Abstract: Bismuth-based firearm projectiles, optionally firearm cartridges containing the same, and methods for forming bismuth-tin-copper alloys or bismuth-nickel alloys and bismuth-based firearm projectiles are disclosed herein. The bismuth-based firearm projectiles include a projectile body comprising a bismuth-tin-copper alloy or bismuth-nickel alloy that forms at least 90 wt % of the projectile body.

Abstract: Frangible firearm projectiles, firearm cartridges, and methods for forming the same. The projectiles are formed from metal powder and include an anti-sparking agent. One or more of iron, zinc, bismuth, tin, copper, nickel, tungsten, boron, and/or alloys thereof may form the metal powder. The projectiles may be formed from a compacted mixture of two or more different metal powders. The anti-sparking agent may include a borate, such as boric acid, zinc chloride, and/or petrolatum. The anti-sparking agent may be dispersed within, and/or applied as a coating on, the exterior of the projectile. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. Such domains may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does form a liquid phase of the metal powder or utilize a polymeric binder.

Abstract: Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from compacted metal powders that may include an anti-sparking agent. The compacted metal powders may be or include a compacted mixture of metal powders that may include powders of one or more of iron, zinc, bismuth, copper, tungsten, nickel, boron, and/or alloys thereof, and/or oxides thereof. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. The anti-sparking agent may include a borate, such as boric acid.

Abstract: Frangible firearm projectiles, firearm cartridges, and methods for forming the same. The projectiles are formed from metal powder and include an anti-sparking agent. One or more of iron, zinc, bismuth, tin, copper, nickel, tungsten, boron, and/or alloys thereof may form the metal powder. The projectiles may be formed from a compacted mixture of two or more different metal powders. The anti-sparking agent may include a borate, such as boric acid, zinc chloride, and/or petrolatum. The anti-sparking agent may be dispersed within, and/or applied as a coating on, the exterior of the projectile. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. Such domains may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does form a liquid phase of the metal powder or utilize a polymeric binder.

Abstract: Bismuth-based firearm projectiles, optionally firearm cartridges containing the same, and methods for forming bismuth-tin-copper alloys or bismuth-nickel alloys and bismuth-based firearm projectiles are disclosed herein. The bismuth-based firearm projectiles include a projectile body comprising a bismuth-tin-copper alloy or bismuth-nickel alloy that forms at least 90 wt % of the projectile body.

Abstract: Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from compacted metal powders that may include an anti-sparking agent. The compacted metal powders may be or include a compacted mixture of metal powders that may include powders of one or more of iron, zinc, bismuth, copper, tungsten, nickel, boron, and/or alloys thereof, and/or oxides thereof. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. The anti-sparking agent may include a borate, such as boric acid.

Abstract: Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from compacted metal powders that may include an anti-sparking agent. The compacted metal powders may be or include a compacted mixture of metal powders that may include powders of one or more of iron, zinc, bismuth, copper, tungsten, nickel, boron, and/or alloys thereof, and/or oxides thereof. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism6 that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. The anti-sparking agent may include a borate, such as boric acid.

Abstract: Die assemblies for forming a firearm projectile and methods of utilizing the die assemblies are disclosed herein. The die assemblies include a forming die, a first punch, and a second punch. The forming die defines a first side, a second side that is opposed to the first side, and a die cavity that extends between the first side and the second side. The first punch is configured to seal against the forming die from the first side. The second punch is configured to be received within the die cavity from the second side. When the first punch seals against the forming die and the second punch is received within the die cavity, the first punch, the second punch, and the forming die collectively define a forming surface shaped to define an external contour of the firearm projectile.

Abstract: Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from compacted metal powders that may include an anti-sparking agent. The compacted metal powders may be or include a compacted mixture of metal powders that may include powders of one or more of iron, zinc, bismuth, copper, tungsten, nickel, boron, and/or alloys thereof, and/or oxides thereof. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. The anti-sparking agent may include a borate, such as boric acid.

Abstract: Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from compacted metal powders that may include an anti-sparking agent. The compacted metal powders may be or include a compacted mixture of metal powders that may include powders of one or more of iron, zinc, bismuth, copper, tungsten, nickel, boron, and/or alloys thereof, and/or oxides thereof. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. The anti-sparking agent may include a borate, such as boric acid.

Abstract: Die assemblies for forming a firearm projectile and methods of utilizing the die assemblies are disclosed herein. The die assemblies include a forming die, a first punch, and a second punch. The forming die defines a first side, a second side that is opposed to the first side, and a die cavity that extends between the first side and the second side. The first punch is configured to seal against the forming die from the first side. The second punch is configured to be received within the die cavity from the second side. When the first punch seals against the forming die and the second punch is received within the die cavity, the first punch, the second punch, and the forming die collectively define a forming surface shaped to define an external contour of the firearm projectile.

Abstract: Frangible firearm projectiles, firearm cartridges, and methods for forming the same. The projectiles are formed from metal powder and include an anti-sparking agent. One or more of iron, zinc, bismuth, tin, copper, nickel, tungsten, boron, and/or alloys thereof may form the metal powder. The projectiles may be formed from a compacted mixture of two or more different metal powders. The anti-sparking agent may include a borate, such as boric acid, zinc chloride, and/or petrolatum. The anti-sparking agent may be dispersed within, and/or applied as a coating on, the exterior of the projectile. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. Such domains may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does form a liquid phase of the metal powder or utilize a polymeric binder.

Abstract: Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from a compacted mixture of metal powders that includes zinc and iron powders and which may include an anti-sparking agent. The compacted mixture is heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. A majority component of the frangible firearm projectile may be iron. One or more of zinc, bismuth, tin, copper, nickel, tungsten, boron, and/or alloys thereof may form a minority component of the frangible firearm projectile. The anti-sparking agent may include a borate, such as boric acid.

Abstract: Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from a compacted mixture of metal powders that includes zinc and iron powders and which may include an anti-sparking agent. The compacted mixture is heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. A majority component of the frangible firearm projectile may be iron. One or more of zinc, bismuth, tin, copper, nickel, tungsten, boron, and/or alloys thereof may form a minority component of the frangible firearm projectile. The anti-sparking agent may include a borate, such as boric acid.