20070600 blended metal technology projectiles review and analysis_redacted

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AD-E403 121

Technical Report ARAET-TR-07009

BLENDED METAL TECHNOLOGY PROJECTILES

REVIEW AND ANALYSIS

Shawn P. Spickert-FultonJeffrey Schutz

June 2007

Further dissemination only as directed by U.S. Army ARDEC, ATTN: AMSRD-AAR-EMK, PicatinnyArsenal, NJ 07806-5000; June 2007; or higher DoD authority.

AD

ARMAMENT RESEARCH, DEVELOPMENT ANDENGINEERING CENTER

Armaments Engineering & Technology Center

Picatinny Arsenal, New Jersey


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The views, opinions, and/or findings contained in thisreport are those of the author(s) and should not beconstrued as an official Department of the Army posi-tion, policy, or decision, unless so designated by otherdocumentation.

The citation in this report of the names of commercialfirms or commercially available products or services doesnot constitute official endorsement by or approval ofthe U.S. Government.

Destroy this report when no longer needed by any methodthat will prevent disclosure of its contents or reconstructionof the document. Do not return to the originator.


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BLENDEDMETALTECHNOLOGYPROJECTILESREVIEWANDANALYSIS

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ShawnP.Spickert-FultonandJeffreySchutz

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FurtherdisseminationonlyasdirectedbyU.S.ArmyARDEC,ATTN:AMSRD-AAR-EMK,PicatinnyArsenal,NJ07806-5000;June2007;orhigherDoDauthority.13.SUPPLEMENTARYNOTES

14.ABSTRACTLeMasLtd.promotedaseriesofpatentedblendedmetaltechnology(BMT)RBCDprojectilesandassertedthattheyaresuperiortomilitaryandlawenforcementalternatives.Thislightweight,highvelocity,smallarmsammunitionperformedwellatshootingcompetitionswhereitexhibitedtheabilitytoperforateasteelplate,automobileglass,andselecttargets.TheLeMascartridgesweremarketedwithclay,meat,andliveanimalteststhatprovedthepurportedeffectivenessoftheproduct.Theclaimsofcontrolled,buteffectivepenetrationgainedtheattentionofCongress,whichissueda$1,050,000defenseappropriationtoUSSOCOMtosupportgovernment-widetestingofrevolutionarysmallarmsammunitionwithfullspectrumoflethalandpenetratingeffects.USSOCOMtookthemandateandformedajointserviceIPTthatincludedparticipationfromtheNavy,Army,USSOCOM,FBI,andOSD.ThisIPTthenproceededtoprocureandtestseveralmodelsofLeMasammunitionincluding9mm,5.56mm,and7.62mmvariants.ThetestshowedthattheLeMasriflecartridgeswereconstructedwithcommercialbulletsthatweremarkedwithathincoatingofmolybdenumdisulfide(adrylubricant).OperationaltestswiththeammunitionshowedthattheLeMasprojectilesperformedwellagainstspecifictargetsinspecificscenarios,butdonotmeettherangeofrequirements,specifications,andoperationalneedsthatarerequired.Additionally,LeMasammunitioncomeswithadditionallogisticalcomplexitiesandahighcomparativecost.ThissurveyreportsummarizestheeffortsofCrane,ARDEC,theFBEAcademy,USSOCOM,andotherstotestLeMasammunitioninafairandunbiasedmanner.ItoutlineswhatLeMasammunitionis;isitsafe;howitperforms;andhowitcompareswiththeM855,M118LR,M882,andsome

commercialequivalents.Someeffortisalsomadetoshowthecomparativeperformanceofpowdermetallurgyprojectilestocurrentoptions.15.SUBJECTTERMSLeMas,RBCD,Blendedmetaltechnology(BMT),Molybdenum,Gelatin,Clay,Liveanimal,Steel,Armor,Glass,Pig,Goat,Hardtarget,Softtarget,Exteriorballistics,Woundballistics,Terminalballistics,Lethality,Smallarms,Ammunition,Pistol,Sierra,Nosler,Speer,ARL,FBI,Crane,M855,M882,M118LR,5.56mm,7.62mm,9mm,EPVAT,(P/M),Lightweight,Softpoint,andBallistictip.16.SECURITYCLASSIFICATIONOF: 19a.NAMEOFRESPONSIBEPERSON

ShawnSpickert-Fulton/JeffreySchutza.REPORT

Ub.ABSTRACT

Uc.THISPAGE

U

17.LIMITATIONOFABSTRACT

SAR

18.NUMBEROFPAGES

16919b.TELEPHONENUMBER(Includearea

code)(973)724- StandardForm298(Rev.8/98PrescribedbyANSIStd.Z39.18

(b) (6)


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CONTENTS

PageExecutiveSummary 1

PreliminaryIPTMeetingwithLeMasLtd. 2 InitialTests 3 PreludetoOperationalandSafetyTests 5 ExecutiveSummaryConclusions 7Introduction 8 InitialIPTMeeting(February2004) 8 2004JS-IPTProposedPlan 9 TaskDistribution 10 FundingandCosts 11

LeMasLTD.MarketingClaims 11 MostSignificantTechnologicalAdvancement 11 ProduceImmediateZeroMissionCapability 12 Non-comparablePerformanceinLivingTissue 13 ProduceEnhancedFragmentationPatterns 14 UniqueManufacturingProcess 15 UsedLeadFreeComponents 15 PatentedAmmunitionProducts 15WhatisBlendedMetalTechnology(BMT) 15 LeMasLtd.DefinitionofBMT 15 AmericanSocietyofMetals(ASM)DefinitionofBlendingMetals 16 UnitedStatesPatentNo.US6,363,856B1 16AnalysisofLeMas(RBCD)Projectiles 18 VisualTests 19 MetallurgicalandStructuralTests 35 SpectrometryandX-rayTests 52PerformanceAnalysisofLeMas(RBCD)Projectiles 57 AmmunitionPerformanceStatistics 57

SafetyandOperationalTests 62 AccuracyandDispersionTests 84 ArmorPenetrationTests 100 SoftTarget/TissueSimulant(BallisticGelatin)Tests 104HistoricalAnimalTestswithSoftPointProjectiles 127

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CONTENTS

PageReviewAvailableInformationonGovernmentTestsDoneonTrue(P/M)Type 129Projectiles

PowderMetallurgyIronFrangibleBulletTest 130 ControlledPenetration(PressedMetalPowder)ProjectileTest 130 ARDEC2002TerminalBallisticsEffort 131ComparisonofLeMasProjectilePerformanceand(P/M)ProjectilePerformance 132AssessmentofLeMasMarketingClaims 132 MostSignificantTechnologicalAdvancement 132 ProduceImmediateZeroMissionCapability 133 VariedPenetrationBasedonTarget 133

Non-comparablePerformanceinLivingTissue 134 ProducedEnhancedFragmentationPatterns 136 CauseHeatGeneratedBlisteringinSoftOrganStructures 137 UniqueManufacturingProcess 37 UseLeadFreeComponents 137 PatentedAmmunitionProducts 138Conclusions 138References 139Appendices ABasicWeaponStatistics 141 BIndependentTesting 147DistributionList 153

FIGURES1 LeMasUWandNoslerballistictipprojectilecrosssectionsandmoldnumber 42 LeMasUWcartridgewithNoslerballistictipbulletcoatedwithmolybdenumdisulfide 4

3 Sample7.62-mmhardtargetpenetrationphotographs 64 Cranehardtargettest 75 LeMasLtd.marketingpictureshowingarmorplatepenetration 13

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FIGURES(continued)

Page

6 PurportedeffectoftemperatureonBMTperformance 14

7 RoscoeStokerspatentedprojectilediagram 168 RoscoeStokerspatentedprojectiledesign 189 Breakoutofammunitionforthiseffort 19

10 LeMas5.56-mmblendedmetalprojectiles[UW(left)andLW(right) 1911 FBIvisualinspectionoftheLeMasUWcartridge 2012 InitialFIcomparisonofLeMas/RBCDUWtosimilarprojectiles 20

13 FBIweightcomparisonbetweenUWandNoslerprojectiles 2114 VisualcomparisonbetweenNoslerballistictipandLeMasUWdesign 2115 FBIphotographshowingNoslerstylemoldnumbersonLeMasUWprojectiles 2216 SidebysideNoslerandUWprojectilecrosssectionvisualinspection 2217 NoslerandLeMasblendedmetalUWprojectiles(moldnumbersfoundonboth 23 projectilestested)(ARDECphotograph)18 AsReceivedLeMasprojectilepictures 2419 SidebysideSierraandLWprojectileas-isvisualinspection 2520 SidebysideSierraandLWprojectilecrosssectionvisualinspection 2621 7.62-mmLeMasLWprojectile(ARDECasreceived) 2722 LeMasUW(left)andLeMasLW(right)jacketexamination 2723 Dimensionalmeasurementsofcrosssectioned5.56-mmprojectiles 2824 USSOCOM5.56-mmvisualinspectiontests 29

25 Basicdescriptionofthe7.62x51-mmtestammunition 3026 Basicdescriptionandphotographsofthe9x19-mmtestammunition 3127 Dimensionalmeasurementstakenontestammunition 32

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FIGURES(continued)

Page

28 UWcrosssectionimageshowinglocationsofmicrostructureanalyzed 36

29 LeMasUWleadcoremicrostructure 3630 UW(Nosler)copperjacketmicrostructureimages 3731 UWcartridgemicrostructure 3732 Noslerballistictipmicrostructure 3833 LWcrosssectionimageshowinglocationsofmicrostructureanalyzed 3934 LWleadcoremicrostructure 39

35 LW(Sierra)copperjacketmicrostructureimages 4036 LWcartridgemicrostructure 4037 SierraVarmintemicrostructure 4138 ResultsofthreeseparatemicrohardnessreadingsonNoslerandLeMas 43 ammunitionsamples39 Repeatabilityofmachinescriteriaformicrohardnesstests 4340 ResultsofthreeseparatemicrohardnessreadingsonSierraandLeMas 45 ammunitionsamples41 Bondedtestsamples(NoslerandUW) 4642 Bondedtestsamples(SierraandLW) 4743 LocationsforVickersDPNhardnessmeasurements5.56-mmcartridgecases 4844 LocationsforVickersDPNhardnessmeasurements7.62-mmcartridgecases 4945 LocationsforVickersDPNhardnessmeasurement9-mmcartridgecases 50

46 Illustrationofbulletcrimp 5147 ExampleUW(Nosler)corechemistryspectrumresult 5248 ExampleUWjacketchemistryspectrumresult 53

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FIGURES(continued)

Page

49 UWjacketcoatingchemistryspectrumresult 53

50 UWandNoslerballistictipcomparativechemicalanalysis 5451 LWcorechemistryspectrumresult 5452 LWjacketchemistryspectrumresult 5553 LWjacketcoatingchemistryspectrumresult 5554 LeMasLWandSierraVarmintercomparativechemicalanalysis 5655 Averagecasemouthpressureversustemperaturefor9-mmammunition 69

56 TestsheetshowingM9weapondamage 7057 BlownprimersandextrudedbulletcorematerialLeMas9-mmEPVATtest-40F 7158 SampleARDECEPVATcurvesforLeMasLW(Sierra)ammunition 7259 Additionalblownprimers(9-mmLeMas)observedduring-40Fvelocitytesting 7660 Bubbletestresults(5.56mm) 7861 Bubbletestresults(7.62mm) 79

62 Bubbletestresults(9mm) 7963 5.56-mmFNM16A4bulletbreak-upresults 8264 BulletRPMversustwistrate(M16A4andM4A1) 8265 Universalbondreceiver/Mann-typebarrel 8466 Dispersion/accuracyrelationship 8567 Definitionsofdispersionmeasurements 8568 5.56-mmextremespreadresults(100mand300m) 8769 7.62-mmextremespreadresults(100mand300m) 8870 9-mmextremespreadresults(25mand50m) 88

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FIGURES(continued)

Page

71 Pistolandrifleweaponmounts 89

72 Average5.56-mmextremespreadM4A1dataonscaledtargets 9273 7.62-mm(Mk11)extremespreadonscaledtargets 9574 9-mmextremespreadonscaledtargets(25m) 9875 Armorpenetrationtestsetup 10076 Cardboardwitnessmaterials 10077 Example5.56-mmshotsagainst3/8-in.AR-500(steelplate) 101

78 Example7.62-mmshotsagainst3/8-in.AR-500steelplate 10279 Example9-mmshotsagainst3/8-in.AR-500steelplate 10380 Cranehardtarget(R50)testdata 10481 Dziemanscomparisonofbulletwoundtractdimensions(ingoats)andenergy 106 absorptionfrombulletsby20%gelatintissuemodels82 Velocitydecaycurvedataformahistorical1960scomparativetest 10683 Historicalcomparisonsofgelatinandtissue 10784 Samplevelocitydecaycurves(m/s)versusdepthofpenetration(cm)forSierra 108 andM855projectilewhenfiredinto10%gelatinsimulant85 Sampleenergydepositcurves(J/cm)versusdepthofpenetration(cm)forSierra 109 andM855projectileswhenfiredinto10%gelatinsimulantattworanges86 Relevantgelatinblockfeatures 11187 SampleM4A15-mbaregelatinresults 11288 SampleM4A1100-mbaregelatinresults 113

89 SampleM4A1300-mbaregelatinresults 11490 SampleM16A4baregelatinshots 115

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FIGURES(continued)

Page

91 Theshotthatchangedlawenforcementammunitioncriteria 115

92 SampleMk115-mbaregelatin 11693 SampleMk11100-mbaregelatin 11694 SampleMk11300-mbaregelatin 11795 SampleM8pistol5-mbaregelatin 11896 SampleM9pistol25-mbaregelatin 11897 SampleM4A15-mautoglassresults 119

98 SampleM16A45-mautoglassresults 12099 SampleM4A1100-mautoglassresults 120100 SampleM16A4100-mautoglassresults 120101 SampleM4A1300-mautoglassresults 121102 SampleM16A4300-mautoglassresults 121103 Non-lethaldesignsthatdonotpenetrateskin,butdopenetrategelatin(about3in.) 122104 SampleMk115-mautoglasstarget 123105 SampleMk11100-mautoglasstarget 124106 SampleMk11300-mautoglasstarget 124107 SampleM9pistol5-mautoglasstarget 125108 SampleM9pistol25-mautoglasstarget 125109 .220Winchestersoftpoint 128

110 Sampledamagepictures 129111 Sample.220Winchestershotintogelatin 129112 SNCCPApenetrationresultsagainstvariousbarriersandgelatinat25and300m 131

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FIGURES(continued)

Page

113 JohnHamilton(right)talksafterdemonstratingablendedmetalroundagainstclay 134

114 SamplemaximumdynamiccavityimageM855andLeMasLW(Sierra)(5mtest 135 withM4)115 Easonsstrikingenergyversusenergyabsorbedforchromesteelspheres 135

TABLES1 CartridgedesignspurchasedfromLeMasLtd. 32 Costcomparisons 3

3 Projectilesurrogates 64 Proposedtestbreakdownbyorganization 105 QuantitiesandtypesofammunitionpurchasedfromLeMasLtd.withcomparisons 11 data6 Weightsanddimensions(NoslerballistictipandUWprojectiles) 257 Weightsanddimensions(SierraandLW) 268 Testammunitioncharacteristics 289 Summaryofmeasurementsfromthedimensionalinspectionof5.56x45mmtest 33 ammunition10 Summaryofmeasurementsfromthedimensionalinspectionof7.62x51mmtest 33 ammunition11 Summaryofmeasurementsfromthedimensionalinspectionof9x19mmtest 34 ammunition12 Samplemicro-hardnessvaluesobtainedforLeMasUWandNoslerballistictip 42 projectiles

13 Samplemicro-hardnessvaluedobtainedforLeMasLWandSierraprojectiles 4414 EstimatedmechanicalpropertiesofprojectilessuppliedbyLeMasLtd. 4615 AverageVickersDPNhardnessmeasurementsfor5.56x45-mmcartridgecases 48

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TABLES(continued)

Page

16 AverageVickersDPNhardnessmeasurementsfor7.62x51-mmcartridgescases 49

17 AverageVickershardnessmeasurementsfor9x19-mmcartridgecases 5018 Summaryofbullet(highlightedresultsareoutsideofspecification) 5119 Calculatedsectionaldensitiesoftestammunition 5820 EstimatedBCoftestprojectiles 5821 5.56-mmmuzzlevelocity 5922 7.62-mmmuzzlevelocitytest 59

23 9-mmmuzzlevelocitytest 6024 5.56-mmimpactenergyandmomentumstatistics 6025 7.62-mmimpactenergyandmomentumstatistics 6126 9-mmmuzzleenergyandmomentumstatistics 6127 5.56-mmrecoildatawithtestammunition 6228 7.62-mmrecoildatawithtestammunition 6329 9-mmrecoildatawithtestammunition 6330 MIL-STDpressurespecifications 6531 SAAMIpressurespecifications 6532 MIL-STDpressureresultsfor5.56-mmcartridgestested 6633 SAMMIpressureresultsfor5.56-mmcartridgestested 6634 MIL-STDpressureresultsfor7.62-mmcartridgestested 67

35 SAMMIpressureresultsfor7.62-mmcartridgestested 6736 MIL-STDpressureresultsfor9-mmcartridgestested 6837 SAMMIpressureresultsfor9-mmcartridgestested 6838 SummaryofLeMas9-mmpressureissues 69

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TABLES(continued)

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39 MIL-STD(left)andSAAMI(right)velocityspecifications 73

40 MIL-STD5.56-mmvelocitytestresults 7441 SAAMI5.56-mmvelocitytestresults 7442 MIL-STD7.62-mmvelocitytestresults 7543 SAAMI7.62-mmvelocitytestresults 7544 MIL-STD9-mmvelocitytestresults 7645 SAAMI9-mmvelocitytestresults 76

46 5.56-mmand7.62-mmWaterproofnesstestresults 7747 9-mmWaterproofnesstestresults 7848 9-mmmalfunctionchart(functionandcasualty) 8349 Testbarrelinformation 8650 Accuracydata(averageofthree10-shotgroups) 8651 Standarddeviationofdispersiontests 8752 Statisticalcomparisonoftestammunitionextremespread(Mannbarrel) 8953 100m5.56-mmM4A1dispersionresults(averageofthreeweapons) 9054 300m5.56-mmM4A1dispersiontestresults(averageofthreeweapons) 9155 Standarddeviationsof100mand300m5.56-mmM4A1dispersiontest 9156 100mANOVAresultsfor5.56-mmM4A1dispersiontest 9257 300mANOVAresultsfor5.56-mmM4A1dispersiontest 93

58 100m7.62-mmMk11dispersionresults(averageofthreeweapons) 9359 300m7.62-mmMk11dispersionresults(averageofthreeweapons) 9460 Standarddeviationsof7.62-mmMk11100mand300mdispersionresults 9461 Differencebetween100mMannbarreland100mMk11results(averageof 94 threeweapons)

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TABLES(continued)

Page

62 Differencebetween300mMannbarreland100mMk11results(averageof 95

threeweapons)63 100-mANOVAresultsfor7.62-mmMk11dispersiontest 9664 300mANOVAresultsfor7.62-mmMk11dispersiontest 9665 25m9-mmBerettadispersionresults(averageofthreeweapons) 9766 Standarddeviationsof9-mmM9Beretta25mdispersionresults 9767 Differencebetween25m9-mmMannbarrelandM9Berettadispersionresults 97 (averageofthreeweapons)

68 ANOVAresultsfor9-mmBerettadispersionresults 9869 Statisticalcomparisonoftestammunitionextremespread(fieldweapons) 9970 300-yarddispersiondata(Cranetest) 9971 5.56-mmpenetrationresultsagainst3/8-in.and5/8-in.steelplate(5and100m) 10172 7.62-mmpenetrationresultsagainst3/in.and5/8-in.AR-500(steelplate) 10273 9-mmpenetrationresultsagainst3/8-in.and5/8in.steelplate 10374 Criticaldimensionsofhumanmales 11075 5.56-mmbaregelatinresultsat5m 11376 5.56-mmbaregelatinresultsat100m 11377 5.56-mmbaregelatinresultsat300m 11478 7.62mm5-mbaregelatinresults 11679 7.62-mmbaregelatinresultsat100m 117

80 7.62-mmbaregelatinresultsat300m 11781 5.56-mm5-mautoglassresults 12082 5.56-mm100-mautoglassresults 12183 5.56mm300-mautoglassresults 122

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TABLES(continued)

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84 7.62mm5-mautoglassresults 123

85 7.62mm100-mautoglassresults 12486 7.62mm300-mautoglassresults 12487 ARDEC2004statictestdatavaluesonrelevanttesting 126

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BottomLineUpFront1.LeMasLtd.promotedaseriesofBlendedMetalTechnologyRBCDprojectilesandassertedthattheyareuniqueinconstructionandsuperiortocurrentmilitaryandlawenforcementalternatives.2.TestingrequestedbyCongressthrougha$1,050,000DefenseappropriationissuedforFiscalYear2003wasconductedbyUSSOCOMIPT.3.LeMasriflebulletswerefoundtobecomposedofroutineandcommonlyavailablecommercialprojectilesofothermanufacturersthathadbeencoatedwithadrylubricant(molybdenumdisulfide).4.AlloftheproductspurchasedfromLeMaswerefoundnottofulfillexistingDoDneeds,requirements,andspecifications.5.LeMasproductsaresignificantlymoreexpensivethanexistingmilitaryalternatives.6.Alegalreviewbasedonthisreportisinprogress.

EXECUTIVE SUMMARY

TheHouseofRepresentativesConferenceReporttotheFiscalYear2003DefenseAppropriationActcontaineda$1,050,000appropriationfortheDepartmentofDefense(DoD)totestblendedmetaltechnology(BMT)bulletstosupportgovernment-widetestingofrevolution-arysmallarmsammunitionwithfullspectrumoflethalandpenetratingeffects.Further

clarificationoftheappropriationrevealedthatthebulletstheDoDweretotestwerethoseproducedbyLawEnforcementMilitaryAmmunitionSales(LeMas)ofLittleRock,Arkansas. LeMashasbeenpromotingavarietyofBMTprojectilesthatitclaimstobesuperiortocurrentmilitaryandlawenforcementsmallarmsammunition.Theseblendedmetalprojectilesweredemonstratedatanumberofshootingcompetitions.Severalgovernmentagenciesevaluatedthemusingnationallyandinternationally(NATO)-acceptedevaluationprotocols 1.ThistestingdidnotsupportLeMasclaimsandthetechnologywasnotpursued.However,LeMasLtd.objectedtothemannerinwhichtheroundsweretested.

_______________________1BoththeArmyandtheNavylookedatseveralLeMascartridgesintheyearspriorto2003.

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Inresponse,theUnitedStatesSpecialOperationsCommand(USSOCOM)formedanintegratedproductteam(IPT)totestbulletsmarketedbyLeMasLtd.asBMT.TheIPTconsistedofrepresentativesfromtheNavalSurfaceWarfareCenter,CraneDivision(NSWCCrane);theU.S.ArmyArmamentsResearch,Development,andEngineeringCenter(ARDEC),PicatinnyArsenal,NewJersey;theFederalBureauofInvestigations(FBI);theOfficeoftheSecretaryofDefense(OSD),aswellassubjectmatterexpertsupportcontractors.

Thescopeoftheinvestigationwasfourfold.Inshortwhatisit,isitsafe,doesitwork,andcanweuseit?Thisreportdiscussesthetestresultsthatwereobtainedtoanswerthosequestions.Thelegal(lawofwar)reviewrequiredbyDoDInstruction5000.2(12May2003),ArmyRegulation27-53(1January1979),andUSSOCOMDirective525-27(14February2001)willbeperformedbytheOfficeofGeneralCounsel,DoD,basedonthetestresultscontainedwithinthisreport.Preliminary IPT Meeting with LeMas Ltd.

ThestudyoftheBMTstartedwithanIPTmeetingwithLeMasLtd.sPresident,JohnHamilton.Mr.HamiltonstatedthatitsammunitionwasmanufacturedbyRBCDPerformance

Plus,Inc.toLeMasLtd.sspecifications.HealsoclarifiedLeMasLtd.smarketingclaimssothattheIPTcouldaccuratelycomparethebulletsperformancetotheirassertions. FromtheLeMaspresentation,fourclaimsrequiredparticularattention:

1. LeMasmadetheassertionthatitsammunitionwasmadeusingBMT.2. LeMasclaimedthatitsroundsproduceimmediatezeromissioncapability, thatis,immediateincapacitation.3. LeMasLtd.claimedthatitsprojectileshadunusualpyrophoricproperties, whichworkedwellinwarm,oxygenated,tissue,butreacteddifferentlyin chilledballisticgelatin.4. LeMasclaimedthattheirbulletsfullypenetrateatargetbehindin.AR500 steelplate,butdonotoverpenetratehumantargets.

Mr.HamiltonshowedvideosofliveanimaltestsconductedbyLeMasLtd.2Infact;theLeMasvideoscontradictedHamiltonszeromissioncapabilityassertion,astheanimalsclearlywereobservedaliveandmovingforanextendedtimeafterbeingshot. Followingthisinitialmeeting,USSOCOMformulatedatestplantoassessLeMasassertions.USSOCOMpurchasedstocksofavarietyofLeMasammunitionfromLeMasLtd.(table1).

_______________________2LeMasLtd.sliveanimaltestingwasnotdoneatthebehestoftheU.S.GovernmentorbyanymemberoftheIPT.LeMasLtd.waslaterbroughttocourtandfinedfortheirtestingpractices.ReferenceUSDA,APHIS,IESCaseNumberAR5002-AC,whichlistednumerouscitationsincluding2.38(f)2(i)physicalabuse.

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Table1CartridgedesignspurchasedfromLeMasLtd.

Caliber(mm) Nomenclature Projectileweight

5.56 RBCD/LeMas"UrbanWarfare"cartridge 37grain

5.56 RBCD/LeMas"LandWarfare"cartridge 45grain

7.62 RBCD/LeMas"LandWarfare"cartridge 110grain

9 RBCD/LeMas"CQBSPLP(H)"cartridge 58grain

LeMasrecommendstheLandWarfare(LW)5.56-mmcartridgeformilitaryuseintheM4andthe5.56-mmUrbanWarfare(UW)cartridgeforlawenforcementuse 3.ThesecartridgesweresubstantiallymoreexpensivethantheM855cartridgethattheU.S.ArmycurrentlypurchasesforalloftheServices(table2).

Table2Costcomparisons

Nomenclature Individualcartridgeprice

Noslerballistictipcartridge(websurvey) $.50to$.79

Sierra1310cartridge(websurvey) $.50to$.80

MilitaryM855(withpackaging)estimated $.20to$.30

LeMasUWcartridge(actualcostpaid)

LeMasLWcartridge(actualcostpaid)

Initial Tests

Initialvisualanddimensionalinspections(fig.1)ledtheIPTtosuspectthattheriflebullets,providedbyLeMas,werenotmadeofblendedmetalsormadebyRBCD.TheriflebulletsthatLeMassoldUSSOCOMwerestandardcommercialprojectiles(ofothermanu-facturers4)thatweregivenathincoatingofmolybdenumdisulfide[adrylubricant(fig.2)].Theseconclusionswereverifiedbymetallurgical,visual,andspectrometricanalysisconductedatseveralindependenttestsites. _______________________3Militaryandlawenforcementammunitionmaydifferbecauseofdifferentrequirements,restrictions,andneeds.Inparticular,militaryammunitionmustadheretoU.S.Treatyobligations.4Threeprojectilemanufacturerswerepositivelyidentified:Speer,Nosler,andSierra.

3

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Figure1LeMasUWandNoslerballistictipprojectilecrosssectionsandmoldnumber

Figure2LeMasUWcartridgewithNoslerballistictipbulletcoatedwithmolybdenumdisulfide

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Spectrometricanalysisrevealedthatthesebulletswerecomposedprimarilyofleadandantimony,likeordinarybullets.AftercuttingtheLeMasLtd.bulletsinhalf,ARDECmetallurgistsdeterminedthatthemicrostructuresoftheriflebulletswereconsistentwithswagingmanu-facturingtechniquesandnotwithpowdermetallurgytechniques.TheFBIsforensicanalysisrevealedthatthelistedprojectileweightsdifferedfromUWprojectileweightsandthattheseprojectilescontaineddistinctiveorangeNoslerstylemoldnumbersthatmatchedthosefoundon

Noslersballistictipprojectiledesign.TheactualweightoftheLeMasUWbulletsmatchedtheweightoftheNoslerballistictipbullets. Ogiveradius,thicknessofthebaseofthejacket,andthicknessofthejacketwallwerealsomeasuredonbothdesigns.Matchinganyofthesedimensionsisoftensufficienttoidentifythemanufacturerofabullet.Opticalcomparatormeasurementsrevealedthattheother5.56-mmsubmission,theLWbullet,wasamatchtotheSierra1310Varminterbulletonallthreedimensions. Whenaskeddirectly,LeMasLtddeniedthattheirprojectileswereanythingotherthanRBCDsownuniqueproprietaryblendedmetaldesign 5.RequestsbytheIPTtotourtheLeMas/RBCDmanufacturingfacilitywererefused.LeMasLtdinsistedthattheIPTcontinuetheir

effortstovalidatetherealworldoperationalcapabilityofBMT.Notwithstanding,LeMasdenialsandclaimstothecontrary,theIPTconcludedthatthe5.56-mmUWprojectileswereleadcoreNoslerballistictipprojectilesthatwerecoatedwithathinfilmofmolybdenumdisulfideandthatthe5.56-mmLWprojectileswereleadcoreSierraprojectilesthathadlikewisebeencoated. TheIPTinvestigationprovedscientificallythatthecartridgespurchasedfromLeMascontainedcommercially-availableprojectilesnotdesignedormanufacturedbyLeMasorRBCD.AsLeMas/RBCDneverclaimedtomanufacturethecartridgecase,primer,orpowder,theonlylogicalconclusionwasthatLeMas/RBCDassembledammunitionfrompartsitpurchasedtosellasitsowndesignandproduct.Prelude to Operational and Safety Tests

AfterdeterminingthattheLeMas5.56-mmprojectileswereordinaryleadcorebullets,theIPTconductedadditionaloperationalandsafetytestingtoevaluateoverallcartridgeperformancewiththe5.56mm,7.62mm,and9-mmLeMassubmissions.USSOCOMtestedandcomparedtheperformanceofthesecartridgeswithcurrentmilitaryalternatives,andwiththeanalogouscommercialbulletdesigns(Sierra,Nosler,andSpeer).TheseanalogouscommercialdesignswerethenloadedtothesamevelocitiesandchamberpressuresastheequivalentLeMascartridge.

_______________________5LeMasLtd.istheexclusivedistributorofRBCDBMTprojectiles.

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ItwasproposedthatifthecommercialbulletsdemonstratedthesameperformanceastheLeMasbullet,thenGovernmenttestinghadnotoverlookedanythingsignificant.Thesesurrogatebulletswereofknownorigin,notblendedmetals,andappearedidenticaltotheLeMas-furnishedbullets(table3)6.ThesesurrogatesservedasadirectgaugeoftheuniquenessoftheLeMasbullets.Testresultsshowedthatboththe5.56mmand7.62-mmsurrogatesperformancematchedtheLeMas-furnishedbulletsperformance.The9-mmpistolresultsdiffered,butnot

overwhelminglyandwerediscontinuedaftersafetyissueswhenthepressuretestsresultedindamagebeingdonetotwotestweapons.

Table3Projectilesurrogates

CaliberProjectileclass

5.56mm 7.62mm 9mm

Militarydesigntested M855 M118LR M882

LeMasproductstested UW,LW LW CQBSPLP

CommercialsurrogatestestedSierra"Varminter",

Nosler"BT"Speer Aguila

Operational and Safety Tests

Thissectionisnotmeanttobeallencompassing.Severalareasofthefollowingsectionareverycomplexandsimplificationsweremadetopromoteunderstanding.Additionaldetailsarefoundinthebodyofthereportandinthesupportingmaterial. ThehardtargetpenetrationtestsconductedaspartofthisinvestigationshowedthatsomeoftheLeMasammunitionismoreeffectivethanthetestedmilitaryalternativesagainstthinsteelbarriersatshortranges.Forexample,the7.62-mmLeMascartridgeperformedbetterinthistestthantheM118LRagainst3/8in.AR500steelplateat5m(fig.3).

Figure3Sample7.62-mmhardtargetpenetrationphotographs 7

_______________________6Therifleprojectileswereexactlyanalogous.The9-mmprojectilewasnot.Referencelatersectionsfordetails.7DODIC:DoDIdentificationcode,OTM:Opentipmatch,SP:Softpoint,LCAAP:LakeCityArmyAmmunitionPlant,BRC:n/a

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However,thetestingalsoshowedthattheLeMasalternativeslostvelocityquicklyandwerenoteffectiveagainstthesametargetsatlongerranges.Inshort,theLeMasalternativeshaveanarroweroveralloperationalband.Additionally,theLeMasprojectileswerelesseffectiveagainstthickertargetsandbehindwindshieldsthatwereslopedtoanobliquityof45deg.

Figure4Cranehardtargettest

LeMasclaimthatitsbulletpenetratesarmorbutdoesnotover-penetratesofttargetsisnotcontested.Thisisbecauseofthebulletdesign(lightweightandexposedsoftleadorpolymertip)andbecauseofitsimpactvelocity,notbecauseofanyuniqueconstructionofthebullet. Lastly,theIPTaddressedthequestion,isitsafeanddoesLeMasammunitionfulfillDoDneeds,requirements,andspecifications?Inshort,theanswerisno.Functiontestsconductedwiththe9-mmLeMaspistolcartridgesresultedinnumeroushighpressureproblems(observedduringcoldtemperaturetests).Thesetestseventuallydamagedtwotestweaponsandhalted

additionalpressuretestswiththatdesign.AccuracytestsonthesamecartridgeshowedthattheLeMasproductwasnotablylessaccuratethancurrentoptions. Additionally,bulletintegritytestsconductedwiththe5.56-mmLW(Sierra)cartridgeandtheM16showedthattheLeMasalternativebroke-upafterlaunch.Bulletbreak-updegradesaccuracy.WaterproofnessfailuresonmultipledesignsfurtherreinforcedthepositionthatnumerousmodificationswouldhavetobemadebeforeaLeMasroundfieldingcouldevenbeconsidered.Thesubstantialcostpercartridgeincreaseisalsonoted.Executive Summary Conclusions

Periodically,theGovernmentreceivesclaimsofrevolutionarybulletdesigns.Theseare

frequentlylightweightdesignswithsofttips,firedathighvelocities.Thesedesigncharacteristicstypicallyyieldimpressiveresultsinspecifictestscenarios,normallyatshorterranges;however,comprehensivetestinginevitablydemonstratesthattheirperformanceistoonarrowlyfocusedandnoteffectiveacrossthebroadspectrumofmilitaryrequirementsthatmustbemet.LeMassubmissionfallsintothisgeneralcategory.

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INTRODUCTION

LeMasLtd,ismarketingseveraltypesofcartridges.Inmarketingbrochures,developedbyLeMasLtd,theseproductsaredescribedasusingBMT,whichispurportedbyLeMasLtd.to:

Produceimmediatezeromissioncapabilitywithrapidterminalresults(ref.1)

Notexhibitover-penetration8inwarm,soft,oxygenatedtissue(ref.1) Produceenhancedfragmentationpatterns(ref.1) Causeheatgeneratedblisteringinsoftorganstructures(ref.2)

In2002,CongressmandatedthattheDODtestBMTSmallArmsAmmunition.Asaresult,USSOCOMputtogetheraJointServiceIPT(JS-IPT)tocarryoutthedirective.ThisIPThadparticipationandinputfrommultiplesourcesincluding:USSOCOM,U.S.Army,U.S.Navy,FederalBureauofInvestigation(FBI),andtheOfficeoftheSecretaryofDefense(OSD).Thisjointservice,jointagency,approachwasdeemeddesirable,as:

Suchapanelofdiverseballisticexpertswouldbringskills,knowledge, experience,andresourcesthatwouldenhancetheeffortandotherwisebe unobtainable. Testcredibilityandobjectivitywereconsideredkeyandessential BMTprojectilesmightbeprohibitedformilitaryuseunderU.S.treaty obligations.Thelegal(lawofwar)reviewrequiredbyDoDInstruction5000.2 (12May2003),ArmyRegulation27-53(1January1979),andUSSOCOM Directive525-27(14February2001)willbeperformedbytheOfficeof GeneralCounsel,DoD,basedonthisreport.

Initial IPT Meeting February 2004)

TheIPTmetinitiallyon19February2004to:

DiscussBMTprojectileswithLeMasPresidentJohnHamilton DiscussUSSOCOMtestersandprocedures

_______________________8Projectiledoesnotexitthetarget.

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Mr.HamiltonpresentedseveralvideoclipsandphotographsshowingvariousteststhatwereconductedbyLeMasLtd.IncludedinthevideoclipswereaseriesofliveanimalteststhatwereconductedbyLeMasLtd.topromotetheirproduct. LeMasconductedtheseliveanimaltestsindependently,withoutanygovernmentrequestoroversight.ItistheopinionoftheIPTthatLeMasdidnotadheretocurrentorhistoricalanimal

testingprotocols,andconductedthesetestsinanunethicalmanner 9,10,11,12(refs.1,3,and4). Followingthevideoclips,Mr.HamiltonpresentedtheIPTwithtestimonialsfromthetwoattendingphysicianswhoperformednecropsiesonfourofthepigsdestroyed.2004 JS-IPT Proposed Plan

FollowingthemeetingwithLeMasLtd.,apathforwardwasoutlinedbytheIPT.

ReviewanddiscussLeMasLtd.marketingclaims(referenceLeMasLtd. MarketingClaimssection)

DeterminewhatconstitutesBMTasitpertainstotheCongressionalmandate (referenceWhatisBMT?section) ReviewanddiscusshowBMTpertainstoLeMasammunition(reference AnalysisofLeMas(RBCD)Projectilessection) ReviewavailableinformationongovernmenttestsdonewithLeMasprojectiles (referencePerformanceAnalysisofLeMas(RBCD)Projectilessection6)

_______________________9LegalactionwastakenagainstLeMasLtd.byPETA.ReferenceUSDA,APHIS,IESCaseNumberAR5002-AC,whichlistednumerouscitationsincluding2.38(f)2(i)physicalabuse.ReferencethenotedPETAwebsiteforadditionalinformation.10Currenttestprotocolstypicallyusetissuesimulantssuchasballisticgelatintomeasureterminaleffectiveness.TheseprotocolswereextensivelyrefinedandvalidatedinthedecadesfollowingWorldWarIIandminimizetheneedforadditionalanimaltesting.11LegalactionwastakenagainstLeMasLtd.byPETA.ReferenceUSDA,APHIS,IESCaseNumberAR5002-AC,whichlistednumerouscitationsincluding2.38(f)2(i)physicalabuse.ReferencethenotedPETAwebsiteforadditionalinformation.12LeMasLtd.objectstootherthanliveanimalorwarmoxygenatedtissuetesting,statingthattheirprojectilesonlyreactwhenimpactingthatmedium(asopposedtoballisticgelatin).

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ReviewanddiscusshistoricaltestsconductedonotherBMTtypeprojectiles (referenceHistoricalAnimalTestswithSoftPointProjectilessection) Research,review,andevaluatecurrentlyavailableBMT)typeprojectiles (formand/orfunction)(referencePerformanceAnalysisofLeMas(RBCD) Projectilessection).

BenchmarkBMT(referencePerformanceAnalysisofLeMas(RBCD) Projectilessection):

Tocurrentmilitarycartridgeperformance Tomilitaryrequirements Costconsiderations(referenceIntroductionsection)

ConducttestsonotherprojectilessimilartoLeMasLtd.BMTprojectilestosee ifBMTammunitionperformanceisuniquetoLeMasLtd.designs(reference PerformanceAnalysisofLeMas(RBCD)Projectilessection). EvaluatepossibleprosandconsofBMTtocurrentmilitaryalternatives (referenceAssessmentofLeMasMarketingClaimsandConclusions sections) ReportResults(thisreport)

Task Distribution

Thetasksjustoutlinedweredistributedappropriatelyacrossmultipletestcenters,withtheideabeingthataparallelapproachwouldbemorecomprehensiveandmorethoroughthanaserialone.13Asaresult,theArmy,Navy,andFBItestedLeMasammunitionintheirinternalfacilities,whileUSSOCOMcontractedanindependentorganizationtotesttheLeMasammuni-

tion(table4).

Table4Proposedtestbreakdownbyorganization

_______________________13Inadditiontosomespecifictestsets,ARDECwastaskedwithwritingthefinalreportfromthedatathatwasgatheredfromtheotherservices.

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Uponconclusionofthisstudy,alegalreviewofsubjectammunitionwillbeconductedbytheOfficeofGeneralCounsel,DoD,todeterminecomplianceofsubjectammunitionwiththelawofwarobligationsoftheUnitedStates.

Funding and Costs

Aformal$1,050,000CongressionalappropriationtotestBMTsmallarmsammunitionwasissuedbytheHouseofRepresentatives107 thCongress2dSessionattheendof2002.ThisfundingwasthenissuedtothevariousgovernmenttestcenterstocoordinateandperformtestsonBMTsmallarmsammunition.Inmostcases,contractualagreementswereinitiatedandfundswereobligatedearlyintheeffort 14(table5).

Table5QuantitiesandtypesofammunitionpurchasedfromLeMasLtd.withcomparativedata 1516

LEMAS LTD. MARKETING CLAIMS

LeMasLtd.istheexclusivelawenforcementandmilitarydistributorofRBCDBMTsmallarmsammunition(ref.5).AstheexclusivedistributorofRBCDBMT,LeMasammunitionhas

madeanumberofclaimsadvancingtheirproduct.Theseclaims(outlinednext)areinitiallylistedheretoprovidethereaderwithinsightintotheexpectedperformancethatwasadvancedbyLeMas.Followingthetestresults,anassessmentoftheseclaimswillbeperformedbasedonthedataandinformationtodate.

Most Significant Technological Advancement

Claim:LeMasLtd.claimsthatitsBMTisthemostsignificanttechnologicaladvancementinsmallarmssincetheadventofthe20 thcentury(ref.5).

Thesenewblendedmetalspayloadsdepartradicallybothinconstructionandcapability,fromthehistoricallymanufacturedleadbulletammunitionsofthelast100years(ref.5).

_______________________14Forthisreason,alloftheindividualtestswerecontinuedtocompletion,eventhoughvalidquestionsandconcernswereraisedaboutwhetheradditionalinformationwasnecessary.15Aspartoftheprocurementprocess,newammunitionDODICsweregenerated.16Commercialcalibernomenclaturesarenotthesameasthemilitary.SAAMIusesthefollowing:.223Remingtoninsteadof5.56mmx45mm,.308Winchesterinsteadof7.62x51mm,and9-mmLugerinsteadof9x19mm.

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TheRBCD.223StateDepartment39grainSpecialPurposeLimitedPenetration(SPLP)armorpenetratingroundoffersexceptionalincapacitationterminalperformanceinrealtissue,defyingtheconventionalmaximumwound/minimumvelocityrequirementsoftraditional.223bulletdesigns(ref.5).

Reference:AssessmentofLeMasMarketingClaimssection.Produce Immediate Zero Mission Capability

Claim:LeMasLtd.claimsthatitsammunitionproducesimmediatezeromission capability,whichrapidlyleadstoterminalresults(ref.1).

Basedonvarioustestsinlivingandnon-livingtissue,webelievethatanyimpacttothetorsowithanySPLPbulletdesignwillproduce"zeromissioncapabilityinthattarget.Wealsobelievethatanyhittoanappendagewillcauseanincapacitatingwoundresultinginthethreattargetsinabilitytocontinuehismission(ref.5).

Reference:AssessmentofLeMasMarketingClaimssection.Varied Penetration Based on Target

Claim:LeMasLtd.claimsthatitsammunitionwilldefeatavarietyofbarrierobstaclessuch asglass,bodyarmor,andin.AR500steelplate(fig.5),butnotoverpenetratewarm, soft,oxygenatedtargets(ref.5).17

WhatmakesLeMasammospecialisitsabilitytopenetratehardbarriers,suchasbodyarmorandsteelplate,yetnotpassthroughasoftmedium,suchasahumantorso(ref.6).TheSpecialPurposeLimitedPenetration9mmLE-HwhenfiredfromaGlock-17willpenetrate5mmofheattreatedhardenedaluminumarmor,thecurrentM882willnotpenetratethisarmorwhenfiredfromaMP-5platform.ThesameSPLP9mmLE-Hwillinflicttraumaticlivetissuedestruction,deployingasafrangiblebulletwithlimitedpenetration,afterdefeatingthishardenedaluminumarmorbarrier(ref.7) 18

_______________________17LeMasisinferringthattheoxygencontentthatispresentwithinalivinganimalisdifferentthantheoxygencontentthatispresentinagelatinblock.18TheHeckler&Koch(HK)MP5isafamilyofclosedboltsubmachinegunsdevelopedbyHKinthe1960s.

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Figure5LeMasLtd.marketingpictureshowingarmorplatepenetration(ref.8)

IamattachingsomehardbarrierteststhatwereconductedinthePhilippinesrecentlywithourammunition.Theyhavepromisedsome2leggedlivetissuenecropsieswithawidevarietyofourAPLPproducts.Iwillforwardthoseto

youiftheycometome.WehaveyettoseeanycurrentlyusednondedicatedAPammunitionthatwillpenetratethesetypesofbarriers,andcertainlynoammunitiontodatethatwilloptimizelivetissuedestruction's(sic)aswellaspenetratethesetypesofhardarmors(ref.8).

Reference:AssessmentofLeMasMarketingClaimssection.Non-comparable Performance in Living Tissue

Claim:LeMasLtd.claimsthatballisticgelatintestsarenotrepresentativeoftheresults thattheyhaveseenintheirliveanimaltests(fig.6).

The5.56mmLandWarfarebulletwhenimpactingcalibrated10%ballisticgelatindemonstratesshallowpenetration,smallpermanentwoundchannel,andverylittlefragmentation.However,whenimpactinglivetissue,thesamelandwarfarebulletdeployswithdramaticdimensionsoffragmentation,largepermanentwoundchannelandgreaterdepthofpenetration(ref.1)

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TheseSPLPBMTmunitionsweredesignedtodeployinrealtissuemediums.Optimalperformancecanonlyberealizedinlivingtemperaturetissue.Coldgelatinblocksortissue,farbelowlivingtemperatures,isnotadesignparameterofthesemunitions(ref.5)

Ourpositionisthatthenewtechnologyofourproductsperformanceisnot

completelyaccurateunlessevaluatedintissue(ref.5) Reference:AssessmentofLeMasMarketingClaimssection.

Figure6PurportedeffectoftemperatureonBMTperformance

Produce Enhanced Fragmentation Patterns

Claim:LeMasLtd.claimsthatthehighrotationalvelocityofitsammunitionenhancesthe fragmentationpatternandgivestheadvantagebacktothemarksman(ref.1).

Thisproductsneteffectistoenhancetheoperationalcapabilitiesofcurrentplatforms,totheperformancelevelsofthenextheavierweaponsplatform(ref.5)

Reference:AssessmentofLeMasMarketingClaimssection.Cause Heat Generated Blistering in Soft Organ Structures

Claim:LeMasLtd.claimsthatitsammunitionproducesblistersandthirddegreeburnson

interiororganswithinthetarget(ref.1). Reference:AssessmentofLeMasMarketingClaimssection.

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Unique Manufacturing Process

Claim:LeMasLtd.claimsthat:

Ouruniquemanufacturingprocessallowsustheabilitytorapidlyrespondtoemergentmissionrequirements.Ifwecurrentlydonotstockamunitionthat

specificallymeetsyourrequirements,wecanprovide,inaveryshorttime,missionspecificmunitions,necessarytosatisfyemergentcommandmissionassignments,usuallyeightweeksorless(ref.5)

Reference:AssessmentofLeMasMarketingClaimssection.Use Lead Free Components

Claim:LeMasLtd.claimsthat:AllRBCDmunitionsuseleadfreecomponents(ref.5)19

Reference:AssessmentofLeMasMarketingClaimssection.

Patented Ammunition Products Claim:LeMasLtd.claimsthat:

Allofourproductsarepatentedorpatentpending.Weareahightechnologycompanythathastheproductioncapacitytogenerate1,000,000rounds,inmostofourproductline,withinthreeweeksofnotification(ref.5)

Reference:AssessmentofLeMasMarketingClaimssection.

WHAT IS BLENDED METAL TECHNOLOGY BMT)

BlendedMetalTechnology(BMT)offersthemostsignificantadvancementinbulletcapabilitiessincetheadventofsmokelesspowderinthe20 thcentury.BlendedMetalspatentedproductionprocessesfacilitatethehomogeneousblendingofmultiplemetalcompositions.LeMasadvertisement

LeMas Ltd. Definition of BMT

20

ThedefinitionofBMTisdeemedproprietarybyLeMasLtd.InresponsetoIPTrequests,LeMasLtd.gavethefollowingdefinitionforblendedmetal:

ThetermBlendedMetalisbothamarketingacronymandnomenclaturewhichreferstothemanufacturingprocessusedtoassemblethecorebullet

constructionmaterialswhichprovidethespecificoperationalcapabilitieswithrespecttoeachbulletdesign.(ref.9)

_______________________19LeMasLtdmadethisclaiminreferencetotheirproduct.ItisunderstoodthatRBCD,whichisthesourceofLeMasammunition,wasnotpartytothisclaim.

20ThemetallurgicalanalysisportionsofthisreportwereconductedbytheMetallicMaterialsTechnologyTeamatARDEC.Amoreindepthdiscussionofthosetopicsarecoveredinadditionalreportsthatareavailableuponrequest.

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TheIPTdeterminedthatthisdefinitiondoesnotuseinternationallyrecognizedtermsthatdefinethemetallurgical,mechanical,orphysicalpropertiesoftheLeMasbullets.American Society of Metals ASM) Definition of Blending Metals

AccordingtotheAmericanSocietyofMetals(ASM)andASTMStd.B243-04a,Standard

TechnologyofPowderMetallurgy,thereisnospecificationforthetermblendedmetalorblendedmetaltechnology.Additionally,asearchofinternationaldatabases,suchasInfonormeLondonInformation(il.co.uk/en/)hasnotrevealedaspecificationforthetermblendedmetalorblendedmetaltechnology. Aftercombingseveralnationalandinternationalmaterialsdatabases,theclosestmetallurgicaltermthatcouldbefoundwasblendingmetals.Thistermisapowdermetallurgytermmeaning,thethoroughinterminglingofpowdersofthesamenominalcomposition,forexample,combiningtungstenpowderstogetherthathavedifferentparticlesizesbuthavethesamechemistry. TheIPTsinitialpremisewasthatBMTwassimilartopowdermetallurgytechniques.A

patentsearchwasconductedtoverifythispremise21

.United States Patent No. US 6,363,856 B1

RBCDPerformancePlusInc.providesLeMasLtd.withtheirpatentedorpatentpendingprojectiles(refs.1and5).Assuch,theIPTconductedapatentsearchtoreviewanyandallpatentsthatwereheldbyLeMasLtd.,RBCD,oranyofitsknownassociates.Onlyonesuchpatentwasfound(fig.7).

Figure7RoscoeStokerspatentedprojectilediagram(ref.10)

_______________________21Thisinitialpremisewasoverturnedasaresultofadditionaltesting.22Reminder,RBCDprovidesLeMasLtd.withtheirpatentedorpatentpendingprojectiles(refs.1and5).

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RoscoeR.Stoker,Jr.,ownerofRBCD22andinventor,filedpatentnumberU.S.6,363,856B1on2April2002.Thepatentbackgroundreadsasfollows:

Applicantsinventionrelatestoaprojectile;andmoreparticularly,toaprojectilehavingalowdensitycoredesignedtotravelatanincreasedmuzzlevelocityascomparedtoconventionalbulletdesignswhenfiredfromconven-

tionalsmallarmsunderthesameconditions.Thelighterweightoftheprojectile,duetothelowdensitycore,actstoquicklyreducethevelocityoftheprojectileafterfiring.Thehighmuzzlevelocityoftheprojectileallowstheprojectiletomoreeffectivelypenetratebodyarmor,andothersolidobjectsatshortranges,generallyunderfifty(50)yards,whiletherapidvelocitylossmakestheprojectilelessdangeroustoinnocentbystandersifthetargetismissed,orduetooverpenetration(ref.10).

Thisquote,takendirectlyfromthepatent,providesinsightintothedesignphilosophythatMr.Stokerbelievedwasadvantageous.Hisgoalwastopatentalight,fast,projectilethatwascapableofpenetratingbodyarmoratcloserangewithoutoverpenetration.

ThepatentsdetailsoutlineMr.Stokersprojectiledesign,whichiscomposedofajacket(firstmetallicalloy),alightweightcorematerial,andaslug(secondmetallicalloy). Forthejacket,ametallicalloycomposedofcopper,molybdenum,zinc,nickel,andsiliconisspecifiedasthepreferredcomposition.Thisjacketalloyactstoreducefrictionoftheprojectileagainstthebarrelasittravelsthroughthebarrelascomparedtoaconventionalprojectile(ref.10). Thecorematerialcompositionisnotspecifieddirectlyinthepatent;however,thepatentindicatesthatthecorematerialshouldhaveadensityoflessthantheslugandpreferablywithavalueoflessthan7g/cm3.Additionally,thecorematerialshouldbemalleableduringacuringperiod,andhaveelasticpropertiesaftercuring(refs.10and11). 23,24

Thecorecanbemadefromvariouslightweightsubstancesthathavetherequiredphysicalpropertyofbeinglessdensethantheslug;howeverpolymers,epoxies,andplasticsarewellsuitedforuseascorematerials.(ref.10)

Fortheslug,Mr.Stokeroutlined:

Theslugismadefromasecondmetallicalloy.Apreferredcompositionoftheslugis30-50%bismuth,upto40%lead,upto20%molybdenum,upto40%epoxysuchasScotch-WeldTMgreyorScotch-WeldTMtranslucent,upto15%aluminum,andupto15%zinc.Theepoxy,suchasScotch-Weld TMgreyorScotch-WeldTMtranslucentisusedtobindthepowderstogether(ref.10).

_________________________23Tyically,asthedensityofthematerialgetsclosertothehumantissue(about1g/cm3)theamountofx-rayabsorptionfromthatmaterialdecreasesproportionallyassumingthatthereisnochangeinthickness(consultBeersLaw).Thishasdirectimplicationsonhowwellthatmaterialwillshowuponamedicalx-ray,whichgenerallyusesdifferencesinabsorptioncharacteristicstodistinguishfeaturesandstructures.24Forreferencepurposes,thedensityofleadistypicallytakenas11.34g/cm3,copperisabout8.92g/cm3,andnylonisroughly1.15g/cm3.

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Mr.Stokerstated,inthispatent(ref.10),thatthispatenteddesignwasnotmaterielorcaliberspecific(fig.8).

Itshouldbeunderstoodthatthematerialsofthecorecompositionandthemetallicalloysmaybealteredorsubstitutedforwithothermaterialshavingsimilarphysicalproperties.Additionally,thesize(orvolume)oftheprojectiles

coremaybeincreasedordecreasedrelativetothesize(orvolume)oftheslug.Theprojectilesotherattributesmayalsobechangeddependinguponuse.Forexample,thesizeoftheprojectilemaybealteredbaseduponthecaliberofthefirearmthatistobeused(ref.10).

Figure8

RoscoeStoker'spatentedprojectiledesign(ref.10) AsfarastheIPTcandetermine,thisistheonlypatentonfileforMr.StokerandforRBCD.

ANALYSIS OF LEMAS RBCD) PROJECTILES

25

Aspreviouslymentioned,BMTcartridgeswerepurchaseddirectlyfromLeMasLtd.usingstandardDODcontractualprocedures. 26Thatsingleammunitionpurchasewasthendistributedtomultiplegovernmentlabsforindependentanalysis(fig.9).

_______________________25Thissectionofthereportcontainsinformationthatmaybeconsideredproprietaryinnature.ThisindepthanalysisintothecharacteristicsofLeMasammunitionwasinitiatedasaresultofrangesafetyconcernsthatweregeneratedasaresultofearliertestingandcorrespondencewithLeMas.Astheanalysisproceeded,itwasexpandedasaresultofotherconcerns.26ThepurchaseisfullydocumentedbySOCOM(ContractagreementH92236-04-P-3245)andisavailableuponrequest.

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Figure9

Breakoutofammunitionforthiseffort 27

Visual Tests

ThreeindependentgovernmentagenciesperformedvisualanddimensionaltestsonLeMasprojectiles(fig.10).Thesetestswereconductedtodetermineiftheprojectileshadasatisfactorylevelofproductionconsistencyandiftheprojectileswereincompliancewith

applicabledrawings,weapontolerances,performancespecifications,andotherrequirements.Theresultssuggestthatalthoughconsistencyissatisfactory,therearemorequestionsabouttheoriginsoftheprojectiles(discussedlater).

Figure10LeMas5.56-mmblendedmetalprojectiles[UW(left)andLW(right)]

FBI UW Analysis The5.56-mm37-grainLeMas/RBCDUWcartridge(lot03020113)wasacquiredbytheFBIfromUSSOCOM(fig.11). 28InitialinspectionoftheprojectilerevealedittobesimilartotheNosler40-grainballistictip.Followingtheprocurementofadditional40-grainballistictipNoslerprojectiles,theFBIconductedacomparisonanalysisofthetwoprojectiles(figs.12through14).The37-graintestprojectiles(sentbyLeMas)werefoundtoweigh40grains._______________________27ItisnotedthatbothARDECandCranehaveacquiredandtestedLeMasammunitionforotherprograms.28Ashasbeenpreviouslymentioned,LeMasmarketsRBCDprojectiles.

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Figure11FBIvisualinspectionoftheLeMasUWcartridge

Figure12InitialFBIcomparisonofLeMas/RBCDUWtosimilarprojectiles

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Figure13FBIweightcomparisonbetweenUWandNoslerprojectiles

Figure14

VisualcomparisonbetweenNoslerballistictipandLeMasUWdesign Noslerwastelephonicallycontactedandaskediftherewereanyidentifyingmarksontheir40-grainballistictipprojectiles.AseniormanageratNosleradvisedthattheycouldpositivelyidentifyanyprojectilesthatweremanufacturedbyNosler. 29 NoslersresponserevealedthattherewerethreemajormanufacturerswhoproduceprojectilessimilartotheNoslerballistictip.However,Noslerballistictipprojectilesaretheonlyplastictipprojectilesthathaveathickbase.Bothoftheothercompaniesuseadrawncup. 30_______________________29NoslerwasnotadvisedoftheinvestigationbeyondthefactthattheFBIwasattemptingtoproveordisprovetheoriginoftheprojectile,andatnotimewastheoriginoftheprojectilerevealedtoNosler.30Bulletjacketsproducedusingadrawncupapproachacquiredtheirfinalshapebystretchingacupshapedpieceofjacketmaterialintoitsfinalform.

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Noslerballistictipprojectilesaremoldedinagangmold.31Consequently,eachprojectilehasamoldnumberimprintedonitsbase.IfaNoslerprojectileiscarefullydisassembled,thenthisnumbershouldbecomevisiblewithamagnifyingglass. TheFBIcarefullyremovedtheplastictipsfromthreeoftheLeMastestprojectilesandexaminedwhetheraNoslerstylemoldnumberwaspresent.Theiranalysisshowedthat

numbersthatwereconsistentwithNoslersfont,numbersystem,color,andplacementwereonallthreeRBCDproprietaryprojectiles(figs.15and16).

Figure15

FBIphotographshowingNoslerstylemoldnumbersonLeMasUWprojectiles

Figure16

SidebysideNoslerandUWprojectilecrosssectionvisualinspection

LeMaswasaskedviaemailiftheUWprojectileswereNoslersdesignandtheresponsefromStanBulmerwasanunequivocalno(refs.12and13)._______________________31Asinglemoldhavingmultipleshapingcompartmentsinwhichmultiplearticlesareformedbyoneoperation.

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AdditionalphotographsweretakenatARDECtosupporttheFBIpositionthatUWprojectileswereNoslerballistictipprojectilesthathadbeencoatedwithmolybdenumdisulfide(fig.17).

Figure17NoslerandLeMasblendedmetalUWprojectiles(moldnumbersfoundonbothprojectiles

tested)(ARDECphotograph) NoslerlaterconfirmedthattheprojectilesthattheFBItestedwere,infact,molybdenumcoatedNosler40-grainballistictipprojectiles. FBI LW Analysis AsaresultofthedisturbinganalysisresultsoftheUW(Nosler)design,andafterrecognizingthesimilaritiesbetweentheLWandtheSierrabullet1310,theFBIinitiatedcorrespondencewithSierratodetermineiftheLWdesignwasinessence,andinfact,aSierraprojectile.Bulletsamples,withnosourcedata,wereeventuallyprovidedtoSierrawhoconfirmedthattheproprietaryLeMas(RBCD)LWprojectilesweremolybdenumcoatedSierra

projectiles.

Sierrahascarefullyexaminedthebulletsamplesyousent.WearecertainthattheseareinfactSierraBullets,stocknumber1310.Thereareseveralreasonswhywebelievethistobetrue.Firstistheogiveradius.Whenmeasuredonanopticalcomparator,thesamplesyousentpreciselymatchSierrasprofile.Secondisthejacketsconstruction.Whenmeasuredonatoolmakersmicroscope,thethicknessofthebaseofthejacketusedtoconstructthisprojectileisexactlythesameasSierras.Additionallythejacketwallthickness(measured0.120fromthebase)isalsoidentical.Third,thesebulletsfallwithinSierrasverytightinhousediametertoleranceof 32.Finally,everyotherphysicaldimensionisidenticaltoSierrasbullet.Individually,any

ofthesethreedimensionsbeingidenticaltoSierraswouldbeunusual.Whencombined,thepreciseduplicationofSierrasdimensionsremovesanyreasonabledoubtthatthesesamplesyousentareSierrabullets.

_______________________32Sierrasexacttolerancevaluewasremovedfromthequoteforproprietaryreasons.

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However,ifthereisanyfurtherquestion,aspectrographofthejacketmaterialandleadalloywouldprovebeyondanydoubtthatthisisaSierraproduct.Onewouldexaminetheantimonialcontentoftheleadandthecompositionofthejacket.SierrausesC210(5%zinc,not10%)initsproduct.Itismostlikelythatthematerialcompositioncouldnotbetraceddirectlytoaspecificmaterialcertification,butitmaybepossible(ref.14). 33,34

ARDEC Dimensional Analysis Tests The5.56-mmUW[Nosler(left)]and5.56-mmLW[Sierra(right)]projectileswereremovedfromtheircartridgesandwerephotographedintheasreceivedcondition(fig.18).SlightdifferencesinthenoseshapesoftheLW(Sierra)bulletswereattributedtotheeasilydeformedtip.

Figure18"Asreceived"LeMasprojectilepictures

_______________________33NotethattheARDECchemicalanalysisoftheLWprojectilerevealedthatthejacketcompositionoftheLWprojectilecontainedabout5wt%zinc.34Theefforttotracethematerialcompositiondirectlytoaspecificmaterialcertificationwasnotrequestedandwasnotconducted.

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Table6showstheresultsofdimensionaltestsdoneontwoLeMasLtd.UW(AandB)andonfiveNoslerballistictipprojectiles(AthroughE)(fig.12).

Table6Weightsanddimensions(NoslerballistictipandUWprojectiles)

ProjectiletypeSamplenumber

Weight(gm)

Weight(gr)

Length(in.)

Borediameter(in.)

A 2.593 40.0 0.701 0.225LeMasUWprojectile

B 2.589 39.9 0.702 0.225

A 2.594 40.0 0.702 0.225

B 2.593 40.0 0.703 0.225

C 2.592 40.0 0.703 0.225

D 2.591 40.0 0.704 0.225

Noslerballistictip

E 2.592 40.0 0.702 0.225

Inthistest,theLeMasUWsubmissionandtheNoslerbulletdifferedbynomorethan0.1grainsinweightand0.02in.inlength.Theborediameterswerevirtuallyidenticalforbothprojectiletypes(fig.19). 35

Figure19SidebySideSierraandLWprojectileas-isvisualinspection

_______________________35NotethattheminordifferencesbetweentheUWprojectilesandNoslerprojectilesareattributabletothestandardmanufacturingvariationsthatroutinelyoccurondifferentproductionlots.

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TwoLW(AandB)andfiveSierra(AthroughE)projectileswerealsotested(fig.20andtable7).

Figure20SidebysideSierraandLWprojectilecross-sectionvisualinspection

Table7

Weightsanddimensions(SierraandLW)

ProjectiletypeSamplenumber

Weight(gm)

Weight(gr)

Length(in.)

Borediameter(in.)

A 2.909 44.9 0.605 0.225LeMasLWprojectile

B 2.911 44.9 0.605 0.225

A 2.916 45.0 0.630 0.225B 2.926 45.1 0.625 0.225C 2.911 44.9 0.625 0.225D 2.916 45.0 0.626 0.225

Sierra1310

E 2.903 44.8 0.631 0.225

TheLeMasLW(Sierra)designandtheSierrabulletdifferedbynomorethan0.2grainsinweightandby0.026in.inlength. 36Borediameterswereidentical._______________________36Thedifferenceinlengthisprimarilyduetodifferencesindeformationintheexposedleadtip.Sinceleadisarelativelysoftalloy,materialcompressioncaneasilyoccur.Differencesintheassemblyprocess,suchastheadditionofthemolycoatingstep,(aswellaslottolotdifferences)mayaccountfortheslightdifferenceinlengthaswell.

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TheLeMas7.62-mmLWprojectilewasalsoexaminedbyARDEC,butonlyonalimitedandpreliminarybasis(fig.21).

Figure217.62-mmLeMasLWprojectile(ARDECasreceived)

ARDEC Cross-Section Visual Inspection Tests Boththe5.56-mmUW(Nosler)andLW(Sierra)projectileswerecrosssectionedandmeasured.Bothdesignshavejacketsthatbeartoolmarks.Thisindicatesthatthejacket

wasstretchedorswagedinadietoachieveitsfinalshape.Thisindicatesthatthejacketswerenotproducedusingpowdermetallurgy(P/M)techniquesasa(P/M)partisusuallyproducedinitsfinalshapeanddoesnothavethetoolingmarksandwrinklesthatwereobservedonthejacketsofbothdesigns(figs.22and23).

Figure22LeMasUW(left)andLeMasLW(right)jacketexamination

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Figure23

Dimensionalmeasurementsofcrosssectioned5.56-mmprojectiles

USSOCOM Physical Inspection of Test Ammunition AsdidtheFBIandARDEC,USSOCOMperformedasetofroutinevisualanddimensionaltestspriortoconductingafullsuiteofperformancetests.Theresultsareoutlinedinthefollowingsectionsandreinforcetheconclusionthatthetestedprojectilesaresimilartoothercommercialprojectiles. Table8documentsthephysicalcharacteristicsofthetestammunition.

Table8Testammunitioncharacteristics

Caliber DODIC Model Manufacturer LotNumber

A059 M855LakeCityAmmunitionPlant

(LCAA) LC-90J082-629

W105 LandWarfare LeMasLtd./RBCD 040401-025.56x45mma.k.a.

.223RemingtonW141

Sierra"Varminter" B.R.Consulting(BRC) BRC-May-2005-556mm

AA11 M118LR LakeCityAmmunitionPlantLC-03D271-012(SubLot

G)

W106 LandWarfare LeMasLtd./RBCD 04041401-027.62x51mma.k.a..308Winchester

W142 Speer"Hot-Cor" B.R.Consulting(BRC) BRC-May-2005-762mm

A363 M882WinchesterCartridge

Company WCC03G037-012

W107 CQBSPLP(H) LeMasLtd./RBCD 03013-49x19mma.k.a.9mmLuger

W143 IQ Aguila n/a

Figures24through26documenttheinitialphotographsthatweretakenofthetest

ammunition.Ineachphotograph,theLeMasLtd.ammunitioncartridgescontainaheadstamp,whichshowsthatthebrasscasewaspurchasedfromanoutsidesource.Itisalsonotedthatthephotographsalsoshowthebulletsurrogates,whichweredevelopedaspartoftheoperationaltestphase.Thiswillbediscussedinlatersections.

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USSOCOM 5.56-mm Test Ammunition Visual Inspection Photographs.

Figure24USSOCOM5.56-mmvisualinspectiontests 37,38,39

_______________________37Photographsarenottoscaleortosize.38LeMasLtd.ammunitionislistedasthemanufacturer,butisactuallythemarketerforRBCDPerformancePlus,Inc.39DODICW141(bottomprojectile)arenotcommerciallyavailable.TheyweredevelopedandmanufacturedforthistestbyBRC(undergovernmentguidance)toprovidetestammunitionofsimilardesignasLeMasLtd.

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USSOCOM 7.62-mm Test Ammunition Visual Inspection Photographs.

Figure25Basicdescriptionofthe7.62x51-mmtestammunition 40,41,42

_______________________40Photographsarenottoscaleoractualsize.41NotethattheLeMasLtd.cartridgehasaWinchesterheadstamp.ThissuggeststhatWinchestercartridgecomponentswereusedintheLeMasproduct.42DODICW142(bottomprojectile)arenotcommerciallyavailable.TheyweredevelopedandmanufacturedforthistestbyBRC(undergovernmentguidance)toprovidetestammunitionofsimilardesignasLeMasLtd.

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USSOCOM 9-mm Test Ammunition Visual Inspection Photographs.

Figure26Basicdescriptionandphotographsofthe9x19mmtestammunition 43,44,45

_______________________43NotethatW107(LeMas)projectileshownissimilarinnappearancetothedesigndescribedintheRBCDpatent.44NotethattheLeMascartridgehasaLugerheadstamp.ThissuggeststhatLugercartridgecomponentswereusedintheLeMasproduct.45DODICW143AguilawasusedintheSOCOM9-mmtests.Fromthecrosssection,itisclearthattherearesomedifferencesinthedesignsofthethree9-mmprojectiles.

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USSOCOM DimensionalAnalysisTests. Whileavisualinspectionwasperformedtodeterminethatthecartridgesareincompliancewithapplicabledrawings,adimensionalinspectiondeterminesthemanufacturersqualitycontrolandconsistencyatmanufacturingammunition(fig.27). References:

MIL-STD-636(VisualInspectionStandards)ANSI/SAAMIZ299.4-1992(CenterfireRifleSportingAmmunition)ANSI/SAAMIZ299.3-1993(CenterfirePistolandRevolverAmmunition)SOP/BRC/2004StandardOperatingProcedure(DimensionalInspectionofSmallArmsAmmunition)ARDECDrawing7643674(ClassificationofCartridgeDefects)

Toaccomplishthisrequirement,asampleof40cartridgesofeachammunitiontypewasrandomlyselectedforvisualanddimensionalinspection.Eachdimensionwasmeasuredtothenearest0.001in.orweighedtothenearest0.1grain(tables9through11).

Observations:Dimensionalmeasurementscaninfluencetheoverallperformanceoftheweaponsystem.Forexample:

Acartridge,whichistoolongmaynotfitinastandardmagazine Acartridge,whichistoolongortooshortmaynotfeedproperly. Arimdiameter,whichissmallerthanthespecificationcanresultina failuretoextract Acartridgewithamouthdiametergreaterthanthespecificationmay resultinafailuretochamber.

Figure27

Dimensionalmeasurementstakenontestammunition

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Table9Summaryofmeasurementsfromthedimensionalinspectionof5.56x45mmtestammunition 46,47

Table10Summaryofmeasurementsfromthedimensionalinspectionof7.62x51mmtestammunition

_______________________46O.A.L.=Overalllength.47SAAMI:SportingArmsandAmmunitionManufacturersInstitute,Inc.

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(b) (4)(b) (4)(b) (4)

(b) (4)

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Table11Summaryofmeasurementsfromthedimensionalinspectionof9x19mmtestammunition

Conclusions:

1. Novisualdefectswerenotedonanyofthetestammunition2. Everycartridgecompliedwithtolerancelimitsestablishedfor commercialindustry3. Thesoftpointdesignswereeasilydeformed.Variationsinnoseshape

canpotentiallyhaveaneffectonvariousperformanceparameterssuch asdispersionandpenetration.Inaddition,itisnotedthatexposedlead tipsdonotfeedintoweaponsaswellasotherdesigns.

GeneralizedSummaryofARDEC,FBI,andUSSOCOMTests . Uponfurtherinspectionofthecommonbrass,propellant,andprimercomponents,itisdifficulttodeterminewhat(ifanything)makestheoverallLeMasrifleproductdifferentfromsimilarlyloadedNoslerandSierrariflecartridges.ItdoesnotseemlikelythatasupposedproprietaryLeMas(RBCD)projectiledesignwouldduplicateotherproprietaryprojectilessoprecisely,andyetproduceanextraordinaryincapacitationresultwhenfiredagainstlivingtissue. 48 LeMass9-mmpistolcartridgewasnotpositivelyidentified,andcouldhave

warrantedfurtherscrutiny;however,theresultsoftheoperationalandsafetytestsshowedthatthecartridgehasotherissues(discussedlater)._______________________48ThisspeculationwaslatertestedbyoneoftheFBIinvestigatorswhousedseveralroundsofLeMasammunitionduringanauthorizedandsuperviseddeerhunt.Twosolidhits(under100yards)wereobservedbytheinvestigatorandbyawitnessinggamewarden.Noinstantincapacitationswereobserved.

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Recommendations TheFBIexaminersrecommendedthefollowingcourseofaction:

1. Ceasealleffortsassociatedwiththistestinguntiltheoriginofthe projectileswaspositivelyestablished.

2. AdviseRBCDthattheIPTrequeststoviewtheirmanufacturingprocess3. DonotprovidefurtherinformationtoRBCDuntiltheyhaveproventhat theymanufacturetheprojectiles.4. ForwardasampleoftheRBCDprojectilestoNoslerandSierrafor examination.(Donotindicatethesourceoftheprojectiles.)5. HaveARDECsmetallurgistteamconductlogical,side-by-side examinationsoftheRBCDandNosler40-grainballistictipprojectiles.49

AnIPTsitevisittoLeMaswasrequestedbytheSOCOMlead(viaemail)on16August2004.LeMasrespondedasfollows:

Therequesttoobserveboththemanufacturingandloadingprocessforthesebulletdesignsisrespectfullydeclinedatthispointinourrelationship.BothLeMasLtd.andRBCDconsiderthisinformationmosthighlyproprietary.LeMasLtd.completelyfailstograspthisrequirementasanelementforanyoperationalevaluation,aspromisedbyCol.Spellissy,todeliveratesttogiveusconclusiveevidenceofthesuitabilityandeffectivenessofthisammunitionformilitaryuse(intheArmedForcesJournalMay04letterspage6)Accesstothemanufacturingfacility,manufacturingprocess,andloadingprocesswillnotbeprovidedtotheUSgovernmentoranyotherentitywithoutcontractualcommitmentsforsustainedprocurement,insubstantivequantitiesIfyoufeelthatbeingdeniedaccesstothemanufacturingfacilityandproprietarydesignconstructioninformation,willprohibittheTIPTteamfromobjectivelyproceedingwitheffortstovalidateandevaluaterealworldoperationalcapabilityfortheBMTammunition,pleaseletusknownow.LeMasLtd.willforwardthisimpassetoourCongressionalrepresentatives. 50

Metallurgical and Structural Tests

MetallurgicaltestswereconductedonLeMasprojectilesatARDEC.Thesetestsuse

visualcuesinthemicrostructureofthematerialtoderiveprobableanswerstothequestionofhowtheprojectilewaslikelymanufactured.Inthisinstance,thesetestswereabletoshowthatLeMasbulletshaveamicrostructurethatisconsistentwithcommon,unbonded,swagedbullets._______________________49Tothisend,ammunitionfromtheSOCOMprocurementwassenttoARDEC.50Emailavailableuponrequest.

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ARDEC Microstructure and Mechanical Property Tests Examiningthemicrostructuresofthematerialspresentprovidesinsightintohowtheprojectilesweremanufacturedandwhether,specifically,theLeMassubmissionswereproducedusing(P/M)techniques.

Urban Warfare Microstructure.Figure28showstheUWcross-sectionimageofthelocationsofmicrostructurethatwereanalyzed.

Figure28

UWcross-sectionimageshowinglocationsofmicrostructureanalyzed Urban Warfare Nosler) Lead Core:Themicrostructureoftheleadcore(fig.29)containsrecrystallized,equiaxedgrainsthataretypicalofextrudedorswagedlead.Theleadcoremicrostructureisnotconsistentwith(P/M)techniques.Morelikely,thecoreswereformedbyplacingasmallpieceofleadintoadieandsqueezedintoitsfinalshape(swaging).Thisisaverycommonpracticeforprojectilecores.

Figure29LeMasUWleadcoremicrostructure 51

Urban Warfare Nosler) Copper Jacket(fig.30):Themicrostructureofthejacketwasexaminedatdifferentlocationsofthebullet(fig.28).Fromtheresults,itwasdeterminedthatthecopperjacketwasformedbyswaging(i.e.,astartingcupwasplacedintoadieandsqueezedintoitsfinalshape).Theelongatedgrainsinthesidewallsofthecupsupporttheideathatthejacketwasformedthroughsomesortofswagingoperation(figs.31and32). 52,53_______________________51Thecolorsshownareattributedtothetestprocessandareforillustrativepurposesonly.52Therewasaconcernthatthemarkingsmightbemistakenassawmarksfromtheactofcuttingtheprojectile.Thisisnotthecase.Foronething,thedirectionofthestretchedgrainsisnotconsistentovertheentirelengthoftheprojectile.Foranother,thesizesvary.Consequently,thisexplanationcanberuledout.53Althoughnotuncommon,bulletjacketsaregenerallydrawnandnotswaged.

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Figure30UW(Nosler)copperjacketmicrostructureimages 54

UW Microstructure

Figure31UWcartridgemicrostructure

_______________________54Thelinetypeformationsonthefirsttwopicturesareelongatedgrainsandareessentiallystretchmarks.

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Nosler Microstructure.

Figure32Noslerballistictipmicrostructure

Note:Theminordifferencesinthetwoimages(figs.31and32)areexpectedandarenotconsideredtobesignificant.Therefore,itcanbeconcludedthatthesearethesamebulletdesign. Land Warfare Sierra) Microstructure.TheLWcross-sectionimageshowing

locationswheremicrostructureswereanalyzedcanbeseeninfigure33.

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Figure33LWcross-sectionimageshowinglocationsofmicrostructureanalyzed

Land Warfare Sierra) Lead Core:Themicrostructure(fig.34)oftheleadcorecontainsgrainsthataredark(lead-rich)andwhite(antimony-rich)andisdeemednormalforantimoniallead96Pb-4Sb.Theseleadcoreimagesarenotconsistentwithwhatwouldbeexpectedif(P/M)techniqueshadbeenused.

Figure31LWleadcoremicrostructure 55

Land Warfare Sierra) Copper Jacket:Themicrostructureofthejacketwasexaminedatdifferentlocationsonthebullet(fig.35).Themicrostructurenearthebasedoesnotshowsubstantialgraindeformation.However,thesidewallofthejacketdoesshowelongateddeformedgrains(fig.35).Basedontheseobservations,theLWjacketisconsistentwithajacketthatwasformedfromastartingcup,whichwassqueezedintoitsfinalshape[swaging(figs.36and37)].

_______________________55Reminder:Thecolorsshownareattributedtothetestprocessandareforillustrativepurposesonly.

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Figure35LW(Sierra)copperjacketmicrostructureimages

LW Microstructure.

Figure36LWcartridgemicrostructure

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Sierra Microstructure.

Figure37

Sierra"Varminter"microstructureNote:Theminordifferencesinthetwoimages(figs.36and37)areexpectedandarenotconsideredtobesignificant.Therefore,itcanbeconcludedthatthesearethesamebulletdesign.

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Microstructure Summary.BoththeLeMassubmissionmicrostructuressuggestthatthejacketsandcorewerenotformedusing(P/M)techniques.Thisisreinforcedbythefactthatthejacketsonbothprojectiledesignsshowevidence(elongatedgrains)ofswaging.Con-sequently,theresultsofthesetestsconclusivelysupporttheFBIspositionthattheLeMasprojectilessoldtothegovernmentwerenotbasedon(P/M)technology. 56

Micro-hardnessData. Thecombinationofmicrostructurephotographsandmicro-hardnessvaluescanbeusedtoprovideanestimationofthemechanicalpropertiesofthematerial.FourteenidenticallocationsonboththeLeMasUWbulletandtheNoslerballistictipbulletwereidentifiedforanalysis(table12).Threemeasurementsweretakenoneachlocation.Hardnessvalues(VickersHardnessscale)forlocations12through14aresignificantlylowersincetheyareontheleadportionofthebullet.

Table12Samplemicro-hardnessvaluesobtainedforLeMasUWandNoslerballistictipprojectiles

_______________________56ItalsosupportedtheassertionthatLeMasacquiredprojectilesfromNoslerandSierra.

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Differencesbetweenthemicro-hardnessvalues(figs.38and39)fortheLeMasandNoslerprojectilesfallwithintheexpectedbandofvariationanddonotsuggestanymechanicalpropertydifferencesbetweenthetwodesigns.ThissuggeststhatthereisnomeasurabledifferencebetweentheLeMasprojectileandtheNoslercontrol.

Hardness Values by Location

0

20

40

60

80

100

120

140

160

180

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Location

VickersHardnessValue(DPH)

LeMas Urban Warfare Reading 1 LeMas Urban Warfare Reading 2 LeMas Urban Warfare Reading 3

Nosler "Bal list ic Tip" Reading 1 Nosler "Bal list ic Tip" Reading 2 Nosler "Bal list ic Tip" Reading 3

Figure38

ResultsofthreeseparatemicrohardnessreadingsonNoslerandLeMasammunitionsamples

Figure39Repeatabilityofmachinescriteriaformicrohardnesstests(ref.15)

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Themicro-hardnessvaluesshownintable13andfigure40aremeasuredontheVickersscale57andareconsideredtobesimilar.Asaresult,theLeMasLWblendedmetalprojectileandtheSierracontrolwerealsoshowntobeequivalentbythistest.

Table13Samplemicro-hardnessvaluesobtainedforLeMasLWandSierraprojectiles

_______________________57ASTMMethodE384.

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Hardness Values by Location

0

20

40

60

80

100

120

140

160

180

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Location

VickersHardnessValue(DPH)

LeMas Land Warfare Reading 1 LeMas Land Warfare Reading 2 LeMas Land Warfare Reading 3

Sierra "Varminter" Reading 1 Sierra "Varminter" Reading 2 Sierra "Varminter" Reading 3

Figure40

Resultsofthreeseparatemicro-hardnessreadingsonSierraandLeMasammunitionsamples Hardnessvaluesatvariouslocationswerealsousedtoestimatesomeofthemechanicalpropertiesoftheprojectiles.Thesepropertiesareanindicationoftheruggednessoftheprojectileandareausefulpartoftheprocessforgauginghoweffectivetheprojectilemightbeagainstvariousintermediatebarriers(cardoors,sand,windows,etc). Theresultsoutlinedintable14areconsistentwithotherleadbulletsofthistype.

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Table14EstimatedmechanicalpropertiesofprojectilessuppliedbyLeMasLtd. 58

ARDEC Bonded Projectile Test

TheLeMas5.56-mmsubmissionswerebothtestedtoseeiftheleadcoreswerechemicallybondedtothecopperjackets.Chemicallybondedbulletsaremoreruggedandare

betterpenetratorsthannon-bondedbullets(fig.41). Bondingtestscanbeconductedby:

Physicallyattemptingtopulltheleadoutofthecopperjacket Examiningtheinterfacebetweenthecopperjacketandtheleadcore materialunderamicroscopetoascertainifleadhaspenetratedthe copperjacket.

Figure41Bondedtestsamples(NoslerandUW)

BoththeLeMas(labeledasblendedmetalinfig.42)andNoslerbulletswereeasilyseparatedanditwasdeterminedthatthebulletswerenotbonded. 59_______________________58Note:Hardnessvaluesweremeasuredinalaboratoryandusedtoobtainestimatedmechanicalpropertiesfromhandbookdata.59Thiswasnotunexpectedasammunitionmanufacturersgenerallyhighlightandadvertisewhichoftheirbulletsarebonded.

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Figure42

Bondedtestsamples(SierraandLW) Insummary,bothoftheLeMassubmissionsshowednoevidenceofbeingbonded. USSOCOM Cartridge Case Hardness Test Thecartridgecaseisrequiredtodoavarietyoftasks.Itmustcontainthepropellantchargeandprimer.Itmustsealofftherearofthechamberwhenfiredandsafelycontaintheimmensepressureinside,yetpermitthecasetoberemovedwitheaseafterfiring.Itmustholdthebulletinplacetightlyenoughtokeepatmosphericdampnessout,yetreleasethebullettotraveldowntheboreunderpressureoftheignitedpowder.Itmustholdtheprimertightlyinplaceduringfiring,sothatitdoesntfallouttojamthefiringmechanism.Figures43through45andtables15to17showwherethehardnessmeasurementsweretakenandtheresults. Reference:

1. ARDECDrawing11820451(Caliber5.56mmCaseHardnessGradient)

2. ARDECDrawing12977196(Caliber7.62mmHardnessGradient)3. DTL85797555(MilitarySpecificationfor7.62mm,SpecialBall,Long Range)4. MIL-C-63989C(MilitarySpecificationfor5.56mm,M855)5. SOP/BRC/2004StandardOperatingProcedure(CaseHardnessTestof 9x19mmSmallArmsAmmunition)6. ASRMMethodE92-82R92(MethodofTestforVickersHardnessof MetallicMaterials)

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Figure43LocationsforVickersDPNhardnessmeasurements5.56-mmcartridgecases

Table15

AverageVickersDPNhardnessmeasurementsfor5.56x45-mmcartridgecases 60,61

Note1:M855s(DODICA059)requirementwasusedasthehardnessrequirement. Allthree5.56x45-mmammunitiontypesfailedtomeetthehardnessrequirement,asspecifiedinthemilitaryspecification. 62

_______________________60Note:DPNvaluesinredfailedtomeetM855(A059)specifications.61DODICA059istheM855,DODICW105istheLeMasLWsubmission,DODICW141isaSierra1310Varminter.

62Whythetestedmilitarycartridgefailedtomeetthehardnessrequirementisunclear,butrupturesgenerallyoccurrednearoneoftheends,notinthemiddlesoitisquitepossiblethatthislotreceivedawaiverwhichwentunnoticed.

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Figure44

LocationsforVickersDPNhardnessmeasurements7.62-mmcartridgecases

Table16AverageVickersDPNhardnessmeasurementsfor7.62x51-mmcartridgecases 63

Note2:M118LRs(DODICAA11)requirementwasusedasthehardnessrequirement.

Bothcommercialammunitiontypesfailedtomeetthehardnessrequirement(inmultipleareas),asspecifiedinthemilitaryspecification._______________________63DODICAA11istheM118LR,DODICW106isthe7.62-mmLeMasLWsubmission,andDODICW142istheSpeerHot-Corprojectile.

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Figure45LocationsforVickersDPNhardnessmeasurements9-mmcartridgecases

Table17

AverageVickershardnessmeasurementsfor9x19-mmcartridgecases 64

Note3:M882(DODICA363)waschosenasthebaseline9x19mmammunitionforthistest;however,therearenoestablishedcasehardnessspecificationsfortheM882.Sincetheobjectiveofthistestwastodevelopadatasetforfuturecomparisons,ahybridrequirementusingtheaveragecasesidewallhardnessresultsfortheM882(+/-3standarddeviations)andthecaseheadhardnessrequirementsfortheM855wasusedasaguide.Note4:TheminimumspecificationisbasedontheaveragehardnesslevelforM882(DODICA363)minus3standarddeviations.

Note5:ThemaximumspecificationisbasedontheaveragehardnesslevelforM882(DODICA363)plus3standarddeviations. Bothcommercialammunitiontypesfailedtomeettheproposedrequirement._______________________64DODICA363istheM882,DODICW107isLeMasCQBSPLP(H)andW143isa65-grainnAguilaprojectile.

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USSOCOM Bullet Pull Extraction) Test Anotherphysicaltestisthebulletpulltest.Thistestdetermines,undercontrolledconditions,theforcerequiredtoremovetheprojectilefromthecaseofanassembledcartridge(fig.46).Bulletpulldata(table18)isusedasameasureofuniformityandefficiencyinwhichthebulletsaresecuredinthecartridgecases.Consistentbulletpullisnecessaryformaintaining

uniformperformance(velocity,pressure,dispersion,reliability,etc.)fromroundtoround.Bulletpullisalsoimportanttoensurethatthebulletdoesnotcomeoutofthecasemouth(de-bullet)whenchambered;orgetpushedintothecaseduringroughhandlingorfeeding.

Figure46Illustrationofbulletcrimp

Reference:

1. MIL-STD-6362. AmmunitionBallisticAcceptanceTestMethods,forcaliber5.56-mm ammunitionandforcaliber7.62-mmammunition.3. DOD-STD-1468(SmallCaliberAmmunitionTestProcedures,9-mm Cartridges)4. MIL-C-63989(Specificationfor5.56mm,BallM855).5. DTL-85975556. MIL-C-70508(Specificationfor9mm,Ball,M882)

Table18Summaryofbulletpullresults(highlightedresultsareoutsideofspecification)

Note:Minimumbullet-pullrequirementsforbaselinesystems:

1. A059(M855)greaterthanorequalto45lb2. AA11(M118LR)greaterthanorequalto20lb3. A363(M882)greaterthanorequalto60lb(individual)and80lb(average)

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Conclusions:SeveraloftheLeMasdesignstestedeitherfailedtomeetexistingstandardsorbarelymetexistingstandards.However,itisnotedthatdifferencesinbulletdesign,waterproofingcompound,andamountofcrimpmayhavecontributedtotheseresults,andthatsomeofthespecificationsarenotabsolutes. 65Spectrometry and X-ray Tests

Semi-quantitativealloyidentificationanalyseswereperformedonthecommercial5.56-mmprojectiles.66Thetestchosen,EnergyDispersiveSpectroscopy(EDS),wasdoneinaccordancewithASTME1508,andenablesidentificationofelementsalongwiththeirrelativeproportions.Severalrunsweredoneoneachsample.TheresultsofthisparticulartestingseriesconfirmedthattheLeMas5.56-mmriflesubmissionscontainedasubstantialquantityoflead. 5.56mm Component Testing Urban Warfare Nosler) Core:Thechemistryofthecore(fig.47)materialisaclosematchtoalloyscontaining96to99weight%leadand1to4weight%antimony(ref.16).Thischemicalrangeencompassestwoantimonialleadalloyscalled:99Pb-1Sband96Pb-4Sb

(whichisalsocalledHardLead96-4).

Figure47ExampleUW(Nosler)corechemistryspectrumresult 67

_______________________

65LeMasammunitionisnotmanufacturedtomeetM855requirementsandspecifications.Consequently,failuretomeetunknownrequirementsandqualificationsisnotunexpectedandcouldpossiblybefixed.66Specifically,theLeMasUW,LeMasLW,Noslerballistictip,andSierraVarmintercartridgesweretested.67Multipleanalyseswereconductedbeforeafinaloveralldeterminationwasmade.Thispictureisanexampleofoneoftherunsthatwasconducted.

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(b) (4)


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Urban Warfare Nosler) Jacket:Thechemistryofthejacket(fig.48)isaclosematchtowhatwouldbeexpectedforcopperalloy21000(gildingmetal)(ref.?). 68,69

Figure48

ExampleUWjacketchemistryspectrumresult69

Urban Warfare Nosler) Jacket Coating:Thechemistryofthejacketcoating(fig.49)ismolybdenumdisulfidewhichiscommonlyusedasadrylubricant.

Figure49UWjacketcoatingchemistryspectrumresult 71

_______________________6895%copper5%zinc.69Thisisacommonbulletjacketmaterial.70Multipleanalyseswereconductedbeforeafinaloveralldeterminationwasmade.Thispictureisjustanexampleofoneoftherunsthatwasconducted.71Ibid.

53

(b) (4)

(b) (4)


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Urban Warfare and Nosler Comparison.Side-by-sideresultsshowthatthechemicalcompositiondifferencesareminimal(fig.50). 72

Figure50UWandNoslerballistictipcomparativechemicalanalysis

Land Warfare Sierra) Core:Thechemistryofthecorematerial(fig.51)isaclosematchtoliteraturereferencesthatcontain96weight%leadand4weight%antimony.Thischemicalrangeencompassesoneantimonialleadalloycalled:96Pb-4Sb(alsoknownasHardLead96-4)(ref.16).

Figure51

LWcorechemistryspectrumresult 73

_______________________72Foragivenprojectiledesigntherewillbearangeofresultsthatreflectlottolotproductionvariances.Additionally,aswithalltests,thereissomeamountofsystemicerrorthatwillresultinminorexperimentaldifferences.Thisisnotsignificant,butisnoted.73Multipleanalyseswereconductedbeforeafinaloveralldeterminationwasmade.Thispictureisanexampleofoneoftherunsthatwasconducted.

54

(b) (4)

(b) (4)

(b) (4)


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Land Warfare Sierra) Jacket:Thejacketmaterial(fig.52)isaclosematchtotheliteraturereferencefor95%copper5%zincorgildingmetal(ref.16).

Figure52LWjacketchemistryspectrumresult 74

Land Warfare Jacket Coating:Thejacketcoating(fig.53)ismolybdenumdisulfidewhichisacommondrylubricant.

Figure53LWjacketcoatingchemistryspectrumresult 75

_______________________74Ibid.

75Ibid.

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Land Warfare and Sierra Comparison.Aswiththeprevioussetoftests,thesidebysideresults(fig.54)showthatthechemicalcompositiondifferencesbetweenthetwoprojectilesarewithintheexpectedrangeofmanufacturingvariation.

Figure54

LeMasLWandSierraVarmintercomparativechemicalanal

20070600 blended metal technology projectiles review and analysis_redacted

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