HS-4083-C01-1240_Rev_C_Frangible,_MK311_MOD_0.pdf

HS/4083/C01/1240 Rev C

HYBRID SPECIFICATION

CARTRIDGE, CALIBER 5.56MM, FRANGIBLE, MK 311 MOD 0

1. SCOPE

1.1 This specification establishes the product and performance requirements for the Cartridge, Caliber 5.56mm, Frangible, MK 311. This ammunition shall be referred to herein as 5.56mm Frangible.

2. APPLICABLE DOCUMENTS

2.1 Government Documents. The following documents of the latest issues shown form a part of the specification to the extent specified herein.

SPECIFICATIONS

Military

MIL-L-63460 Lubricant, Cleaner and Preservative for Weapons and Weapons Systems

STANDARDS

Military

MIL-STD-636 Visual Inspection Standards for Small Arms Ammunition through Caliber .50

MIL-STD-644 Visual Inspection Standards and Inspection Standards for Inspection of Packaging, Packing and Marking of Small Arms Ammunition

MIL-STD-1168 Ammunition Lot Numbering Shipment

DOD-STD-2101 Classification of Characteristics

DRAWINGS

U.S. Army Armament Research and Development Command

19200-7643674 Classification of Cartridge Case Defects 19200-9378276 Case 19200-11820451 Case

19200-8649409 Barrel, Test, Accuracy, 5.56mm

PUBLICATIONS

U.S. Army Armament Command

SCATP-5.56MM (Heavy Bullet) Small Caliber Ammunition Test Procedures, 5.56mm (Heavy Bullet) Cartridges

(Unless otherwise indicated, copies of the above specifications and standards are available from the Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Avenue, Philadelphia, PA 19111- 5094.) (Copies of drawings and publications required by contractors in connection with specific procurement functions should be obtained from NAVAL SURFACE WARFARE CENTER CRANE DIV, CODE JXNN, CRANE, IN 47522-5005.)

2.2 Non-Government Documents. The following documents of the

exact issues shown form a part of this specification to the extent specified herein.

ANSI/ASQC A8402-1994 Quality Management and Quality Assurance - Vocabulary

ASTM B19-10 Standard Specification for Cartridge Brass Sheet, Strip, Plate, Bar, and Disks ANSI/ASQC Z1.4-2008 Sampling Procedures and Tables for

Inspection by Attribute

(Application for copies should be addressed to the American National Standards Institute Headquarters, 1899 L Street, NW, 11th Floor, Washington, DC 20036 or the American Society for Testing and Materials International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. ANSI and ASTM may also be contacted via their web sites at www.ansi.org or www.astm.org.)

2.3 Order of Precedence. In the event of a conflict between the contract, the text of this document, and the references cited herein, the contract takes precedence, followed by the text of this document, then the documents referenced herein. However, nothing in this document supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 General.

3.1.1 Item Definition. The cartridge described by this

specification is 5.56mm Frangible ammunition and is intended to be used in rifles and carbines chambered for this caliber without modification.

3.2 Classification of Characteristics. DOD-STD-2101 shall be

used for classification of characteristics. Where critical or major characteristic requirements are listed in this specification, they are annotated by a "C" or "M" and sequential reference number starting with "1" for critical and "101" for major. The letter and number are contained in parentheses. The main statement of the requirement is then surrounded by brackets, "[]". Minor characteristic requirements contain no annotation.

3.2.1 Critical Characteristic. One that analysis indicates is likely, if defective, to create or increase a hazard to human safety or to result in failure of a weapon system or major system to perform a required mission.

3.2.2 Major Characteristic. One that analysis indicates is not critical but is likely, if defective, to result in failure of an end item to perform a required mission.

3.2.3 Minor Characteristic. One that analysis indicates is

significant to product quality but is not likely, if defective, to impair the mission performance of the item.

3.3 Components. All components, packaging, and shipping

materials shall be of new manufacture and shall look to be clean and in new condition.

3.3.1 Projectile. (C1) [The projectile shall not contain lead and other toxic material.] The core of projectile shall be made of metal powder or powders that are either compressed or bound with polymer material and semi-jacketed with gilding metal. The projectile tip shall not be hollowed.

3.3.1.1 The projectile diameter along the cylindrical bore

bearing surface shall be 0.2245 inch maximum, 0.2239 inch minimum.

3.3.2 Cartridge Case. The cartridge case shall be constructed of copper alloy in accordance with ASTM B19-10 and shall not be plated. The cartridge case shall meet the external dimensional requirements of Drawing 19200-9378276 or Drawing 19200-11820451.

The vent hole dimensions can be modified in order to optimize the burning characteristics of primer/propellant. (C2) [A vent hole shall be present in the primer pocket of the cartridge case.]

3.3.2.1 The cartridge case headstamp marking shall consist of the Identification Code of the Manufacturer and last two digits of year of manufacture.

3.3.3 Propellant. Each cartridge shall contain smokeless

propellant. Nominal charge weight shall be established by the manufacturer to meet performance requirements.

3.3.4 Primer. (C3) The primer mix shall not contain lead and

other heavy metals such as antimony, barium, cadmium, etc.

3.3.5 Primed Case Sensitivity. The average critical height (H) plus three standard deviations (3 sigma) shall be 12.0 inches maximum and the average critical height minus three standard deviations (3 sigma) shall be 3.0 inches minimum

3.3.6 Residual Stress. The cartridge case shall not split when subjected to a one percent mercurous nitrate solution for 15 minutes.

3.4 Complete Cartridge.

3.4.1 Primer Seating Depth. (M101) [The primer shall be seated flush to 0.008 inch below flush] of the face of the cartridge case head.

3.4.2 Cartridge Overall Length. (M102) The overall length of the assembled cartridge shall be 2.260 inches maximum, 2.165 inches minimum.

3.4.3 Bullet Extraction. The force required to extract the

projectile from the cartridge case shall be 25 pounds minimum.

3.5 Cartridge Ballistics Tests.

3.5.1 Chamber Pressure.

3.5.1.1 (M103) The average chamber pressure (corrected) of sample cartridges, conditioned at 70 °F 2 °F shall not exceed 58,700 pounds per square inch (psi). Neither the chamber pressure of an individual sample test cartridge nor the average chamber pressure plus three standard deviations of chamber pressure shall exceed 64,700 psi.

3.5.1.2 (M104) The average peak chamber pressure (corrected) of sample cartridges, conditioned at 125 °F 2 °F and -25 °F 2 °F, shall not vary from the average chamber pressure of the sample test cartridges conditioned at 70 °F 2 °F by more than 7,000 psi. The average chamber pressures of the sample cartridges of the same lot conditioned at 125 °F 2 °F shall not exceed 63,700 psi. Any decrease in chamber pressure is acceptable.

3.5.2 Accuracy. The extreme spread of any individual five (5) shot group at 100 yards using 5.56mm NATO test barrels (Drawing No. 19200-8649409) shall be 6.0 inches maximum, and the average extreme spread of all targets shall be 4.5 inches maximum.

3.5.3 Function and Casualty. The 5.56mm Frangible ammunition

shall meet the function and casualty accept/reject requirements of Table I for the M16A2/M16A3 rifle and M4A1 carbine. Misfires shall be considered separately in accordance with Table I.

3.5.4 Penetration. (M105) Fired from the M4A1 carbine, the

frangible projectiles must not penetrate or crack 3/8-inch AR500 armor plate when 20 rounds are fired at a NATO angle of 0° into a ½-inch diameter impact area from a distance of 10 feet. There shall not be fragments greater than 3.0 grains returning to the shooter during the firing. A penetration or crack occurs when a projectile or fragment has penetrated the armor sufficiently to permit the passage of light through a hole or crack developed in the armor or when the projectile lodged in the armor can be seen from the rear of the plate.

3.5.5 Ballistic Match. (M106) Fired from a 5.56mm NATO test

barrels (Drawing No. 19200-8649409), the center of impact of 5.56mm Frangible ammunition shall be no more than 2½ inches away from the center of impact of the M855 cartridge at 100 yards.

3.5.6 Bullet Integrity. (M107) The 5.56mm Frangible projectile shall not break during the firing sequences or in flight when fired from the respective weapons at temperatures ranging from -25 °F to 125 °F.

3.5.7 Function and Casualty Defects in Ballistic Test. For any ballistic test except function and casualty where the occurrence of a firing defect, the following shall apply:

a. The defect shall be recorded under the appropriate function and casualty defect category and included in the defect count for determining acceptance or rejection in accordance with Table I.

b. A replacement round shall be fired to obtain the data for the characteristic being tested if the occurrence of a firing defect prevents the obtaining of a valid data for the characteristic being tested.

c. The particular test for which the round was fired shall not be penalized.

TABLE I

FUNCTION AND CASUALTY DEFECT CLASSIFICATION AND ACCEPT/REJECT CRITERIA 1/

FIRST SAMPLE CUMULATIVE

Characteristic 2/ Classification ACCEPT/REJECT ACCEPTANCE

1. Misfire 3/ (M108) at 70 °F 2 °F and 125 °F 2 °F 1 3 2 at -25 °F 2 °F 1 3 2

2. Bullet remaining in bore 4/ (C4) 0 1 -

3. Primer leaks

a. Perforation in firing pin indent in primer cup

(1) M4A1 carbine (M109) 1 3 2

(2) M16A2/M16A3 Rifle (M110) 1 3 2

b. Escape of gas through primer cup (excluding 3.a. above) (M111) 1 3 2

c. Escape of gas around primer cup

(1) 50% or more than 50% of periphery (minor) 3 7 9

(2) Less than 50% of periphery (minor) 5 9 13

d. Blown primer - Primer separates from casehead and primer pocket is grossly distorted. 4/ (C5) 0 1 -

e. Dropped primer - Primer falls out of pocket upon retraction of bolt (M112) 0 2 1

f. Loose primer - Primer remains in pocket but is physically loose Vent area (M113) 0 2 2

4. Case casualties

a. Longitudinal split 5/

(1) Neck and shoulder (I or S) (minor) 5 9 13

(2) Body (J) (minor) 3 7 9

(3) Body (K) (M114) 0 2 1

(4) To head (L) (M115) 0 2 1

(5) Through head (M) (M116) 0 2 1

b. Circumferential rupture 5/

(1) Partial, shoulder or body (J and S) (M117) 1 3 2

(2) Partial, body (K) 4/ (C6) 0 1 -

(3) Partial, head (L) 4/ (C7) 0 1 -

(4) Complete 4/ (C8) 0 1 -

5. Weapon Stoppage (M118)

a. M4A1 carbine 4 6 8

b. M16A2/M16A3 rifle 4 6 8

6. Bullet Integrity 6/ 1 3 3

1/ The acceptance and retest numbers of Table I shall be as follows:

a. The acceptance and retest numbers shall be applied to the

M16A2/M16A3 results (all temperature combined) and the M4A1 results (all temperature combined) individually.

b. All function and casualty defects observed in ballistic tests shall be included in the defect counts of weapon type that was used in the test.

c. If function and casualty defects occurred in a test barrel, the defects shall be included in both the M4A1 and M16A2/M16A3 defect counts.

d. When either weapon test is failed and a retest is permitted by Table I, retest is performed using a double sample size in the failed weapon type only. The test shall be conducted in accordance with Appendix B. The cumulative (1st and 2nd test combined) defect count shall be evaluated against the cumulative acceptance criteria of Table I for the failed weapon type only.

2/ For definition of characteristics, see 6.1.

3/ Each cartridge that misfires shall be disassembled and examined to determine the cause of the misfire.

a. The lot shall be rejected if the cartridge does not meet the critical requirements of paragraph 3.3.2 (presence of primer pocket vent hole) or paragraph 3.3.3 (presence of propellant charge).

b. If the misfire is attributed to the test weapon, the weapon shall be repaired or replaced and another cartridge fired in place of the misfire.

4/ No second sample is permitted. Lot shall be rejected.

5/ For location of defects indicated by letters in parentheses, see Drawing 19200-7643674.

6/ The accept/reject and cumulative acceptance numbers shall be applied to the M16A2/M16A3 and M4A1 combined results (all temperature combined).

When the test is failed and a retest is permitted by Table I, retest is performed using the same sample size used in the initial test. The cumulative (1st and 2nd test combined) defect count shall be evaluated against the cumulative acceptance criteria of Table I.

3.6 Workmanship.

3.6.1 Defects. Metallic components and the completed cartridge shall be free from folds, wrinkles, deep draw scratches, scaly metal, dents, burrs, and other defects.

3.6.2 Foreign Material. All components and the completed

cartridge shall be free of foreign material including, but not limited to, corrosion, stains, dirt, oil, grease, smears of lacquer, and metal chips.

3.6.3 Visual Standards. The cartridge and components shall meet the visual standards requirements of MIL-STD-636A.

Classification of individual visual and workmanship characteristics shall be as defined by MIL-STD-636A.

3.6.4 Mixed Ammunition Types. (C9) [The occurrence of any mixed ammunition types other than a dummy or blank cartridge shall be classified as a critical defect and result in rejection of the lot.] (M119) [Occurrence of a dummy or blank cartridge shall be classified as a major defect] and shall require cartridge replacement and subsequent 100% re-inspection of the lot. If the occurrence of dummy and/or blank cartridges is more than 0.001% of the lot size, the lot shall be rejected.

3.6.5 Lot Formation. Each inspection lot of cartridges shall be submitted in accordance with ANSI/ASQC Z1.4-2008. Lot size shall be 200,000 cartridges minimum and 1,200,000 cartridges maximum.

Each lot shall be assigned a lot number in accordance with MIL-STD-1168. Only one type and weight of propellant shall be used in a lot of cartridges. Each lot shall contain no more than one lot of primers and one lot of propellant. Individual components manufactured by more than one contractor shall not be used in a lot of cartridges.

3.6.6 Primer Lots. The size of any lot of primers used in the cartridges shall be 200,000 units minimum and 1,300,000 units maximum. A primer lot shall consist of a specific product, made on consecutive work shifts, with no break in the production of that specific product.

4. VERIFICATION

4.1 Responsibility for Inspection. Unless otherwise specified herein, in the contract, or in the purchase order, the supplier is responsible for the performance of all inspection and test requirements as specified herein. Except as otherwise specified, the supplier may utilize his own facilities or any commercial facility acceptable to the Government. The Government reserves the right to perform any of the inspections and tests set forth in this specification where such inspections and tests are deemed necessary to ensure supplies and services conform to prescribed requirements. Unless otherwise specified herein, in the contract or in the purchase order, all test and inspection equipment (including test barrels and test weapons) shall be supplied and maintained by the contractor.

4.2 Responsibility for Compliance. All items shall meet all

requirements of sections 3 and 5. The inspections set forth in this specification shall become a part of the contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of ensuring all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements; however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to accept defective material.

4.3 Quality Assurance Terms and Definitions. Reference shall be made to ANSI/ASQC A8402-1994 for definitions of quality assurance terms.

4.4 Non-Destructive Inspection Provisions. Unless otherwise

specified herein, the contract or purchase order, General Inspection Level II and Single Sampling Plans for Normal Inspection that are detailed in Table I and Table II of ANSI/ASQC Z1.4-2008 shall be used as the sampling plans and acceptance criteria for nondestructive acceptance inspection of major and minor defects. Inspection shall be by characteristic. Unless otherwise specified the Acceptance Quality Level (AQL) shall be .15 for the inspection of major defects, and the AQL shall be .65 for the inspection of minor defects. Unless otherwise specified, 100% inspection shall be used for all non-destructive inspection of critical characteristics. The acceptance criteria shall be to accept on zero defects and reject on one or more defects for the inspection of critical characteristics. Section 3 and 5 requirements that are not annotated as critical or major shall be classified as minor. Unless otherwise specified, each lot of components and each lot of cartridges shall be inspected in accordance with paragraphs 4.4.1 through 4.4.5 as applicable.

Classification of characteristics shall be defined in accordance with DOD-STD-2101.

4.4.1 Workmanship. Cartridges and components shall be visually inspected to determine compliance with the requirements of paragraph 3.6.

4.4.2 Dimensional and Weight Requirements. All dimensional and weight requirements in section 3 shall be verified by contractor gauges or by Standard Measuring Instruments (SMIs).

4.4.3 Vent Hole and Propellant. For each cartridge, the presence of primer pocket vent hole (paragraph 3.3.2) and propellant charge (paragraph 3.3.3) shall be verified by visual inspection or automated equipment prior to projectile insertion.

4.4.4 Packaging, Packing, Palletizing, and Marking. During or immediately prior to the packaging operation, 100% examination of the cartridges shall be performed to ascertain that the cartridge type conforms to the requirements of paragraph 3.6.4. All non-conforming cartridges shall be rejected. Inspection of packaging, packing, palletizing, and marking shall be in accordance with MIL-STD-644A, Chg. Notice 5 and section 5 of this specification.

4.4.5 Certifications. The contractor shall maintain certificates and test results showing compliance with all material and lot formation requirements of section 3. Certifications and test results shall be made available upon request for each production lot.

4.5 Test Provisions. Unless otherwise specified, each lot of

components and each lot of cartridges shall be tested in accordance with paragraphs 4.5.1, 4.5.2, 4.5.3 and Table II as applicable. Unless otherwise specified, all testing shall be conducted with samples conditioned at 70 °F ±5 °F for a minimum of 2 hours. Cartridges shall be randomly selected in such a manner that the sample is representative of the lot. The cartridges shall be thoroughly mixed before being divided into sample groups for each test. If an equipment/weapon failure occurs that prevents the obtaining of a reliable test result, the equipment/weapon shall be replaced or repaired; the individual test cartridge result shall be disregarded, and another sample cartridge shall be fired for record. If the equipment/weapon failure prevented the obtaining of reliable results for the entire test series, the entire test result shall be disregarded and a complete sample shall be fired for record. If a firing defect occurs that is not attributable to the test conditions, and that prevents obtaining a reliable result for the test, an additional cartridge shall be fired in its place; the test shall not be penalized, but the defect shall be counted in the cumulative ballistics sample for Table I.

TABLE II

TEST REQUIREMENTS

Temperature Conditioning Range and Sample Size

-27 °F 68 °F 123 °F to to to Tests -23 °F 73 °F 127 °F Requirement Test

Component/Subassembly

1. Primed Case Sensitivity 1/,2/ See 4.3.1.1 3.3.5 4.5.1.1

Cartridge

1. Residual Stress 2/ 50 3.3.6 4.5.1.2

2. Bullet Extraction 2/ 25 3.4.3 4.5.2.1

Cartridge Ballistics Tests 5/

1. Chamber Pressure 2/,6/ 30 60 3/ 30 3.5.1 4.5.3.1

2. Accuracy 2/ 3.5.2 4.5.3.2

a. Barrel #1 50

b. Barrel #2 50

3. Function and Casualty 4/ 3.5.3 4.5.3.3

a. M4A1 270 540 270

b. M16A2/M16A3 270 540 270

4. Penetration 2/ 20 3.5.4 4.5.3.4

5. Ballistic Match 2/ 3.5.5 4.5.3.5

a. Barrel #1 30

b. Barrel #2 30

6. Bullet Integrity 7/ N/A 3.5.6 4.5.3.6

1/ Test sample shall consist of the number of cartridges required to perform a complete rundown test wherein 50 primers are tested at each height.

2/ Failure of the cartridges to comply with the applicable requirement shall be cause for rejection of the lot, subject to testing of a second sample consisting of double the quantity of cartridges used in the first test. Failure of the cartridges in the second sample to comply with the applicable requirement shall be cause for rejection of the lot.

3/ Thirty samples shall be fired with the propellant positioned at the primer end of the cartridge and the other thirty samples shall be fired with the propellant intentionally positioned at the projectile end of the cartridge. The latter requirement shall be accomplished by rotating each cartridge and inserting it into the test barrel in such a manner as to ensure the propellant is positioned at the base of the projectile.

Reference cartridges and all other chamber pressure test samples shall be fired with the propellant at the primer end of the cartridge per SCATP-5.56mm. Each 30 round sample shall meet the requirement of paragraph 3.4.1.

4/ A retest is permitted using a double sample size in the failed weapon type only. Failure of the cartridges in the second sample to comply with the applicable requirement shall be cause for rejection of the lot.

5/ The results of all ballistics tests, including examination of misfired cartridges and fired cartridge cases and primers, shall be used to determine compliance with the requirements of Table I. The occurrence of any critical defects attributable to the cartridges (including firings of warm and foul cartridges from the test lot) shall result in rejection of the lot and no further testing shall be conducted.

6/ Unless otherwise substantiated that the applicable chamber pressure requirements are met, chamber pressure testing shall be completed and the applicable requirements shall be met prior to conducting any other ballistic tests. Acceptable methods of substantiating that the chamber pressure requirements have been met are in process chamber pressure checks, propellant checks, or propellant acceptance tests. These acceptable methods do not eliminate the requirement to perform chamber pressure testing. The contractor shall submit substantiating documentation to and receive approval from the Contracting Officer for each lot that will not be subjected to chamber pressure testing prior to other ballistic tests.

7/ The bullet integrity shall be performed concurrently with Function and Casualty test during the single firing mode.

4.5.1 Component/Subassembly Tests.

4.5.1.1 Primed Case Sensitivity. The complete sensitivity

rundown test shall be conducted in accordance with SCATP-5.56mm (Heavy Bullet) using empty primed cases. The test shall be conducted on each lot of primers with 50 primed cases being tested at each 1-inch increment of height between 0 percent and 100 percent firing.

4.5.1.2 Residual Stress. A total of 50 cartridges shall be used for the residual stress test in accordance with SCATP-5.56mm (Heavy Bullet).

4.5.2 Cartridge Tests.

4.5.2.1 Bullet Extraction. A total of 25 cartridges shall be

used for the bullet extraction test in accordance with SCATP- 5.56mm (Heavy Bullet) cartridges.

4.5.3 Cartridge Ballistic Tests. The contractor shall obtain the 5.56mm NATO reference cartridges for calibration of acceptance test equipment, for verification of calibration, and for applying correction factors to test results during Lot Acceptance testing.

Also, the contractor shall be responsible for furnishing secondary reference cartridges needed for in-process and in-house testing. Specified barrel length of test weapons shall be determined by measuring from the breech face of the test weapon to the end of the muzzle.

4.5.3.1 Chamber Pressure. The test shall be conducted in

accordance with SCATP-5.56mm (Heavy Bullet). Velocity and port pressure data shall be recorded for informational purposes. The lot shall be rejected if the average peak chamber pressure of any test sample at any temperature range fails the requirements of paragraph 3.5.1 or if one or more cartridges fail the individual sample requirements of paragraph 3.5.1.

4.5.3.2 Accuracy. The accuracy test shall be conducted in

accordance with Appendix A. The requirements of paragraph 3.5.2 shall be met. The lot shall be rejected if the average extreme spread of all 5-shot groups exceeds the specified requirement or if two or more 5-shot groups exceed the individual group requirement.

4.5.3.3 Function and Casualty. The function and casualty test shall be conducted in accordance with Appendix B. A sheet of 48-inch x 48-inch witness paper shall be placed 4 feet to 10 feet from the muzzle of the test weapon to check occurrence of the projectile breakage during the single mode firing. The requirement of paragraph 3.5.3 shall be met. The acceptance/rejection shall be as shown in Table I.

4.5.3.4 Penetration. The 3/8-inch AR500 armor plate penetration tests shall be conducted in accordance with Appendix C. The requirements of paragraph 3.5.4 shall be met. The lot shall be rejected if the test result does not meet the requirements of paragraph 3.5.4.

4.5.3.5 Ballistic Match. The ballistic match test shall be

conducted in accordance with Appendix D. The requirements of paragraph 3.5.5 shall be met. The lot shall be rejected if the test result does not meet the requirement of paragraph 3.5.5.

4.5.3.6 Bullet Integrity. The bullet integrity shall be

performed concurrently with Function and Casualty test during the single mode firing. The requirement of paragraph 3.5.6 shall be met. The lot shall be rejected if the test result does not meet the requirement of paragraph 3.5.6.

5. PACKAGING

5.1 Packaging. For acquisition purposes, the packaging

requirements shall be specified in the contract or order. When actual packaging of material is performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point's packaging activity within the Military Department or Defense Agency, or within the Military Department's System Command.

Packaging data retrieval is available from the managing Military Department's or Defense Agency's automated packaging files, CD- ROM products, or by contacting the responsible packaging activity.

6. NOTES

6.1 Definitions.

a. Misfire: Failure of a cartridge to fire after the initiating impulse has been applied to the primer, normally due to:

(1) The primer fails to fire when struck by the firing pin.

(2) The propellant does not ignite when the primer fires.

b. Hangfire: Any perceptible delay in the functioning of a cartridge after the initiating impulse has been applied to the primer.

c. Blown primer: A blown primer is a primer that, when the cartridge is fired, is separated completely from the head of the cartridge case, and both the head of the case and primer pocket are enlarged and deformed.

d. Longitudinal split: A longitudinal separation of the metal in the cartridge case wall produced by firing.

e. Circumferential rupture: A circumferential separation of the cartridge case wall produced by firing. A partial rupture is one that extends less than 360° around the case. A complete rupture is one that extends entirely around the case, separating the case into two parts.

f. Premature cartridge function: A premature function of the cartridge prior to intentional initiation of the firing mechanism of the weapon. Such failures usually occur during cycling of the weapon mechanism and prior to complete locking of the weapon's bolt.

g. Loose primer: Independent movement of primer in cartridge case primer pocket or primer falls out of pocket.

APPENDIX A

A. ACCURACY TEST PROCEDURE

A.1 Scope. The accuracy test shall be performed to determine the uniformity and dispersion of the bullets at a specified distance from the test weapon.

A.2 Equipment.

A.2.1 Barrel. The test barrels shall consist of two 5.56mm NATO accuracy barrels (Drawing No. 19200-8649409).

A.2.2 Mount. The barrel shall be supported during testing by mounting in suitable fixtures as required to permit manual operation of the test weapon. The test fixtures shall be constructed and mounted so as to prevent fixture movement during testing. It is important that the weapon maintains its original position from shot to shot.

A.2.3 Targets. All test targets shall be rigidly mounted at the specified test range from the muzzle of the test weapon.

A.2.4 Range. The firing range shall be arranged such that a horizontal distance of 99 to 101 yards is maintained from the muzzle of the test weapon to the face of the test targets.

A.3 Test Procedure.

A.3.1 Cartridge Examination. If visual defects are found in the test cartridges prior to testing, the defective cartridge(s) shall be replaced.

A.3.2 Cartridge Conditioning. The required number of test cartridges shall be permitted to come to a temperature of 60 °F to 80 °F prior to being placed in the controlled-temperature room or container. The cartridges shall be placed in a controlled-temperature room or container in such a manner that all the cartridges are subjected to a uniform temperature for a minimum of 2 hours prior to firing. The room or container shall be maintained at 70 °F 2 °F and be of sufficient capacity to allow free circulation of air.

A.3.3 Barrel Preparation. The chamber and the bore of the test barrel shall be thoroughly cleaned and wiped dry prior to firing.

A.3.4 Firing.

A.3.4.1 A minimum of three unrecorded cartridges of the type of ammunition under test shall be fired to ensure the test barrel is correctly sighted on the target, to warm and foul the barrel, and to settle the barrel in the test fixtures.

A.3.4.2 After the warming and fouling cartridges have been fired, the target shall be changed so as to present a fresh surface for the succeeding rounds. Thereafter, the target shall be changed after each group of five cartridges has been fired.

A.3.4.3 All cartridges shall be singly loaded into the chamber of the test barrel. The required number of cartridges is removed from the controlled-temperature room or container and placed at a point convenient to the technician, provided temperature of the firing room is 70 °F 2 °F. Otherwise the cartridges shall be placed in an insulated box (five cartridges at a time) that has been conditioned at 70 °F 2 °F, and the box placed at a point convenient to the technician. The cartridges are then removed singly from the insulated box immediately before firing. If an insulated box is not available, the cartridges shall be removed singly from the controlled-temperature room or container immediately before firing.

A.3.4.4 Five cartridges shall be fired for record. The target shall be changed, and a second 5-shot group shall be fired in the same manner. A total of ten 5-shot groups shall be fired.

A.3.4.5 The temperature of the test barrel should be controlled so that the exposed metal surface of the barrel does not become too hot to grasp with the bare hands (approximately 140 °F). If the barrel becomes too hot to use, it shall be cooled to ambient temperature before the test is continued. After the barrel has cooled to ambient temperature, two warming (fouling) shots shall be fired prior to continuation of the test.

A.3.4.6 The second test barrel shall then be placed in the test fixture, and the cartridges shall be tested using the procedures of paragraphs A.3.4.1 through A.3.4.6.

A.3.4.7 Each 5-shot target shall be measured to determine the maximum extreme spread of each 5-shot group. This shall be accomplished by measuring the distance between the two outermost bullet holes (the two holes that are farthest apart). The measurement shall be taken from the centers of the holes.

Measurements shall be accurate within plus or minus 0.1 inch, and results shall be recorded to the nearest 0.1 of an inch.

A.3.4.8 Misfired cartridges and fired cartridge cases and primers shall be retained for further examination.

A.4 Examinations. All fired cartridge cases and primers shall be visually examined to determine compliance with the applicable requirements of Table I. In the event that fired case or primer defects are encountered, or if a misfire(s) occurs, the test weapon shall be examined to determine if the defect(s) are attributable to the weapon. If the weapon is at fault, the test shall be disregarded and the weapon shall be repaired or replaced prior to performing a retest. If the defect cannot be attributed to the weapon, the defect shall be attributed to the cartridges.

Misfired cartridges, fired cartridge cases, and primers shall be retained for further examination.

APPENDIX B

B. FUNCTION AND CASUALTY TEST PROCEDURE

B.1 Scope. The purpose of the function and casualty test is to determine if the ammunition will perform and function satisfactorily in the weapons for which it has been designed.

B.2 Equipment.

B.2.1 Test Weapons. Test weapons shall be three M4A1 carbines and three M16A2/M16A3 rifles without suppressors. No alterations to the test weapons, beyond the requirements and specifications of the original manufacturer or supplier, shall be permitted.

B.3 Test Procedure.

B.3.1 Cartridge Examination. If visual defects are found in the test cartridges prior to testing, the defective cartridge(s) shall be replaced.

B.3.2 Cartridge Conditioning. Test samples shall be temperature conditioned in loaded magazines at the specified temperatures for 2 hours minimum and shall be fired within 2 minutes after removal from the controlled-temperature conditioning chamber.

B.3.3 Weapon Preparation. Test weapons and magazines shall be thoroughly cleaned prior to the beginning of testing but shall not be cleaned again until testing at all temperature ranges has been completed. The test weapons shall be lubricated using Cleaner, Lubricant and Preservative (CLP, MIL-L-63460). The magazine parts shall be wiped with a cloth that was sprayed with CLP prior to assembly. All test magazines shall be serialized so as to maintain identity throughout all testing. The weapons shall be maintained at room temperature (55 °F minimum) for a minimum of 2 hours prior to the start of testing. Test sequence shall be cold temperature condition first, hot temperature condition second, and ambient temperature condition last for each test weapon.

B.3.4 Firing.

B.3.4.1 Table III shows the number of rounds to be fired at each temperature range.

TABLE III

FUNCTION AND CASUALTY TEST

Temperature Range (°F) -27 68 123 to to to Weapon Mode -23 72 127 M16A2/M16A3 #1 Single 45 90 45 M16A2/M16A3 #1 Burst 45 90 45 M16A2/M16A3 #2 Single 45 90 45 M16A2/M16A3 #2 Burst 45 90 45 M16A2/M16A3 #3 Single 45 90 45 M16A2/M16A3 #3 Burst 45 90 45 M4A1 #1 Single 45 90 45 M4A1 #1 Burst 45 90 45 M4A1 #2 Single 45 90 45 M4A1 #2 Burst 45 90 45 M4A1 #3 Single 45 90 45 M4A1 #3 Burst 45 90 45

B.3.4.2 Cartridges to be fired shall be loaded into 30-round magazines. The 3-round burst mode shall be conducted with 2 to 5 seconds between bursts, and single shots shall be fired at a rate of 20 to 30 rounds per minute.

B.3.4.3 Barrels shall be forced air cooled to ambient temperature after every 150 rounds fired.

B.3.4.4 During the single mode firing, a sheet of 48-inch x 48-inch target paper shall be placed 4 feet to 10 feet from the muzzle of the test weapon to check occurrence of the projectile breakage.

B.3.4.5 In the event of a weapon stoppage during the test, the test weapon shall be examined to determine if the stoppage is attributable to the weapon.

B.3.4.5.1 If the weapon is at fault, the stoppage shall be disregarded and the weapon shall be repaired prior to continuing the test.

B.3.4.5.2 If the weapon is at fault and the weapon must be replaced, the stoppage shall be disregarded and the test shall be re-fired for that temperature only, using a new weapon of the same weapon type.

B.3.4.5.3 If the magazine is at fault, the stoppage shall be disregarded, the magazine shall be replaced with a new magazine, the new magazine shall be reloaded with remaining rounds needed to complete the test, and the test shall be continued.

B.3.4.5.4 If a cartridge(s) becomes nonconforming due to a condition attributable to the weapon, the nonconforming cartridge(s) shall be replaced with a new cartridge(s) for use in completion of the test.

B.3.4.5.5 If the stoppage cannot be attributed to the weapon, the defect shall be attributed to the cartridges including the following stoppages:

a. Failure of the last cartridge case to eject from the weapon during any sequence of fire.

b. Failure of the slide/bolt to lock open in the rearward position after firing the last cartridge in each magazine.

c. Failure of the manually chambered cartridge to fully chamber in the barrel of the weapon.

d. Failure of any cartridge to completely chamber, fire, and completely eject due to residue build-up in the weapon mechanism from previous firings.

B.3.4.6 Misfired cartridges and fired cartridge cases and primers shall be retained for further examination.

B.3.5 Examinations. All fired cartridge cases and primers shall be visually examined to determine compliance with the applicable requirements of Table I. In the event that fired case or primer defects are encountered, or if a misfire(s) occurs, the test weapon shall be examined to determine if the defect(s) are attributable to the weapon. If the weapon is at fault, the test shall be disregarded and the weapon shall be repaired or replaced prior to performing a retest. If the defect cannot be attributed to the weapon, the defect shall be attributed to the cartridges.

Misfired cartridges shall be disassembled to determine the cause of the misfire.

APPENDIX C

C. PENETRATION TEST PROCEDURE

C.1 Scope. The penetration test shall be performed to determine the penetration capability of the cartridges against steel plates of known characteristics.

C.2 Equipment.

C.2.1 Test Weapon. The test weapon shall be one M4A1 carbine without a suppressor. No alterations to the test weapon, beyond the requirements and specifications of the original manufacturer or supplier, shall be permitted.

C.2.2 Mount. The weapon shall be supported during testing by mounting in suitable fixtures as required to permit manual operation of the test weapon. The test fixtures shall be constructed and mounted so as to prevent fixture movement during testing. It is important that the weapon maintains its original position from shot to shot.

C.2.3 Targets. The 3/8-inch AR500 steel plate shall be rigidly mounted at the specified test range from the muzzle of the test weapon.

C.2.4 Range. The firing range shall be arranged such that a horizontal distance of 10 feet is maintained from the muzzle of the test weapon to the face of the test targets.

C.3 Test Procedure.

C.3.1 Cartridge Examination. If visual defects are found in the test cartridges prior to testing, the defective cartridge(s) shall be replaced.

C.3.2 Cartridge Conditioning. The required number of test cartridges shall be permitted to come to a temperature of 60 °F to 80 °F prior to being placed in the controlled-temperature room or container. The cartridges shall be placed in a controlled-temperature room or container in such a manner that all the cartridges are subjected to a uniform temperature for a minimum of 2 hours prior to firing. The room or container shall be maintained at 70 °F 2 °F and be of sufficient capacity to allow free circulation of air.

C.3.3 Weapon Preparation. Test weapon shall be thoroughly cleaned prior to the beginning of testing. The test weapons shall be lubricated using CLP (MIL-L-63460). The weapons shall be maintained at room temperature for a minimum of 2 hours prior to the start of testing.

C.3.4 Firing.

C.3.4.1 The steel plate shall be placed at a distance of 10 feet downrange of the muzzle of the test weapon. The weapon shall be sight-in to the center of the target.

C.3.4.2 Test weapon shall be loaded with one cartridge, and the projectile shall be fired at the steel plate with NATO angle of 0 5.

C.3.4.3 After each firing, the steel plate shall be inspected for penetration.

C.3.4.4 The procedures of paragraphs C.3.4.2 and C.3.4.3 shall be repeated until a total of 20 cartridges have been fired or the penetration occurs. All shots shall be fired into a ½-inch diameter impact area.

C.3.4.5 A sheet of 6-ft x 6-ft witness paper shall be placed approximately 6 inches behind the muzzle of the test weapon to check occurrence of the fragments returning to a shooter. The center of a witness paper shall have an opening that is large enough for the weapon muzzle to perforate.

C.3.4.6 After each shot, the steel plate shall be inspected for penetration. If penetration occurs before firing of 20 cartridges, the number of shots to produce penetration shall be recorded.

C.3.4.7 Misfired cartridges and fired cartridge cases and primers shall be retained for further examination.

C.4 Examinations. All fired cartridge cases and primers shall be visually examined to determine compliance with the applicable requirements of Table I. In the event that fired case or primer defects are encountered, or if a misfire(s) occurs, the test weapon shall be examined to determine if the defect(s) are attributable to the weapon. If the weapon is at fault, the test shall be disregarded and the weapon shall be repaired or replaced prior to performing a retest. If the defect cannot be attributed to the weapon, the defect shall be attributed to the cartridges.

Misfired cartridges and fired cartridge cases and primers shall be retained for further examination.

APPENDIX D

D. MATCHING TEST PROCEDURE

D.1 Scope. The matching test shall be performed to ensure trajectories of 5.56mm Frangible projectiles are similar to that of the M855's at a specified distance from the test weapon.

D.2 Equipment.

D.2.1 Barrel. The test barrels shall consist of two 5.56mm NATO accuracy barrels (Drawing No. 19200-8649409).

D.2.2 Mount. The barrel shall be supported during testing by mounting in suitable fixtures as required to permit manual operation of the test weapon. The test fixtures shall be constructed and mounted so as to prevent fixture movement during testing. It is important that the weapon maintains its original position from shot to shot.

D.2.3 Targets. All test targets shall be rigidly mounted at the specified test range from the muzzle of the test weapon.

D.2.4 Range. The firing range shall be arranged such that a horizontal distance of 99 to 101 yards is maintained from the muzzle of the test weapon to the face of the test targets.

D.3 Test Procedure.

D.3.1 Cartridge Examination. If visual defects are found in the test cartridges prior to testing, the defective cartridge(s) shall be replaced.

D.3.2 Cartridge Conditioning. The required number of test cartridges shall be permitted to come to a temperature of 60 °F to 80 °F prior to being placed in the controlled-temperature room or container. The cartridges shall be placed in a controlled-temperature room or container in such a manner that all the cartridges are subjected to a uniform temperature for a minimum of 2 hours prior to firing. The room or container shall be maintained at 70 °F 2 °F and be of sufficient capacity to allow free circulation of air.

D.3.3 Barrel Preparation. The chamber and the bore of the test barrel shall be thoroughly cleaned and wiped dry prior to firing.

D.3.4 Firing.

D.3.4.1 A minimum of three unrecorded cartridges of the type of ammunition under test shall be fired to ensure the test weapon is correctly sighted on the target, to warm and foul the weapon, and to settle the weapon in the test fixtures.

D.3.4.2 After the warming and fouling cartridges have been fired, the target shall be changed so as to present a fresh surface for the succeeding rounds.

D.3.4.3 All cartridges shall be singly loaded into the chamber of the test barrel. The required number of cartridges is removed from the controlled-temperature room or container and placed at a point convenient to the technician, provided temperature of the firing room is 70 °F 2 °F. Otherwise, the cartridges shall be placed in an insulated box (five cartridges at a time) that has been conditioned at 70 °F 2 °F, and the box shall be placed at a point convenient to the technician. The cartridges are then removed singly from the insulated box immediately before firing.

If an insulated box is not available, the cartridges shall be removed singly from the controlled-temperature room or container immediately before firing.

D.3.4.4 Thirty M855 cartridges shall be fired for record. All 30 cartridges must strike the target. The lay of the test barrel shall not be changed after the firing.

D.3.4.5 The target shall be changed but shall maintain the previous target’s original position. Using the same barrel and barrel position, thirty 5.56mm Frangible test cartridges shall be fired. All 30 cartridges must strike the target.

D.3.4.6 The temperature of the test barrel should be controlled so that the exposed metal surface of the barrel does not become too hot to grasp with the bare hands (approximately 140 °F). If the barrel becomes too hot to use, it shall be cooled to ambient temperature before the test is continued. The chamber and bore shall be cleaned and wiped dry and the warming and fouling cartridges shall again be fired prior to continuation of the test.

D.3.4.7 The second test barrel shall then be placed in the test fixtures and the cartridges shall be tested using the procedures of paragraphs D.3.3.1 through D.3.3.7.

D.3.4.8 Each target shall be measured to determine the center point of impacts of the M855 and 5.56mm Frangible. The measurement shall be taken from the centers of the holes.

Measurements shall be accurate within plus or minus 0.1 inch, and results shall be recorded to the nearest 0.1 of an inch.

D.3.4.9 Misfired cartridges and fired cartridge cases and primers shall be retained for further examination.

D.4 Examinations. All fired cartridge cases and primers shall be visually examined to determine compliance with the applicable requirements of Table I. In the event that fired case or primer defects are encountered, or if a misfire(s) occurs, the test weapon shall be examined to determine if the defect(s) are attributable to the weapon. If the weapon is at fault, the test shall be disregarded and the weapon shall be repaired or replaced prior to performing a retest. If the defect cannot be attributed to the weapon, the defect shall be attributed to the cartridges.

Misfired cartridges, fired cartridge cases, and primers shall be retained for further examination.