. A method for forming clad ammunition shot, the method
comprising: forming ammunition shot from a length of clad wire, the
clad wire including an inner core and a cladding surrounding the
inner core, wherein the ammunition shot is configured to be
received within a standard caliber shot shell, wherein the cladding
is metallurgically bonded to the inner core and formed from a
different composition than the inner core.
11. The method of claim 10, wherein the clad wire is copper-clad
steel wire.
12. The method of claim 10, wherein the forming includes forming
ammunition shot with a diameter that corresponds to a standard
ammunition shot diameter.
13. The method of claim 10, wherein the forming includes: reducing
a standard gauge clad wire from a standard diameter to a reduced
diameter, wherein the reduced diameter corresponds at least
approximately to a standard ammunition shot diameter.
14. The method of claim 10, wherein the forming includes: working
the clad wire into a plurality of interconnected beads, wherein
each bead has a dimension generally corresponding to a desired
diameter of the ammunition shot; and separating the plurality of
interconnected beads into individual pellets.
15. The method of claim 10, wherein the forming includes: cutting
individual pellets from the length of clad wire, wherein each
pellet has a dimension generally corresponding to a desired
diameter of the ammunition shot; after the cutting, rounding the
individual pellets into generally spherical pellets.
16. The method of claim 10, wherein the forming includes pinching
the clad wire to form individual pellets so that the cladding of
the clad wire wraps around the metal from the inner core of the
clad wire, and wherein the individual pellets substantially do not
include exposed metal from the inner core of the clad wire.
17. The method of claim 16, wherein the method further includes
refining the pellets to make the pellets more spherical in shape
than prior to the refining.
18. The method of claim 10, wherein the method further includes
passivating the ammunition shot.
19. The method of claim 10, wherein the method further includes at
least one of electroplating, painting, and plastic coating the
ammunition shot.
20. The method of claim 10, wherein the method further includes
loading a plurality of the ammunition shot into a shotgun
cartridge.
21. The method of claim 10, further comprising: prior to the
forming, obtaining a supply of the clad wire from a third party,
wherein the third party manufactures the clad wire as electrical
wire.
22. The method of claim 10, further comprising, prior to the
forming, manufacturing the clad wire.
23. Ammunition shot manufactured according to the method of claim
10.
24. A shotgun cartridge comprising a plurality of ammunition shot
according to claim 23.
Description
RELATED APPLICATIONS
[0001] This application is a divisional patent application that
claims priority to Non-Provisional U.S. patent application Ser. No.
13/023,727, which was filed on Feb. 9, 2011, and which issued as
U.S. Pat. No. 8,783,187 on Jul. 22, 2014, which claims priority to
U.S. Provisional Patent Application Ser. No. 61/337,614, entitled
"NON-TOXIC PROJECTILES AND METHODS UTILIZING `CLAD STEEL` WIRE,"
which was filed on Feb. 9, 2010, and to U.S. Provisional Patent
Application Ser. No. 61/440,572, also entitled "NON-TOXIC
PROJECTILES AND METHODS UTILIZING `CLAD STEEL` WIRE," which was
filed on Feb. 8, 2011. The complete disclosures of these patent
applications are incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates generally to the field of
firearm ammunition and more specifically to bullets, shot, and
firearms cartridges, as well as to methods of manufacturing the
same.
BACKGROUND OF THE DISCLOSURE
[0003] Perhaps no other subject pertaining to adverse impacts on
wildlife by human activity has generated more global concern and
response during the past decade than the well-documented
occurrences of poisoning in a wide variety of avian (and other)
species by incidental ingestion of lead (Pb), almost entirely
attributed to spent ammunition. For example, approximately 150
professional bioscientists from throughout the USA, Canada, Europe,
Australia, et al. met during May 12-15, 2008 in Boise, Id. at a
conference sponsored by The Peregrine Fund, United States
Geological Survey, Tufts Center for Conservation Medicine and Boise
State University, and entitled, "Ingestion of Lead from Spent
Ammunition: Implications for Wildlife and Humans."
[0004] While no attempt will be made herein to discuss the 53
invited technical presentations at the Boise conference, it is
relevant to offer brief examples of general consensus among the
participants:
[0005] (1) Outlawing of lead shot for hunting waterfowl in the U.S.
and Canada has drastically reduced losses of ducks, geese, et al.
by lead poisoning and has not contributed to other types of loss
(for example, by crippling due to steel shot). Serious
consideration is being given throughout the U.S. to extending the
ban on lead shotgun shot to other types of bird and small-game
hunting. While steel shot is considered to be acceptable for its
intended purpose, it should be noted that it is only considered to
be appropriate for modern shotguns with relatively hard steel
barrels. It is therefore not recommended for a wide spectrum of
older, fine-quality guns manufactured prior to the modem
prohibitions against toxic lead shot. This factor is quite relevant
to some embodiments of the present disclosure.
[0006] (2) Voluntary restriction of the use of lead bullets for
big-game hunting was not sufficiently effective in the condor range
of California, but produced somewhat better results in Arizona and
Utah. Both scavengers and raptors eat carrion, such as that
associated with lead-killed animals.
[0007] (3) California will continue to enforce its July 2008
mandatory statewide ban on lead bullets (including not only
"centerfire" big-game and varmint bullets, but also smaller
"rimfire" bullets for target and varmint shooting).
[0008] (4) Other U.S. states and many foreign countries are
presently in various stages of studying further lead bullet
restrictions, and some countries have already instituted new
policies and/or laws.
[0009] (5) While as yet unproven, there is evidence that game meat
contaminated with small lead fragments may constitute an
unnecessary risk to humans who knowingly or innocently ingest them.
This concern, whether fully justified or not, has resulted in
warnings to the public by governmental health agencies and in
curtailment of distribution of game meat to charitable agencies and
organizations.
[0010] At the present time, bullets comprised primarily of copper
(Cu) and copper alloys (e.g., Cu--Zn and Cu--Sn) are the most
popular available alternatives to lead. Barnes Bullet Company
pioneered a wide spectrum of pure copper bullets, beginning as far
back as 1985, as represented in U.S. Pat. No. 5,131,123, the
disclosure of which is hereby incorporated by reference. It is
relevant to note that the incentive for these efforts was based
upon claimed superior bullet ballistic performance, rather than on
any consideration of toxicity. Since the California ban, several
other manufacturers have offered other types of copper-based
bullets, all of which, as already mentioned, contain copper as the
primary constituent.
[0011] While an interim consensus was evident at the Boise
conference that copper was much preferable to lead, actual in vivo
tests of American kestrels (the target/study bird selected as
representative of raptors and scavengers), in which subject birds
have been gavaged (i.e., force-fed) with solid copper samples, are
scheduled to be completed sometime during the spring of 2011 by
USGS personnel. It should be noted that bullets produced from both
solid and particulate forms of copper and its alloys are presently
being offered by manufacturers, the different varieties of which
may have correspondingly different dissolution rates, toxicities,
etc. when ingested by birds or other living creatures.
[0012] Aside from toxicological considerations, intensive debate
continues among sportsmen and wildlife personnel as to the impact
of additional costs associated with non-toxic, copper-based
ammunition, especially in such areas as varmint and/or target
shooting, sports in which relatively large numbers of cartridges
are expended. Copper bullets typically cost several times as much
as traditional copper-jacketed lead bullets, a factor which is
perceived as potentially reducing the number of hunters/shooters,
as well as the frequency of their activities. From a
conservationist standpoint, hunters who are reluctant or unable to
practice their skills are more likely to wound game animals, with
resulting waste of the resource.
[0013] The dual requirements of non-toxicity and economy argue for
development of projectiles made, in whole or in part, from steels.
Common grades of steel (for example, in wire/rod form) are
available at commodity prices (per unit weight) that are
approximately 60% of those of lead and only about 15% of those of
copper. Considerations of acute and low-level/long-term toxicity
and "environmental fate" also demonstrate attractive attributes of
iron and steel. Iron (Fe), the fourth most abundant element on
earth, is generally considered to be "environmentally friendly" and
easily oxidized to insoluble compounds. No other metallic material
can begin to compare with steel from the standpoints of industrial
experience, metallurgical technology, product diversity, variety of
available process capability, etc. While steel bullet and jacket
types have been used in certain military applications (often
motivated by war-time shortages of critical materials such as
copper and lead), one might well ask why steel bullets have not
been applied to a wider variety of bullets, including those
suitable for law enforcement and civilian applications.
[0014] Whereas military bullets for such common calibers as 0.223
in. (5.56 mm) and 0.30 in. (7.62 mm) are prohibited from expanding
("mushrooming") or fragmenting by international agreements (e.g.,
The Hague and Geneva Conventions), bullets used for big-game,
small-game, and varmint hunting are designed specifically to expand
and/or fragment in the target. An exception to this is found in
very large African game, for example, elephant or cape buffalo, for
which solid brass or other alloy bullets are designed to penetrate
heavy skulls. A further consideration in hunting bullets is that
they are preferably designed to penetrate and expand in a
controlled manner, often specific to particular sizes and/or
species of animals. A primary objective is for the bullet to
penetrate sufficiently to reach critical organs, while depositing
all or most of its energy in vital regions. Premature expansion may
result in non-lethal "flesh wounding," while delayed expansion may
allow the bullet to pass entirely through the animal, leaving an
under-sized wound path and wasting kinetic energy beyond the
target.
[0015] In law enforcement applications for bullets, penetration and
expansion also are important attributes to be controlled. As in
hunting applications, it may be desirable for a bullet to expand in
such a manner as to deposit all of its kinetic energy in the
target, in this case, a human being deemed to be a threat to the
lives of peace officers or others. However, the human factor
greatly complicates bullet requirements for given situations. For
example, a perpetrator may be wearing a variety of clothing
(including body armor), which significantly affects bullet
expansion and subsequent penetration. This variable is especially
important when "hollow point" bullets are employed, since different
types of cloth may plug the bullet's nose cavity, thereby
preventing it from expanding properly. Police officers also face
many situations in which the perpetrator is shielded behind
barriers such as automobile windshields, construction materials,
panels, etc., situations which could benefit from a highly
penetrative bullet. Further complicating the law officer's
responsibilities are considerations of bullet over-penetration and
ricocheting, both of which may result in injury to bystanders.
Because of these and other factors, law enforcement agencies must
constantly make potentially "life and death" decisions as to
precisely which bullet types represent the best compromise for
officers to carry at a particular instance.
[0016] Both accuracy and retained energy of bullets are influenced
by such factors as bullet density (mass-per-unit-volume),
dimensions and shape, as well as variables inherent in gun barrel
design (e.g., length, twist rate, etc.) and environment (e.g., air
temperature, pressure, humidity, etc.). While bullet density may be
directly related to energy retention and fluid drag resistance, the
success attained with solid copper bullets (e.g., Barnes Bullets,
Inc. products) during the past 25 years illustrates that lower
material density need not be viewed as an insurmountable obstacle
to acceptable ballistic performance. In fact, several advantages of
such bullets have been claimed, including that lighter bullets may
be launched at higher velocities (for a given barrel pressure) and
therefore may actually display less gravitational drop at certain
distances. Another factor is that copper bullets "mushroom" in a
manner quite different from conventional lead hunting bullets. In
the former, the unfolded bullet "petals" created at impact remain
attached to the base of the bullet (thereby retaining integral
mass), while lead bullets tend to shed and scatter fragments of
lead along the wound path (poor "weight retention"). This
characteristic behavior observed in many lead bullets is presumably
the result of its extreme softness and low melting point.
[0017] Because expanding copper bullets (8.96 g/cc density) perform
well enough to satisfactorily substitute for corresponding lead
bullets (11 g/cc density), obtaining acceptable performance with
steel bullets also appears to be feasible. The shift in density
from lead to copper represents a decrease of about 22%, whereas the
difference between steel at 7.86 g/cc and copper is only about 14%.
Appropriate grades of low-carbon steel, properly fabricated in
accordance with specific processes and bullet designs, possess
sufficient ductility to replicate the "folded petal" behavior of
copper, including its inherently high weight-retention, when
desired.
[0018] Another factor, which cannot be ignored, is that a bullet
must possess surface properties such that the machined rifling
grooves in modern gun barrels are not prematurely eroded, nor are
they filled or "fouled" by bullet residues. With lead-core bullets,
fouling is prevented by individually encapsulating cores in copper
alloy (often 97% Cu-5% Zn "gilding metal") jackets. These jackets
typically are separately formed "housings" into which the bullet
core is positioned during production of the assembled bullet. The
jacket also contributes significantly to the overall strength of
the bullet, which must withstand high rotational and translational
stresses without flying apart or "obturating" (i.e., becoming
mechanically distorted) in flight. In addition to encapsulating the
main bearing surface of the bullet in this way, it is usually
necessary to place a "gas check" disc on its rearward face to
prevent the melting of lead by hot combustion gases upon firing the
cartridge. Other means of coating conventional lead-cored bullets
include electrolytic plating (restricted to cartridges with
relatively low velocities), non-metallic coatings (e.g., nylon,),
and jacketing sub-sized bullets in relatively thick plastic
"sabots." Obviously, none of these bullet coating schemes is
necessary in the case of solid copper bullets.
[0019] While an inexperienced engineer or metallurgist might assume
that a metallic shape of basically round cross-section (e.g., a
bullet) could be advantageously clad in a different metal by means
of a continuous process, resulting in a long clad wire, attempts to
do so with lead and copper have proven to be technically and
economically impractical. This is believed to be primarily due to
the widely different mechanical, physical and metallurgical
properties of such dissimilar metals as lead and copper. The
overall result of these property differences is that conventional
high-velocity bullets must be produced by individually fitting each
lead core with a precisely-tailored copper alloy jacket, and then
maintaining precision, uniformity, repeatability, etc. throughout
all subsequent operations. While many bullet manufacturers make
advertising claims of "bonded" bullets, consideration of the Cu--Pb
equilibrium diagram illustrates that there is no discernable solid
solubility (i.e., "alloying") directly between solid copper and
solid lead, indicating that any so-called "bonding" would be
metallurgically marginal. Conversely, the Cu--Fe binary system
does, in fact, display significant degrees of solid solubility,
both in Cu-rich and Fe-rich regions of the alloy system.
[0020] Bonding strength between jackets and cores is not a trivial
consideration, with respect to both performance and safety. For
example, if jacket material is "stripped" from the core as the
bullet travels down the gunbarrel, it may become lodged in the
barrel, resulting in an obstruction to subsequent firings.
Conventional swaged jacket-core assemblies must be held to strict
production quality-control standards to ensure adequate bond
strengths. Electroplated copper jackets are viewed as having
relatively low bonding strengths to degrees that limit their
usefulness to low velocities (e.g., in pistols and a few relatively
low-power rifles).
[0021] In the case of steel shotgun pellets, copper, zinc, and
nickel are routinely applied as electroplated films by various
manufacturers to obtain some degree of corrosion-resistance, along
with aesthetically pleasing surface appearance. These films,
however, are relatively thin (e.g., 0.0005-0.001 inch), porous, and
merely mechanically bonded to steel substrates. None of these
coated steel pellet types is considered to be acceptable for use in
older shotguns, the present markets being served by expensive
alternatives to lead, such as bismuth.
SUMMARY OF THE DISCLOSURE
[0022] The present disclosure is directed to firearm projectiles
and to methods of manufacturing firearm projectiles, including
bullets and shot. The disclosed methods utilize a source of clad
wire to form the projectiles. For example, in some embodiments, the
clad wire may be manufactured as electrical wire, such as
copper-clad steel wire. In other embodiments, the clad wire may be
custom made for the purpose of forming projectiles. In some methods
according to the present disclosure, a standard gauge clad wire is
reduced in diameter to correspond to a desired diameter of a
projectile being formed. In other methods according to the present
disclosure, the diameter of a length of standard gauge clad wire is
enlarged to correspond to a desired diameter of a projectile being
formed. Firearms projectiles formed from clad wire according to the
present disclosure may provide stronger bonds, optionally including
metallurgical bonds, between the copper and the core metal to which
it is clad, and/or may have thicker copper layers than conventional
firearm projectiles electroplated with outer copper layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic cross-sectional view of two relative
sizes of clad wire that may be used to form firearm projectiles
according to the present disclosure and that may be used in methods
according to the present disclosure.
[0024] FIG. 2 is a flowchart schematically illustrating
illustrative, non-exclusive examples of methods of forming bullets
according to the present disclosure.
[0025] FIG. 3 is a schematic cross-sectional view of an
illustrative, non-exclusive example of a bullet according to the
present disclosure, and which may be formed according to methods
according to the present disclosure.
[0026] FIG. 4 is a schematic cross-sectional view of another
illustrative, non-exclusive example of a bullet according to the
present disclosure, and which may be formed according to methods
according to the present disclosure.
[0027] FIG. 5 is a flowchart schematically illustrating additional
illustrative, non-exclusive examples of methods of forming bullets
according to the present disclosure.
[0028] FIG. 6 is a schematic side view of a bullet according to the
present disclosure illustrated with various optional features, and
which may be formed according to methods according to the present
disclosure.
[0029] FIG. 7 is a flowchart schematically illustrating
illustrative, non-exclusive examples of methods of forming shot
according to the present disclosure.
[0030] FIG. 8 is a schematic cross-section view of an illustrative,
non-exclusive example of a shot according to the present
disclosure, and which may be formed according to methods according
to the present disclosure.
[0031] FIG. 9 is a schematic cross-section view of an illustrative,
non-exclusive example of another shot according to the present
disclosure, and which may be formed according to methods according
to the present disclosure.
[0032] FIG. 10 is a flowchart schematically illustrating additional
illustrative, non-exclusive examples of methods of forming shot
according to the present disclosure.
[0033] FIG. 11 is a flowchart schematically illustrating additional
illustrative, non-exclusive examples of methods of forming shot
according to the present disclosure.
DETAILED DESCRIPTION AND BEST MODE OF THE DISCLOSURE
[0034] The present disclosure relates both to firearm projectiles,
such as bullets and shot, as well as to methods for forming, or
manufacturing, firearm projectiles. More specifically, projectiles
according to the present disclosure are formed from, and methods
according to the present disclosure utilize, clad wire.
[0035] As used herein, "clad wire" refers to a composite,
bimetallic wire having an inner core of a first metal surrounded by
an outer layer, or cladding, of a second metal that is bonded to
the inner core and that is different than the inner core. FIG. 1
schematically illustrates two cross-sectional representations of
clad wire 10, including an inner core 12 and an outer layer, or
cladding, 14.
[0036] Illustrative, non-exclusive examples of clad wire include
(but are not limited to) steel clad wire (i.e., wire with a steel
inner core 12 and a non-steel cladding 14). Illustrative,
non-exclusive examples of steel clad wire include (but are not
limited to) copper-clad steel wire, aluminum-clad steel wire,
tin-clad steel wire, and zinc-clad steel wire, all of which may be
described as commodity clad steel wire, because such wires are
produced in abundance around the globe, such as for electrical
wire. Other examples of clad wire are also within the scope of the
present disclosure and may be utilized by methods according to the
present disclosure to form firearm projectiles, such as bullets and
shot, according to the present disclosure.
[0037] Copper-clad steel wire, in particular, is used throughout
the electrical industry as a less expensive alternative to solid
copper wire. Copper-clad steel wire was developed to provide
electrical conductors that are much stronger than pure copper but
which, nevertheless, retain the relatively high conductivity and
corrosion resistance of copper. The various grades of copper-clad
steel wire are typically identified in terms of standard AWG
(American wire gauge), with additional identifiers pertaining to
conductivity relative to that of pure copper (% IACS--International
Annealed Copper Standard). For example, at least twenty-eight AWG
wire diameters are commonly available in the U.S. with at least
three common % IACS values: 21%, 30% and 40%. The % IACS identifier
also relates to the relative thickness of the copper cladding of
copper-clad steel wire. Specifically, 21% IACS indicates copper
thickness equal to 3% of the total diameter of the wire; 30% IACS
indicates 6.5% copper thickness and 40% indicates 10% copper
thickness. Standard grades of core steels are AISI 1006 (0.06 wt %
carbon) and AISI 1022 (0.22 wt % carbon) plain-carbon steels. Other
copper-clad steel wire configurations and associated values, as
well as other steel grades, are within the scope of the present
disclosure and may be used in methods to form firearm projectiles
according to the present disclosure.
[0038] As an illustrative, non-exclusive example, copper-clad steel
wire products for the electrical industry are typically made using
thermo-mechanical processing (i.e., metallurgical processes in
which combinations of pressure and heat are applied to effect
strong, homogeneous diffusion bonds between the steel and copper
components). While most such processes currently comprise
heating/bonding strips of copper to a steel core-rod by means of
heated, counter-rotating rolls, other thereto-mechanical processes
such as hot coextrusion of composite copper-steel assemblies, also
may be utilized and therefore are included within the scope of the
present disclosure.
[0039] The following table identifies various diameters of standard
AWG clad wire, standard caliber bullets, and standard ammunition
shot:
TABLE-US-00001 AWG # (inches) Bullet Caliber (inches) Shot #
(inches) 0 (0.3249) .375 Mag. (0.375) OOOO Buck (0.380) 1 (0.2893)
.35 Rem. (0.358) OOO Buck (0.360) 2 (0.2576) .338 Mag. (0.338) OO
Buck (0.330) 3 (0.2294) .30 cal. (0.308) O Buck (0.320) 4 (0.2043)
7 mm (0.284) I Buck (0.300) 5 (0.1819) .270 Win. (0.277) 2 Buck
(0.270) 6 (0.1620) .260 Rem. (0.264) 3 Buck (0.250) 7 (0.1443) .257
WM, .25-06 (0.257) 4 Buck (0.240) 8 (0.1285) .243 Win., 6 mm
(0.243) FF (0.230) 9 (0.1144) .223 Rem. (0.224) F (0.220) 10
(0.1019) .22 (0.223) TT (0.210) 11 (0.0907) .17 (0.172) T (0.200)
12 (0.0808) BBB (0.190) 13 (0.0720) BB (0.180) B (0.170) 1 (0.160)
2 (0.150) 3 (0.140) 4 (0.130) 5 (0.120) 6 (0.110) 7 (0.100) 8
(0.090) 9 (0.080)
[0040] The present disclosure is not limited to the
above-identified illustrative, non-exclusive examples of sizes of
ammunition projectiles, and other sizes, or calibers, of
projectiles are within the scope of the present disclosure
(including custom-sized projectiles) and may be formed by methods
according to the present disclosure
[0041] As evidenced in the above table, only a few of the clad wire
standard gauges have diameters corresponding approximately to a
diameter of a standard ammunition projectile. For example, a #3 AWG
clad wire has a diameter of 0.2294 inches, while a .22 caliber
bullet has a diameter of 0.223 inches. Similarly, a #FF shot has a
diameter of 0.23 inches. A #11 AWG clad wire has a diameter of
0.0907 inches, while a #8 shot has a diameter of 0.090 inches. A
#12 AWG clad wire has a diameter of 0.0808 inches, while a #9 shot
has a diameter of 0.080 inches. Accordingly, #3, #11, and #12 AWG
clad wire may be appropriately sized to form ammunition projectiles
according to the present disclosure without a required step of
altering, or modifying, the diameter of the clad wire; however, as
seen in the above table, most standard ammunition projectiles have
diameters that are not equal to, or closely equal to, standard AWG
clad wire. Therefore, as discussed herein, methods of forming
ammunition projectiles according to the present disclosure may
include a step of decreasing or a step of increasing the diameter
of a selected clad wire to form a desired size of ammunition
projectile. Also within the scope of the present disclosure,
however, is to manufacture, or form, clad wire that does not
necessarily correspond to a standard AWG and that does have a
diameter corresponding to a desired size of ammunition projectile.
This manufacturing, or forming, of a non-standard clad wire may be
described as manufacturing, or forming, a custom clad wire for
purposes of forming ammunition projectiles according to the present
disclosure.
[0042] The decreasing and increasing of the diameter of clad wire
is schematically illustrated in FIG. 1, in which a first clad wire
16 is illustrated having a first diameter together with a second
clad wire 18 having a second diameter that is greater than the
diameter of the first clad wire. FIG. 1 is not drawn to scale, and
therefore does not illustrate specific proportions of inner cores
12 to cladding 14, nor does it illustrate specific increasing
and/or decreasing of diameters of clad wire, as may be performed
according to methods according to the present disclosure.
[0043] The flowcharts in the Figures of the present disclosure
schematically represent illustrative, non-exclusive examples of
methods 100 of forming ammunition projectiles. Some steps in the
flowcharts are illustrated in dashed boxes, with such dashed boxes
indicating that such steps may be optional or may correspond to an
optional embodiment or version of a method according to the present
disclosure. That said, not all methods according to the present
disclosure are required to include the steps illustrated in solid
boxes. The methods and steps illustrated in the flowcharts are not
limiting, and other methods and steps are also within the scope of
the present disclosure, including methods having greater than or
fewer than the number of steps illustrated, as understood from the
discussions herein. Moreover, methods according to the present
disclosure are not limited to the illustrated steps being performed
in the illustrated order, and variations on the illustrated order
are within the scope of methods 100 according to the present
disclosure. Additionally or alternatively, one or more steps of one
illustrated method of a Figure may be incorporated into another
illustrated method of another Figure without departing from the
scope of the present disclosure. Moreover, where one illustrated
and discussed method includes a step described, named, and/or
numbered similarly to another step of another illustrated and
discussed method, for the purpose of brevity, each step or variant
thereof may not be discussed in detail with respect to each
illustrated and discussed method; however, it is within the scope
of the present disclosure that discussed features, options,
variants, etc. of the various steps of methods discussed herein may
be incorporated into any suitable method according to the present
disclosure, where appropriate.
[0044] Referring first to the flowcharts of FIGS. 2 and 5,
illustrative, non-exclusive examples of methods 100 of forming
ammunition projectiles are schematically illustrated. The
illustrated methods 100 of FIGS. 2 and 5 are more specifically
directed to methods of forming bullets and are indicated generally
at 150. As discussed herein, methods of forming ammunition
projectiles may include a step of decreasing or a step of
increasing the diameter of a selected clad wire to form a desired
size of ammunition projectile. The flowchart of FIG. 2 illustrates
methods 200 that include a step of reducing the diameter of a
selected clad wire, whereas the flowchart of FIG. 5 illustrates
methods 300 that include a step of enlarging the diameter of a
selected clad wire. These optional steps of decreasing or
increasing the diameter of clad wire of methods 150 according to
the present disclosure are schematically represented in FIG. 1, in
which two diameters of clad wire are schematically illustrated.
That is, FIG. 1 schematically illustrates both a reduction of a
diameter of a length of clad wire as optionally may be performed
according to methods 200 according to the present disclosure, and
an increase of a diameter of a length of clad wire as optionally
may be performed according to methods 300 according to the present
disclosure.
[0045] Methods 200 according to the present disclosure may be
described as methods of forming bullets in which the diameter of
clad wire, such as a standard gauge clad wire, is reduced to
correspond to a desired diameter, such as that of a desired caliber
bullet to be formed. Accordingly, as illustrated at 202 in FIG. 2,
the clad wire may be reduced in diameter, for example, via a
drawing process. Additionally or alternatively, the clad wire may
be reduced in diameter via a swaging process. Step 202 may be
described as reducing a standard gauge clad wire from a standard
gauge diameter to a reduced diameter, with such reduced diameter
corresponding at least approximately to a diameter associated with
a standard caliber bullet. In other words, the diameter of a length
of standard gauge clad wire may be reduced so that it corresponds
to a desired diameter of a bullet. Methods 200 may be particularly
well-suited for producing so-called non-expanding, or solid
bullets, such as in calibers less than about 0.35 inches in
diameter; however, methods 200 are not limited to producing such
bullets, and non-solid bullets and bullets having a caliber larger
than 0.35 inches also may be formed by methods 200 according to the
present disclosure.
[0046] In some methods 200 according to the present disclosure, it
may be desirable to heat treat the clad wire, as optionally
indicated at 204 in FIG. 2, after the clad wire has been reduced in
diameter. For example, the drawing or swaging process may impart
properties to the clad wire, and/or the clad wire may have
properties prior to step 202, that are undesirable for bullets.
Illustrative, non-exclusive examples of such properties may include
(but are not limited to) the hardness and/or the ductility of the
clad wire. Additionally or alternatively, the reducing step may
have an undesired effect on the bonding between the inner core and
the cladding of the clad wire. Heat treating, therefore, may enable
a manufacturer to control desired properties of the bullets being
formed, and annealing is an illustrative, non-exclusive example of
a heat treating process that may be appropriate in some methods
according to the present disclosure. Additionally or alternatively,
a heat treating step may be performed at any suitable point in a
method 100 according to the present disclosure, including at the
point illustrated and/or after one or more other steps including
after a final configuration of a bullet, or other projectile, has
been formed.
[0047] As discussed herein, clad wire is often manufactured in
bulk, for example, as electrical conductors. Often, such bulk
produced clad wire is coiled on spools and may be purchased in a
coiled configuration. Accordingly, it may be desirable in some
methods according to the present disclosure to first straighten the
clad wire as schematically and optionally indicated at 206 in FIG.
2, prior to the drawing step 202. However, methods according to the
present disclosure are not limited to utilizing coiled clad wire,
and clad wire may be produced, distributed, and/or obtained in a
straight bar, or rod configuration. Furthermore, when a
straightening step is utilized, it optionally may be performed
after the drawing step (or in the case of FIG. 5, the upsetting
step). Moreover, an initial straightening step 206 is not
necessarily required, even when a coiled clad wire is utilized. For
example, depending on such factors as the radius of curvature of
the coiled clad wire and additional steps of methods according to
the present disclosure, which may straighten the clad wire as a
result of the additional steps, an initial straightening step may
not be required. Furthermore, in methods 200 that include an
optional heat treating step 204, it may be desirable to maintain
the clad wire in a coiled configuration to facilitate the heat
treatment thereof. For example, it may be easier to implement a
heat treating step when an entire coil of clad wire may be easily
positioned in a heat treating apparatus, such as an oven. However,
it is also within the scope of the present disclosure that heat
treatment may be performed on straight lengths of clad wire,
including long lengths of straight clad wire, such as that is fed
through a heat treatment apparatus.
[0048] As indicated at 208 in FIG. 2, some methods 200 according to
the present disclosure may optionally include a cutting step, for
example to cut the clad wire into a bullet length, that is, into a
length corresponding to a desired configuration of bullet being
formed. Step 208 is indicated in dashed lines as an optional step
because a distinct cutting step may not be required, and other
steps, including optional steps of methods 200, may result in the
clad wire being cut to a bullet length, or otherwise resulting in a
length of clad wire being removed from the supply of clad wire. The
cutting step 208 may alternatively refer to an optional step in
which a length of clad wire is cut from the supply of clad wire
that is greater than a single bullet length, for example to permit
easier manipulation of the clad wire for subsequent steps of the
method.
[0049] Some methods 200 according to the present disclosure may
include a working step 210. By working, it is meant that the clad
wire, or a portion thereof, may be worked into a near-final
configuration of a bullet. Illustrative, non-exclusive examples of
working processes include (but are not limited to) heading,
swaging, and rolling to form a near-final configuration of a
bullet. By near-final configuration, it is meant that the general
shape and size of the bullet may be generally formed out of the
clad wire, but that further refinement, such as to have the bullet
within acceptable tolerances, to add additional features to the
bullet, etc. may be performed subsequent to the working step 210.
As an illustrative, non-exclusive example, a length of clad wire
may be rolled to form a series of interconnected cylindrical
portions, with each portion corresponding to a bullet length.
Additionally or alternatively, a working step may form the nose of
the bullet, with subsequent steps refining the desired
configuration of the bullet being formed.
[0050] As illustrated in FIG. 2, methods 200 according to the
present disclosure typically include a machining, or finishing,
step 212, in which a length of the clad wire is machined, or
otherwise modified, to generally form a final configuration of the
bullet. For example, one or more of the length of the bullet, the
diameter or the bullet, and the size and shape of the nose of the
bullet may be machined or otherwise finished to a desired
configuration, such as (but not necessarily) corresponding to a
standard caliber bullet. By final configuration it is meant that
after the machining step 212, the bullet is at least generally in
the form of a bullet, and in some methods according to the present
disclosure the bullet, after this step, may be configured, or may
be ready, to be utilized, such as by being loaded into a
cartridge.
[0051] However, as indicated optionally at 214 in FIG. 2, it is
also within the scope of methods 150 according to the present
disclosure, that subsequent to the machining and/or other steps
discussed herein, the outer surface of the bullet may be treated.
For example, the bullet may be coated, such as including one or
more of electroplating, painting, passivating, and plastic coating.
Such coatings, for example, may impart a corrosion-resistant
coating to the bullet, which may be desirable in some
implementations of methods according to the present disclosure. For
example, when steel clad wire is utilized in a method according to
the present disclosure, it may be desirable to prevent, or at least
restrict, oxidation of any exposed steel from the inner core of the
clad wire that was utilized to form the bullet. Other coatings and
reasons for coating bullets are also within the scope of the
present disclosure.
[0052] Finally, as indicated optionally at 216 in FIG. 2, it is
within the scope of methods 150 according to the present disclosure
to include a loading step, that is, a step to load the bullet into
a cartridge, such as into a standard caliber firearm cartridge.
This step is optional, as a large population of firearm enthusiasts
prefer to load, and reload, their own cartridges for various
reasons.
[0053] FIG. 3 schematically illustrates in cross-section, an
illustrative, non-exclusive example of a bullet 20 according to the
present disclosure. Bullet 20 is an example of a bullet that may be
formed according to a method 200 according to the present
disclosure. As illustrated, bullet 20 includes a core and an outer
layer corresponding to the inner core 12 and cladding 14,
respectively, of the clad wire from which it was formed. Bullet 20
includes a nose 22 and a heel 24, in which the metal from the inner
core of the clad wire is exposed. Such a configuration may result
depending on the specific steps utilized during a method 200. For
example, the nose 22 of the bullet may have been formed by direct
machining of a length of clad wire, during a step 212. Such a
machining step may remove the cladding 14 from the portion of the
length of clad wire that became the nose of the bullet 20.
[0054] In examples in which steel clad wire is utilized to form a
bullet 20 according to the present disclosure, it may be desirable
to include a surface treating step 214, such as to prevent, or at
least restrict, oxidation of the exposed steel from the inner core
of the steel clad wire. Surface treating of such exposed regions
also may be performed for aesthetic purposes. However, as
mentioned, such surface treatment step is optional and not required
to all methods 150 according to the present disclosure.
[0055] FIG. 4 schematically illustrates in cross-section, another
illustrative, non-exclusive example of a bullet according to the
present disclosure, with the bullet of FIG. 4 being indicated
generally at 30. As schematically illustrated, bullet 30 differs
from bullet 20 of FIG. 3 in that the cladding 14 of the clad wire
extends at least substantially over the nose 22 of the bullet. Such
a configuration may result depending on the specific steps utilized
during a method 150. For example, the nose 22 of the bullet may
have been formed during an optional working step 210, with such
working step including a process in which the cladding 14 remains
on the outer surface of the nose. An illustrative, non-exclusive
example of a suitable working process that may result in such a
configuration includes rolling. Additionally or alternatively, a
working step may include pinching the clad wire so that the
cladding of the clad wire wraps around a substantial portion of the
inner core to form a nose of the bullet being formed. Other working
processes, including processes resulting in a bullet 30, are also
within the scope of the present disclosure.
[0056] Turning now to the flowchart of FIG. 5, additional
illustrative, non-exclusive examples of methods 150 according to
the present disclosure are schematically illustrated and are
indicated generally at 300. Methods 300 according to the present
disclosure may be described as methods of forming bullets in which
the diameter of the clad wire being utilized, such as standard
gauge clad wire, is increased, or enlarged, to correspond to a
desired diameter, such as that of a desired caliber bullet to be
formed. Accordingly, as illustrated at 302, a length of clad wire
is upset, increased, or enlarged in diameter by any suitable
process. As an illustrative, non-exclusive example, a length of
clad wire may be compressed in a die with a punch, but other
processes of upsetting, or enlarging, the diameter of a length of
clad wire are also within the scope of methods 300 according to the
present disclosure. Step 302 may be described as enlarging a
diameter of a length of clad wire from a standard gauge diameter to
an enlarged diameter, such as corresponding at least approximately
to a diameter associated with a standard caliber firearm bullet.
Methods 300 may be particularly well suited for producing
non-expanding, or solid bullets in calibers greater than about 0.35
inches in diameter; however, methods 300 may be utilized to form
bullets of any suitable size, including those of calibers less than
0.35 inches in diameter. Referring back to Table 1, it can be seen
that a #0 AWG clad wire, which is typically the largest common
gauge of solid clad wire, has a diameter of approximately 0.325
inches, whereas larger electrical conductors are typically formed
from braided cables or ropes of several individual strands of
smaller wire. Accordingly, commodity pricing of clad wire with
diameters greater than a #0 AWG clad wire may not be generally
available, and methods 300 according to the present disclosure may
be utilized to produce bullets of a caliber having diameters
greater than 0.325 inches.
[0057] In some methods 300 according to the present disclosure, the
upsetting step 302 may be described as altering the dimensions of a
cylinder formed from a length of clad wire. For example, in some
methods 300, the length of a cylinder is decreased and the diameter
of the cylinder is increased. In some such versions of methods 300,
the upsetting step is used exclusively to define a desired diameter
of the length of clad wire and no other features of the bullet are
formed during the step. However, it is also within the scope of the
present disclosure that an upsetting step, in addition to
increasing the diameter of the length of clad wire, forms other
aspects and/or characteristics of the bullet being formed. This may
be described as working the clad wire into a near-final
configuration, similar to the step 210 discussed above with respect
to methods 200 according to the present disclosure, such as forming
at least a nose of the bullet. For example, the upsetting step may
utilize a die that is bullet shaped and that defines at least a
bullet nose shape, such as a conical or frustoconical end region,
as opposed to merely cylindrical in shape. Utilizing an upsetting
step that forms a near-final configuration of a bullet being formed
may enable formation of a bullet 30 as illustrated in FIG. 4, in
which the cladding of the clad wire extends at least substantially
over the nose 22 of the bullet. This configuration may result, for
example, as the cylindrical length of clad wire is pressed, or
compressed, into a bullet shaped die, and the cladding of the clad
wire is pinched into the cone-shaped or frustoconical portion of
the die. In contrast, an upsetting step, in which an altered
cylinder is formed (e.g., without a conical or frustoconical end
region) from the length of clad wire may require subsequent
machining to form the nose of the bullet, and therefore may result
in a bullet 20 as schematically illustrated in FIG. 3.
[0058] Although not required, it may be desirable to first cut an
individual length of clad wire, as indicated in FIG. 5 at 304. For
example, this may be helpful if it is difficult or less practical
to upset a supply of clad wire, such as a spool of coiled clad wire
or even an elongate length of clad wire. A suitable length of clad
wire may be selected such that during the upsetting step 302, an
appropriate bullet length is formed.
[0059] As discussed, clad wire is often supplied in a coiled
configuration, and therefore in some methods 300 according to the
present disclosure, it may be desirable to first straighten the
clad wire, as schematically and optionally indicated at 206 in FIG.
5, prior to cutting individual lengths of clad wire. However,
depending on such factors as the radius of curvature of the coiled
clad wire, the length of bullet being formed, the particular
upsetting process being utilized, a straightening step may not be
needed.
[0060] Depending on the desired properties of the bullet being
formed, and depending on the upsetting process being utilized as
part of a method 300, it may be desirable to heat treat the length
of clad wire after it has been upset, as schematically and
optionally indicated at 204 in FIG. 5. Heat treatment also may be
desirable in such circumstances in which the upsetting process may
affect the bonding between the inner core and the cladding of the
clad wire. Annealing is an illustrative, non-exclusive example of a
heat treating process that may be suitable, but other heat treating
processes are also within the scope of the present disclosure.
[0061] As illustrated in FIG. 5, methods 300 according to the
present disclosure may include a machining, or finishing, step 212,
in which the upset length of clad wire is machined, or otherwise
modified, to generally form a final configuration of the bullet
being formed. This machining step is similar to the machining step
212 discussed herein with respect to methods 200 according to the
present disclosure, and may result in a bullet 20 or a bullet 30,
for example, depending on the upsetting step 302 discussed
herein.
[0062] As indicated optionally at 214 in FIG. 5, it is also within
the scope of methods 300 according to the present disclosure, that
subsequent to the machining and/or other steps discussed herein,
the outer surface of the bullet may be treated. For example, the
bullet may be coated, such as including one or more of
electroplating, painting, passivating, and plastic coating. As
discussed herein, such coatings may impart a corrosion-resistant
coating to the bullet, which may be desirable in some
implementations of methods according to the present disclosure.
[0063] Finally, as indicated optionally at 216 in FIG. 5, it is
within the scope of methods 300 according to the present disclosure
to include a loading step to load the formed bullet into a
cartridge, such as into a standard caliber firearm cartridge.
[0064] Turning now to FIG. 6, a less schematic illustration of a
bullet 40 is provided and includes various optional features of
bullets according to the present disclosure, with such various
optional features optionally being formed during one or more steps
of methods 150 according to the present disclosure. As
illustrative, non-exclusive examples, bullet 40 is illustrated as
including driving bands 42, grooves 44, a cannelure 46, a heel
cavity 48, a nose cavity 50, and a boat-tail 52. Nose cavities,
when present, define what are generally referred to as hollow-point
bullets and may be left void or, alternatively, may be filled with
soft metal, plastic, or other material that is configured to
facilitate expansion and/or fragmentation of the bullet upon impact
with soft targets. Optional heel cavities, when present, may be
filled with a metal, or other material, having a greater density
than that of the clad wire's inner core, for example, to configure
a desired mass distribution along the length of the bullet.
[0065] One or more of these various optional features of bullets
discussed may be formed during, for example, a working step, an
upsetting step, a machining step, and/or an additional step
performed after the discussed steps of methods 150 according to the
present disclosure. It is within the scope of the present
disclosure, however, that bullets formed according to methods 150
not include any of these various additional and optional
features.
[0066] The methods 100 illustrated in the flowcharts of FIGS. 7 and
10-11 are examples of methods 100 in which ammunition shot is
formed. These methods are indicated generally at 350 in FIGS. 7 and
10-11 and may more specifically be described as methods of forming
ammunition shot from a length of clad wire. The three flowcharts of
FIGS. 7 and 10-11 illustrate various steps, some of which are
common to the three illustrated flowcharts and others which are
exclusive to only one or two of the illustrated flowcharts.
However, as discussed herein, it is within the scope of the present
disclosure that various steps of one illustrated flowchart may also
be utilized in the method of another illustrated flowchart, and
methods according to the present disclosure are not limited
exclusively to the illustrated steps of each flowchart. All three
of the illustrated methods of FIGS. 7 and 10-11 include an optional
step 352, in which clad wire is first drawn, swaged, or otherwise
reduced in diameter to a desired size of ammunition shot. Step 352
may be described as reducing a standard gauge clad wire from a
standard gauge diameter to a reduced diameter, with such reduced
diameter corresponding at least approximately to a desired diameter
of the ammunition shot being formed. This step is optional,
however, as it is also within the scope of the present disclosure
that ammunition shot be formed with diameters generally
corresponding to standard gauge clad wire. Moreover, as discussed
herein, it is also within the scope of the present disclosure that
clad wire be formed with a desired diameter corresponding to a
desired diameter of projectile (e.g., ammunition shot) that does
not necessarily correspond to a standard gauge of clad wire.
[0067] Referring first to FIG. 7, which illustrates a first method
400 of forming ammunition shot, a length of clad wire is worked to
form a string of interconnected beads, as indicated at 402, such as
in which each bead has a dimension generally corresponding to a
desired diameter of the ammunition shot being formed. That is, a
string of beads is formed in which generally spherical pellets, or
shot, are interconnected by generally cylindrical connecting
portions of the clad wire that are reduced in diameter during the
working step. Examples of suitable working processes include (but
are not limited to) roll-forming, heading, and stamping.
[0068] Methods 400 according to the present disclosure will
typically include a cutting step 404, as optionally illustrated in
FIG. 7, to separate the individual beads, or pellets, from each
other. The cutting may include a shearing process, for example,
resulting in a generally flat, or planar, separation surface, in
which the inner core material of the clad wire is at least
partially exposed. An example of an individual shot, or pellet,
with these characteristics is schematically illustrated in
cross-section in FIG. 8 and is indicated generally at 50. Despite
the potential for flat surfaces having exposed metal from the inner
core of the clad wire, this exposed inner core metal will not
actually be permitted (or substantially will not be permitted) to
come into contact with the inside surface of a firearm barrel,
simply due to the geometric shape of the individual pellet and the
cylindrical inside surface of a firearm barrel. Accordingly, even
when utilizing a steel clad wire, in which the steel is generally
thought to be potentially damaging to the inside surface of a
firearm barrel, the steel of a shot 50 will not actually come into
contact with the inside surface of the barrel.
[0069] Additionally or alternatively, the individual beads may be
pinched from the string of beads during the cutting step, such as
utilizing a rolling process, for example, resulting in a more
spherical pellet in which the cladding of the clad wire wraps
around the metal from the inside of the clad wire so that
individual pellets substantially do not include exposed metal from
the inner core of the clad wire. An example of an individual
pellet, or shot, with these characteristics is schematically
illustrated in cross-section in FIG. 9 and is indicated generally
at 60.
[0070] Next, as indicated at 406, the individual pellets cut from
the string of beads may be further refined, rounded, or finished,
into a more spherical shape. An illustrative, non-exclusive example
of a suitable finishing process includes tumbling the individual
pellets; however, any other appropriate process for generally
refining or rounding the individual pellets into a desired shape
for ammunition shot is also within the scope of the present
disclosure.
[0071] The optional step 214 of treating the surface of the formed
ammunition shot may be performed. Examples of surface treating
processes include (but are not limited to) electroplating,
painting, passivating, and plastic coating. Such processes may be
performed for functional purposes such as to import a
corrosion-resistant coating to the shot and/or for aesthetic
purposes, such as in the example of forming a shot 50, in which the
inner metal of the clad wire is at least partially exposed. Despite
the geometric limitations of this exposed inner metal being able to
contact the inside surface of a firearm barrel, some consumers,
such as those that load their own cartridges, may find the
appearances of shot 50 less than optimal, when in fact they may
function just as well as traditional shot and shot 60 according to
the present disclosure.
[0072] Finally, it is within the scope of methods 350 according to
the present disclosure to include a loading step 216 to load the
formed ammunition shot into a cartridge, such as into a standard
caliber shotgun cartridge. This step is optional, however, because
shot is often sold in bulk, for example, for consumers to load, and
reload, their own cartridges.
[0073] Still referring to FIG. 7, it is noted that a straightening
step is not illustrated. Accordingly, methods 400 may be utilized
with clad wire that is already straight, such as that is
manufactured, or least received in a straight, bar, or rod
configuration. The flowchart of FIG. 7, however, also illustrates
methods 400 in which coiled clad wire is utilized and a
straightening step is simply not required. In such examples, the
methods may be described as coil-fed methods, and the working step
402 and cutting step 404 may be appropriately configured so that
coiled clad wire may be utilized as a supply of clad wire.
[0074] Turning now to the flowchart of FIG. 10, a second method 350
according to the present disclosure is schematically illustrated
and is indicated generally at 500. Methods 500 according to the
present disclosure include a straightening step 206, which, as
discussed herein, may be utilized when a supply of coiled clad wire
is used. After straightening the coiled clad wire, the clad wire
may then be cut into lengths of straight clad wire, as indicated at
502. These lengths of straight clad wire may be of any suitable
length that is appropriate for facilitating subsequent steps of
methods 500. As an illustrative, non-exclusive example, lengths of
approximately 12 feet may be suitable; however, lengths greater
than and less than 12 feet also may be used.
[0075] After the cutting step 502 of methods 500, the lengths of
clad wire may then be worked, cut and finished into individual
pellets, or shot, utilizing steps 402, 404, and 406, respectively.
However, because the clad wire is not maintained in a coiled
configuration, a method 500 may be described as a bar-, or rod-,
fed method. Optional surface treating and loading steps 214 and
216, respectively, are also illustrated in the flowchart of FIG. 10
and are within the scope of methods 500 according to the present
disclosure.
[0076] The flowchart of FIG. 11 schematically illustrates yet
another variation of methods 350 of forming ammunition shot.
Specifically, FIG. 11 illustrates a method 600 in which a cutting
step 602 cuts off an individual pellet mass from a supply of clad
wire, for example, corresponding to a desired mass of ammunition
shot being formed. This cutting step may result in a generally
cylindrical length of clad wire, such as by utilizing a shearing
process to cut off the individual pellet masses. Additionally or
alternatively, a rolling, or other process, may be utilized in
which lengths of clad wire are pinched off, resulting in the
cladding of the clad wire wrapping around at least a portion, and
optionally a substantial portion, of the inner core of the clad
wire, thereby resulting in little, and optionally substantially
none, of the metal of the inner core being exposed on the outer
surface of the individual pellet masses after the cutting step.
This optional process may result in ammunition shot 60, such as
schematically illustrated in FIG. 9 and discussed herein, being
formed.
[0077] Following the cutting step, a working step 604 may then be
performed on the individual pellet masses, as illustrated in FIG.
11. This working step may, for example, include heading or swaging
the pellet masses to round them into a generally spherical shape.
This working step is illustrated as optional in FIG. 11, because
depending on the form of the pellet masses resulting from the
cutting step, a further rounding of the pellet masses may not be
required. For example, as mentioned, the cutting step itself may
result in a generally spherical pellet. Finally, the individual
pellets may be finished and optionally treated and loaded in steps
406, 214, and 216, respectively, as illustrated in FIG. 11.
[0078] In addition to the various specific processes and steps of
methods illustrated in the flowcharts of the Figures and discussed
herein, other optional processes may be utilized in the forming of
ammunition projectiles pursuant to methods according to the present
disclosure. As illustrative, non-exclusive examples, the following
paragraphs discuss a few of such optional processes that are within
the scope of the present disclosure and that may be incorporated
into methods according to the present disclosure.
[0079] (1) Alternate clad alloys may be used in copper-clad steel
production runs without significantly modifying equipment. For
example, copper alloy (e.g., 95Cu-5Zn "gilding metal") may be
substituted for normal high-conductivity grades of pure copper.
[0080] (2) If conventional pure copper cladding is found to be too
soft for a particular ammunition projectile type, surface hardening
may be accomplished by shot-peening, burnishing, et al.
[0081] (3) Whereas plain-carbon steels such as AISI 1006 and AISI
1022 are conventionally used for electrical copper-clad steel wire
core material, substituting alternate types of steel (e.g.,
free-machining grades) is an available option.
[0082] (4) Properties of cladding and/or core materials may be
modified by different types of metal-working, heat-treating, and/or
combinations thereof, provided that good metallurgical practices
are followed for both material types of the composite. For example,
if it were desirable to anneal a copper-clad steel bullet
consisting of pure, high-conductivity electrolytic tough pitch
(ETP) copper over a steel core, consideration would need to be
given to final annealing atmosphere. Using a reducing-gas
atmosphere (to minimize steel oxidation) could potentially result
in stress-corrosion-cracking of ETP copper, induced by the
reduction of copper-oxide precipitates at grain boundaries. In this
example, a remedy may be to substitute oxygen-free,
high-conductivity (OFHC) copper as cladding.
[0083] (5) In addition to conventional coatings and lubricants
(e.g., for corrosion-resistance), the use of additional surface
coatings, such as stearates, molybdenum-disulfide, graphite,
polymeric films, et al. may advantageously reduce friction, barrel
fouling, etc.
[0084] Because of the availability of many processing options for
the various methods of the present disclosure, it is within the
scope of the present disclosure to design customized fabrication
processes to be design-specific for individual customer
specifications. For example, if a customer desires a rifle bullet
for extremes of velocity and barrel "twist rate" (barrel length, in
inches, per revolution) with exceptionally high penetrating
strength, one may select a work-hardened copper-zinc alloy cladding
over a higher-carbon or alloy steel (properly heat-treated). It is
within the scope of the present disclosure to supply customized
clad wire bullet "starting blanks" to specific customer
specifications and bullet designs, such as to enable customers to
produce their own proprietary ammunition projectiles.
[0085] Illustrative, non-exclusive examples of inventions according
to the present disclosure are presented in the following enumerated
sentences. It is within the scope of the present disclosure that an
individual step of a method recited herein, including in the
following enumerated sentences, may additionally or alternatively
be referred to as a "step for" performing the recited action.
[0086] A A method, comprising:
[0087] forming a bullet from a length of clad wire, wherein the
bullet is configured to be received within a standard caliber
firearm cartridge.
[0088] A1 The method of paragraph A, wherein the clad wire is clad
steel wire.
[0089] A1.1 The method of paragraph A1, wherein the clad steel wire
is one of copper-clad steel wire, aluminum-clad steel wire,
tin-clad steel wire, and zinc-clad steel wire.
[0090] A1.2 The method of paragraph A1, wherein the clad steel wire
is copper-clad steel wire.
[0091] A1.2.1 The method of paragraph A1.2, wherein the thickness
of the copper cladding of the copper-clad steel wire is at least
one of at least 2%, at least 3%, at least 5%, at least 7%, at least
9%, between about 2% and about 10%, about 3%, about 6.5%, and about
10% of the diameter of copper-clad steel wire.
[0092] A2 The method of any of paragraphs A-A1.2.1, wherein the
length of clad wire is from a supply of coiled clad wire.
[0093] A2.1 The method of paragraph A2, further comprising:
[0094] prior to the forming, straightening the length of clad
wire.
[0095] A3 The method of any of paragraphs A-A2.1, wherein the
forming includes:
[0096] reducing a standard gauge clad wire from a standard gauge
diameter to a reduced diameter.
[0097] A3.1 The method of paragraph A3, wherein the reduced
diameter corresponds at least approximately to a diameter
associated with the standard caliber firearm cartridge.
[0098] A3.2 The method of any of paragraphs A3-A3.1, wherein the
reducing includes drawing the standard gauge clad wire.
[0099] A3.3 The method of any of paragraphs A3-A3.2 (only when
depending from paragraph A2 and not depending from paragraph A2.1),
wherein the forming further includes:
[0100] after the reducing, straightening the length of clad
wire.
[0101] A4 The method of any of paragraphs A-A3.3, wherein the
forming includes:
[0102] (after the steps of any of paragraphs A3-A3.2 and prior to
the step of paragraph A3.3 when depending therefrom) heat-treating
the clad wire.
[0103] A4.1 The method of paragraph A4, wherein the heat-treating
includes annealing.
[0104] A5 The method of any of paragraphs A-A4, wherein the forming
includes:
[0105] (after the steps of any of paragraphs A3-A4.1 when depending
therefrom) cutting the clad wire into a bullet length.
[0106] A6 The method of any of paragraphs A-A5, wherein the forming
includes:
[0107] (after the steps of any of paragraphs A3-A5 when depending
therefrom), working the clad wire into a near-final configuration
of the bullet.
[0108] A6.1 The method of paragraph A6, wherein the working
includes at least one of heading, swaging, and rolling to form the
near-final configuration of the bullet.
[0109] A6.2 The method of any of paragraphs A6-A6.1, wherein the
working includes forming a nose of the bullet.
[0110] A6.2.1 The method of paragraph A6.2, wherein the forming
includes forming the nose of the bullet so that the cladding of the
clad wire remains on at least a substantial portion of an outer
surface of the nose of the bullet.
[0111] A7 The method of any of paragraphs A-A2.1, wherein the
forming includes:
[0112] enlarging a diameter of a length of clad wire from a
standard gauge diameter to an enlarged diameter.
[0113] A7.1 The method of paragraph A7, wherein the enlarged
diameter corresponds at least approximately to a diameter
associated with the standard caliber firearm cartridge.
[0114] A7.2 The method of any of paragraphs A7-A7.1, wherein the
enlarging includes compressing the length of clad wire in a die
with a punch.
[0115] A7.3 The method of any of paragraphs A7-A7.2, wherein the
forming further includes:
[0116] prior to the enlarging, cutting the length of clad wire from
a supply of clad wire.
[0117] A7.4 The method of any of paragraphs A7-A7.3, wherein the
forming further includes:
[0118] after the enlarging, heat treating the length of clad wire.
A7.4.1 The method of paragraph A7.4, wherein the heat treating
includes annealing.
[0119] A8 The method of any of paragraphs A-A7.4.1, wherein the
forming includes:
[0120] (after the steps of any of paragraphs A2-A7.4.1 when
depending therefrom) machining the length of clad wire.
[0121] A8.1 The method of paragraph A8, wherein the machining
includes machining to form a final configuration of the bullet.
[0122] A8.1.1 The method of paragraph A8.1, wherein the final
configuration includes at least a nose.
[0123] A8.1.1.1 The method of paragraph A8.1.1, wherein the final
configuration includes one or more of a driving band, a groove, a
cannelure, a heel cavity, a nose cavity, and a boat tail.
[0124] A8.1.1.2 The method of any of paragraphs A8.1.1-A8.1.1.1,
wherein the nose includes exposed metal from the inside of the clad
wire.
[0125] A9 The method of any of paragraphs A-A8.1.1.2, wherein the
forming further includes:
[0126] (after the steps of any of paragraphs A2-A7.1.1.2 when
depending therefrom) coating the bullet.
[0127] A9.1 The method of paragraph A9, wherein the coating
includes one or more of electroplating, painting, passivating, and
plastic coating.
[0128] A9.2 The method of any of paragraphs A9-A9.1, wherein the
coating includes imparting a corrosion-resistant coating to the
bullet.
[0129] A10 The method of any of paragraphs A-A9.1, further
comprising:
[0130] prior to the forming, obtaining a supply of the clad wire
from a third party.
[0131] A10.1 The method of paragraph A10, wherein the third party
manufactures the clad wire as electrical wire.
[0132] A11 The method of any of paragraphs A-A9.2, wherein the
forming includes:
[0133] manufacturing the clad wire.
[0134] A11.1 The method of paragraph A11 (when not depending from
any of paragraphs A3-A3.3 and A7-A7.4.1), wherein the clad wire has
a diameter suitable for forming the bullet without requiring the
steps of either of paragraphs A2 or A3.
[0135] A12 The method of any of paragraphs A-A11.1, further
comprising:
[0136] after the forming, loading the bullet into a standard
caliber firearm cartridge.
[0137] A12.1 A firearm cartridge manufactured according to the
method of paragraph A12.
[0138] A13 A firearm cartridge containing a bullet manufactured
according to the method of any of paragraphs A-A11.1
[0139] A14 A bullet manufactured according to the method of any of
paragraphs A-A11.1
[0140] B A method, comprising:
[0141] forming ammunition shot from a length of clad wire.
[0142] B1 The method of paragraph B, wherein the clad wire is clad
steel wire.
[0143] B1.1 The method of paragraph B1, wherein the clad steel wire
is one of copper-clad steel wire, aluminum-clad steel wire,
tin-clad steel wire, and zinc-clad steel wire.
[0144] B1.2 The method of paragraph B1, wherein the clad steel wire
is copper-clad steel wire.
[0145] B1.2.1 The method of paragraph B1.2, wherein the thickness
of the copper cladding of the copper-clad steel wire is at least
one of at least 2%, at least 3%, at least 5%, at least 7%, at least
9%, between about 2% and about 10%, about 3%, about 6.5%, and about
10% of the diameter of copper-clad steel wire.
[0146] B2 The method of any of paragraphs B-B1.2.1, wherein the
length of clad wire is from a supply of coiled clad wire.
[0147] B2.1 The method of paragraph B, further comprising:
[0148] prior to the forming, straightening the length of clad
wire.
[0149] B2.1.1 The method of paragraph B2.1, further comprising:
[0150] after the straightening, cutting the length of clad wire
from the supply of clad wire.
[0151] B3 The method of any of paragraphs B-B2.1.1, wherein the
forming includes:
[0152] working the clad wire into a plurality of interconnected
beads, wherein each bead has a dimension generally corresponding to
a desired diameter of the ammunition shot.
[0153] B3.1 The method of paragraph B3, wherein the working
includes one or more of heading and roll-forming to form the
plurality of interconnected beads.
[0154] B3.2 The method of any of paragraphs B3-B3.1, wherein the
plurality of interconnected beads is a plurality of interconnected
generally spherical beads.
[0155] B3.3 The method of any of paragraphs B-B3.2, wherein the
forming further includes:
[0156] separating the plurality of interconnected beads into
individual pellets.
[0157] B4 The method of any of paragraphs B-B2, wherein the forming
includes:
[0158] cutting individual pellets from the length of clad wire,
wherein the length of clad wire generally corresponds to a desired
diameter of the ammunition shot.
[0159] B4.1 The method of paragraph B4, wherein the forming further
includes:
[0160] after the cutting, rounding the individual pellets into
generally spherical pellets.
[0161] B4.1.1 The method of paragraph B4.1, wherein the rounding
includes one or more of heading and swaging.
[0162] B5 The method of any of paragraphs B3.3-B4.1, wherein the
individual pellets are generally spherical.
[0163] B6 The method of any of paragraphs B3.3-B5, wherein
individual pellets include exposed metal from the inside of the
clad wire.
[0164] B6.1 The method of paragraph B6, wherein the exposed metal
defines generally flat surfaces.
[0165] B7 The method of any of paragraphs B3.3-B5, wherein
individual pellets substantially do not include exposed metal from
the inside of the clad wire.
[0166] B7.1 The method of paragraph B7, wherein the forming
includes pinching the clad wire to form the individual pellets so
that the cladding wraps around the metal from the inside of the
clad wire.
[0167] B8 The method of any of paragraphs B3.3-B7.1, wherein the
forming further includes:
[0168] rounding the individual pellets.
[0169] B8.1 The method of paragraph B8, wherein the rounding
includes tumbling the individual pellets.
[0170] B9 The method of any of paragraphs B3.3-B8.1, wherein the
forming further includes:
[0171] (after the steps of any of paragraphs B3.3-B8.1) coating the
individual pellets.
[0172] B9.1 The method of paragraph B9, wherein the coating
includes one or more of electroplating, painting, passivating, and
plastic coating.
[0173] B9.2 The method of any of paragraphs B9-B9.1, wherein the
coating includes imparting a corrosion-resistant coating to the
individual pellets.
[0174] B10 The method of any of paragraphs B3-B9.2, wherein the
forming further includes:
[0175] (prior to the steps of any of paragraphs B3-B9.2 and
optionally prior to the step of paragraph B2.1 when depending
therefrom) reducing a standard gauge clad wire from a standard
diameter to a reduced diameter.
[0176] B10.1 The method of paragraph B10, wherein the reduced
diameter corresponds at least approximately to a desired diameter
of the ammunition shot.
[0177] B10.2 The method of any of paragraphs B10-B10.1, wherein the
reducing includes drawing the standard gauge clad wire.
[0178] B11 The method of any of paragraphs B-B10.2, further
comprising:
[0179] prior to the forming, obtaining a supply of the clad wire
from a third party.
[0180] B11.1 The method of paragraph B, wherein the third party
manufactures the clad wire as electrical wire.
[0181] B12 The method of any of paragraphs B-B10.2, wherein the
forming includes:
[0182] manufacturing the clad wire.
[0183] B12.1 The method of paragraph B12 (when not depending from
any of paragraphs B10-B10.2), wherein the clad wire has a diameter
corresponding at least approximately to a desired diameter of the
ammunition shot.
[0184] B13 The method of any of paragraphs B-B12.1, further
comprising:
[0185] after the forming, loading the ammunition shot into a
standard caliber firearm cartridge.
[0186] B13.1 A firearm cartridge manufactured according to the
method of paragraph B13.
[0187] B14 A firearm cartridge containing shot manufactured
according to the method of any of paragraphs B-B12.1.
[0188] B15 Ammunition shot manufactured according to the method of
any of paragraphs B-B12.1.
[0189] In the event that any of the references that are
incorporated by reference herein define a term in a manner or are
otherwise inconsistent with either the non-incorporated portion of
the present disclosure or with any of the other incorporated
references, the non-incorporated portion of the present disclosure
shall control, and the term or incorporated disclosure therein
shall only control with respect to the reference in which the term
is defined and/or the incorporated disclosure was originally
present.
[0190] As used herein the terms "adapted" and "configured" mean
that the element, component, or other subject matter is designed
and/or intended to perform a given function. Thus, the use of the
terms "adapted" and "configured" should not be construed to mean
that a given element, component, or other subject matter is simply
"capable of" performing a given function but that the element,
component, and/or other subject matter is specifically created for
the purpose of performing the function. It is also within the scope
of the present disclosure that elements, components, and/or other
recited subject matter that is recited as being adapted to perform
a particular function may additionally or alternatively be
described as being configured to perform that function, and vice
versa.
[0191] The disclosure set forth above encompasses multiple distinct
inventions with independent utility. While each of these inventions
has been disclosed in its preferred form or method, the specific
alternatives, embodiments, and/or methods thereof as disclosed and
illustrated herein are not to be considered in a limiting sense as
numerous variations are possible. This present disclosure includes
all novel and non-obvious combinations and subcombinations of the
various elements, features, functions, properties, methods, and/or
steps disclosed herein. Similarly, where any disclosure above or
claim below recites "a" or "a first" element, step of a method, or
the equivalent thereof, such disclosure or claim should be
understood to include incorporation of one or more such elements or
steps, neither requiring nor excluding two or more such elements or
steps.
[0192] It is believed that the following claims particularly point
out certain combinations and subcombinations that are directed to
one of the disclosed inventions and are novel and non-obvious.
Inventions embodied in other combinations and subcombinations of
features, functions, elements, properties, methods, and/or steps
may be claimed through amendment of the present claims or
presentation of new claims in this or a related application. Such
amended or new claims, whether they are directed to a different
invention or directed to the same invention, whether different,
broader, narrower, or equal in scope to the original claims, are
also regarded as included within the subject matter of the
inventions of the present disclosure.
INDUSTRIAL APPLICABILITY
[0193] The methods and ammunition projectiles of the present
disclosure are applicable to the firearm and ammunition fields.
* * * * *