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Hybrid Ceramic Matrix/Metal Matrix Composite Gun Barrels

Article in Materials and Manufacturing Processes · September 2006

DOI: 10.1080/10426910600602846

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Hybrid Ceramic Matrix/Metal Matrix Composite Gun
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Materials and Manufacturing Processes, 21:6, 579 - 583
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 Materials and Manufacturing Processes, 21: 579–583, 2006
Copyright © Taylor & Francis Group, LLC
ISSN: 1042-6914 print/1532-2475 online
DOI: 10.1080/10426910600602846

Hybrid Ceramic Matrix/Metal Matrix Composite Gun Barrels

Downloaded By: [Katz,] At: 20:02 24 April 2007

R. N. Katz2 , L. A. Bracamonte1 , J. C. Withers1 , and S. Chaudhury2

1
MER Corporation, Tucson, Arizona, USA
2
Department of Mechanical Engineering, Worcester Polytechnic Institute, Worcester, Massachusetts, USA

Future Army gun systems will require lighter weight and significantly more erosion-resistant materials. One route to achieve this goal is via
the development of ceramic matrix composite barrel liners with lightweight metal matrix composite jackets. Such materials systems are hybrids of
a ceramic matrix composite/metal matrix composite (CMC/MMC), which can provide functionally graded properties. This paper will describe the
materials system development, fabrication, and property validation testing of such a hybrid CMC/MMC for a 25-mm-bore, 915-mm-long, rifled
barrel.
Keywords Burst tests; Ceramic matrix composites; Gun barrels; Hoop strength; Hybrid ceramic matrix/metal matrix composites; Metal matrix
composites; Processing.

Background ceramic liners were performed using a specially designed

Lightweight and highly erosion-resistant gun barrels are high energy ammo with J-2 propellant (3450 K flame
essential to enhanced future warfighting capabilities for temperature). These rounds had a ∼6000 ft/sec muzzle
several reasons. Most compelling in the near term is the velocity, which represented a 17% increase over the
ability of such a development to reduce logistic burdens and standard round (i.e., a 37% increase in kinetic energy).
reduce sustainment costs. More intriguing in the long term Single-round and 10-round bursts did not cause failures, and
is the prospect that more erosion- and temperature-resistant the first circumferential cracking was encountered during
materials will enable the use of higher energy propellants. the first 20-round burst. While any cracking is unacceptable,
This in turn would enable the ability to either deliver more it is important to note that the circumferential cracks were
energy to the target, or to operate at longer engagement not catastrophic, and the barrel could still be fired. This body
distances. Given the many probable future scenarios where of work revealed three very important things: 1) silicon
airmobile light forces will likely engage heavier entrenched carbide and silicon nitride based ceramics can function as
forces, either or a combination of these two capabilities is a gun tube liner; 2) these ceramics exhibit a consistent and
highly desirable. noncatastrophic failure mode; and 3) these materials exhibit
The two main avenues of R&D aimed at developing significantly reduced erosion, even with the use of high
enhanced erosion and temperature-resistant barrels are a energy propellants (see Table 1).
ceramic liner with a metal-based jacket or a refractory Encouraged by the above findings, the Army’s weapons
metal liner with a lighter weight metal jacket. Both of these design community has been performing in-depth analytical
approaches have been investigated at MER Corporation. studies [2, 3] aimed at developing designs to eliminate the
The objective of the work described herein was to observed failure mode. Similarly, materials development
investigate ceramic matrix composite (CMC) lined metal programs have been ongoing, aimed at materials specific
matrix composite (MMC) hybrid barrels. Prior to discussing solutions to the circumferential cracking problem. One
this work on CMC composite lined MMCs it is appropriate materials solution is to utilize a CMC liner, functionally
to briefly review past efforts on ceramic lined barrels. graded into an MMC. Such a materials system would
The progress on the use of ceramics as gun barrel liners allow for a gradual change in coefficient of thermal
has been reviewed by one of the authors [1] regarding expansion (CTE) within the liner/jacket, thereby preventing
work from the 1970s through the early 1990s. The results or substantially mitigating the loss of axial constraint that
from firing tests of .50 cal barrels using standard M33 ultimately leads to the circumferential cracks. Several of
ball ammo indicated that both silicon carbide and silicon the authors have demonstrated the capability to fabricate a
nitride could sustain single round firing of 1000 rounds rifled hybrid CMC/MMC barrel with a .22 cal bore (5.56-
or more, and bursts to 100 rounds with essentially no mm) [4]. The challenge in our present program is to extend
erosion. The eventual failure mode was the formation of this processing capability to the 25-mm barrel scale, and to
circumferential ring cracks due to loss of axial compression. demonstrate the efficacy of the hybrid CMC/MMC barrel
Tests on 25-mm barrels with short (14-inch) SiC monolithic concept by testing.

Objectives
Received November 15, 2005; Accepted December 20, 2005 The overall objectives of this program are three-fold.
Address correspondence to R. N. Katz, Department of Mechanical First, develop a materials system/fiber architecture that
Engineering, Worcester Polytechnic Institute, 100 Institute Road, will provide the required properties (principally, a hoop
Worcester, MA, USA; E-mail: katz1731@[Link] strength of ∼400 MPa) so that the gun barrel can survive
579
 580 R. N. KATZ ET AL.

Table 1.—Erosion resistance of gun barrel material—vented combustor tests.

Material Propellant # of Tests Ave. wt. loss, mg Diam. loss,
in

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Si3 N4 M2 10 0.5 96
SiC JA2 10 3.7 690
Ta-10 W M2 5 5.0 190
Cr-Mo V M2 1 90 7100
4340 M2 3 125 9900

Data from Final Program Review, Contract DAAA21-88-C-003.

firing pressures. Second, a processing methodology must

be developed that will allow the selected materials system
to be fabricated as a 25-mm-bore × 41-mm-outer diameter
(OD) × ∼915-mm-length rifled tube. Third, performance
of the materials system/architecture and the final rifled gun
barrel must be validated. Each of these three areas will be
described in more detail in the following sections.

The materials system

The hybrid composite is referred to as a materials
system, as it consists of a CMC (comprising of a ceramic
matrix material and a reinforcing fiber) and an MMC
Figure 1.—SEM micrograph of gun barrel after fabrication of CMC and
(comprising a metal matrix material and a reinforcing fiber). MMC layers.
The architecture of the fiber windings has a profound
effect on mechanical and other properties of the finished
barrel. Clearly one goal is to provide as much strength
as possible in the major stress orientation (hoop strength); guide the development. One such matrix experiment was
however, the system must also survive the transient thermal aimed at selecting the appropriate combination of fiber
stresses induced by materials transformations and possible architecture, preceramic matrix precursor, and pyrolysis
CTE mismatches with the mandrel during fabrication. A furnacing conditions. The results illustrated in Table 2
significant observation is that even relatively small CTE guided the decision as to which options to select for further
mismatches over a 36-inch-length can produce significant optimization.
axial stresses. Based on the results of the study illustrated in Table 2, it
Thus, throughout this program there were continuing was decided to optimize the materials system using CMC
trade-offs between optimizing materials properties and architecture B, matrix precursor B, MMC architecture B,
optimizing fabricability. Rapid measurement of hoop and pyrolysis condition B. The decision to utilize pyrolysis
strength, as will be described in a subsequent section, condition B was based on the significantly lower standard
guided both materials system development and fabrication deviation, rather than the trivial difference in strength.
development throughout the program. This example is illustrative of how materials systems
The CMC at its present state of development consists development/processing/property trade-off decisions were
of a composite Al2 O3 fiber/SiC matrix formed by winding made during the program. As will be seen in the testing
Nextel 610 alumina fibers in the desired orientations and section below, the strength values of the chosen materials
thickness onto a mandrel followed by infiltration of a system are significantly higher than the strengths shown in
liquid preceramic polymer (Starfire) with a SiC particulate. Table 2.
The preceramic polymer is converted by thermal treatment
to SiC, and the CMC inner bore liner of the barrel Tube and barrel fabrication
is approximately 3-mm thick. The rest of the structure There are several steps involved in the fabrication and
is a continuously graded MMC consisting of radial and assembly of gun barrels of any caliber as shown in Fig. 2.
longitudinal wraps of Nextel 610 with an aluminum matrix.
This structure is shown in the SEM micrograph in Fig. 1.
Early in the program both SiC fibers and alumina fibers Table 2.—Effect of CMC architecture, preceramic matrix precursor, and
were considered as reinforcement for the CMC. However, pyrolysis conditions on hoop strength of hybrid composite rings.
cracking due to CTE mismatch was a greater problem
when SiC fibers as opposed to alumina fibers were utilized CMC Matrix MMC Pyrolysis Ave. Hoop
architecture precursor architecture condition strength Std. Dev.
due to the high CTE of the graphite mandrel. Thus, in
the “downselected” materials system, Nextel 610 alumina A A A A 244 MPa 37
fiber was chosen as the reinforcement for both the CMC A A A B 238 MPa 29
and MMC. Throughout the materials system development B B B A 330 MPa 91
B B B B 332 MPa 27
portion of the program, matrix experiments were used to
 CMC/MMC GUN BARRELS 581
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Figure 2.—Schematic of fabrication process for CMC/MMC 25-mm gun barrels.

For the 25-mm barrel, MER has developed a procedure in Traditional methods for measuring hoop strength usually
which the CMC is first fabricated by essentially building rely on hydraulic systems, with complex pressure seals.
the barrel from the inside to the outside, where a grooved Such tests are time consuming and expensive. By contrast,
mandrel has the desired rifling pattern machined into its the method described below is rapid (several tests per hour)
surface. Uniaxial aligned fibers are then wound into the and inexpensive. It is, however, limited to approximately
grooves, followed by a variety of winding schemes for room temperature and is limited to the strain rates obtainable
each layer of fibers that comprise the liner. For example, on a conventional Instron Type of universal test machine
combinations of longitudinal, hoop, and angled wraps can be (in this case an Instron 8502 servo-hydraulic unit with a
utilized in conjunction with the incremental densification of 250,000 N load cell).
these layers using liquid preceramic polymers or chemical This method builds upon the work of Jardaan et al.
vapor infiltration. Following fabrication of the CMC liner, [5] and Lara-Curzio [6], who demonstrated that one can
the barrel is wrapped in a similar manner to the outside utilize incompressible isotropic elastomers as pseudo fluids
diameter of the barrel with alumina fibers, and subsequently, in order to internally pressurize short rings. Prior work
aluminum metal is squeeze cast into the outer fibers to relied on castable elastomers, which are not suitable since
achieve a gun barrel with minimal to no porosity. The final at pressures approaching those found in gun tube use
fabrication steps include contouring of the outer surface (∼400 MPa), castable elastomers tend to “break down” and
and assembly, typically by companies with that specific extrude through the narrow clearance between the ring and
expertise such as current gun barrel manufacturers, e.g., for pressurizing rams. Thus, the key to using this technique for
the 25-mm barrel, ATK. high-pressure testing was to find elastomers that would not
break down under the pressure. Several polyurethane and
silicone rubbers in the 40 to 60 Shore A Durometer range
Mechanical behavior validation were found to be suitable.
As has been stated above, a key element of this project The test is carried out in a modified forging die fixture
has been the ability to quickly assess the impact of changes (see Fig. 3). This configuration is essentially a “mini
in materials, reinforcement architecture, and/or fabrication load frame” within the main load frame and provides
steps on the key property of the gun tubes, namely, the several advantages. The dual columns fitted with low-
hoop strength. A method was required whereby short rings friction bushings maintain parallelism of the upper and
could be sliced from the 8- to 12-inch tubes used for lower platens and relax the demand for rigorous attention to
process development, rapidly tested, and the results input axial alignment and load concentricity. The use of relatively
for further process iteration. By using thin rings, some short loading rams (ground parallel to within +/−00005 in)
statistical information could be acquired, which helped to prevented cocking, thereby providing unimpeded loading
assess the uniformity of strength along the length of the tube. of the elastomer in the cavity. Post-fracture examination
 582 R. N. KATZ ET AL.
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Figure 4.—Results of Weibull study.

Figure 3.—Hoop stress fixture with specimen.

of failure of a test component of N sub-elements as:

N  m 
of the inner surfaces of tested rings showed no evidence   Vi
that the loading rams damaged the specimen or scratched Pf = 1 − exp − (2)
i=1 o Vo
the specimen sidewalls, thus demonstrating good axial
alignment and load transmission. The force on the specimen where  = the applied stress; Vo = a unit volume of
due to the weight of the upper die platen was calculated to
the material, set as 1; Vi = the volume of the material
be 25.6 N, or less than 0.05% of typical applied loads.
under the stress, app ; o = a normalizing stress referred
Hoop stress, , was calculated using the following
to as the characteristic stress; m = Weibull modulus;
formula:
Pf = cumulative probability of failure.


 By breaking the part into infinitesimal sub-elements,
Pmax di2 do2
= 1 + (1) Eq. (2) becomes an integral:
do2 − di2 di2
   m 

where Pmax = maximum internal pressure in MPa (N/mm , 2 Pf = 1 − exp − dV (3)
o
di = inner diameter in mm, and do = outer diameter in mm. V

If one knows the two Weibull statistical parameters, i.e.,

Weibull analysis of hoop strength o and m, one can predict the probability of failure of a
ceramic component at any applied stress level. In order to
To address the problem of designing reliable components obtain these two parameters, one uses Weibull probability
with materials exhibiting broad strength distributions, 1
paper [8] to plot lnln 1−Pf  vs. ln , for each failed test
Weibull [7] developed a statistical method for predicting
a material’s strength based on the probability of failure specimen. This should yield a straight line with a slope equal
of the weakest sub-element of the component or structure. to m, and the intersection of the line at lnln 1−Pf 1
 = 0
His model is often referred to as a “weakest link” yields o .
model, analogous to a chain that fails at the weakest Results of a Weibull evaluation of 16 rings, 11 of which
link. This method is particularly well-suited to materials were valid tests and five of which were categorized as
such as ceramics, ceramic matrix composites (CMCs), or suspended (but not invalid) tests, are presented in Fig. 4.
hybrid composites that exhibit broad strength distributions. Weibull statistics use suspended test data to adjust the
Weibull statistics allow one to predict the strength of large probabilities of failure of completed tests, but do not use
components from small test specimens. them in plotting strength data. The characteristic strength
CMCs and hybrid composites, even when fabricated by of this set of hybrid composite rings is 392 MPa, and the
the best manufacturing practices, contain a distribution of Weibull modulus is 10.5. The hoop strength is within 8 MPa
varying size and randomly oriented flaws. Under a given of the goal of 400 MPa.
applied stress, there is a finite probability that in some sub-
element of a component of this material, a flaw will have Summary and conclusions
the proper orientation and size to lead to failure of that sub- This work demonstrates that fiber-reinforced
element, and consequently the entire component (i.e., the ceramic/metal hybrid composites can be fabricated with
weakest link analogy). For such a circumstance, Weibull [7] good hoop strength within 2% of the targeted strength
derived a function that describes the cumulative probability of 400 MPa for 25-mm gun barrel application. Further
 CMC/MMC GUN BARRELS 583

improvements in strength are possible via tailoring and 3. Underwood, J.H.; Cote, P.J.; Vigilante, G.N. Thermo-mechanical
design of materials and fiber architecture to more closely and fracture analysis of SiC in cannon bore applications. Ceram.
match thermal expansion properties of all processing Eng. and Science Proceed. 2003, 24 (3), 503–508.
components. In particular, development of a mandrel 4. Withers, J.C.; Bracamonte, L. Unpublished research.
Downloaded By: [Katz,] At: 20:02 24 April 2007

material with a closer CTE match to the desired materials 5. Jadaan, O.M.; Shellman, D.L.; Conway, J.C.; Macholsky, J.J.;
system was identified as a major issue. Tressler, R.E. Prediction of the strength of ceramic tubular
components—Part I. J. Testing and Evaluation 1991, 19 (3),
Acknowledgments 181–191.
6. Lara-Curzio, E. Standard test method for tensile hoop strength
This work was funded by the US Army under Contract
of fiber-reinforced advanced ceramic tubular specimens at
No. DAAD19-02-C-0066, “Novel, Low-Cost Processing
ambient temperature. Draft ASTM Standard version 3 (ASTM
of Functionally Gradient Ceramic-Matrix, Metal-Matrix
Subcommittee C28-07).
Composite Materials,” 2002.
7. Weibull, W. A Statistical Theory of the Strength of
Materials; Ingeniorsvetenskapsakademiens Handlingar Nr 151;
References Generalstabens Litografiska Anstalts Forlag: Stockholm,
1. Katz, R.N. Ceramic Gun Barrel Liners: Retrospect and Prospect, 1939.
Proceedings of Sagamore Workship on Gun Barrel Wear and 8. Abernethy, R.B.; Breneman, J.E.; Medin, C.H.; Reinman,
Erosion, US Army Research Laboratory, July 1996, pp. 69–84. G.L. Weibull Analysis Handbook, Pratt & Whitney Aircraft,
2. Grujicic, M.; DeLong, J.R.; Rossett, W.S. Reliability analysis of West Palm Beach, FL, Air Force Report AFWAL-TR-83-2079
hybrid ceramic/steel gun barrels. Fatigue Fract. Eng. M. 2003, (National Technical Information Service AD-A143 100) Nov,
26 (5), 405–420. 1983.

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