Abstract: In making frangible objects, including lead-free bullets and other projectiles, powdered metal primary and powdered ceramic secondary phases are mixed and densified at an elevated temperature such that the ceramic phase forms a brittle network. Different combinations of metal and ceramic phases may be used to achieve desired chemical and physical properties. Any appropriate mixing, forming, and/or thermal processing methods and equipment may be used. Degrees of frangibility, strength, and toughness can be adjusted to suit a given application by precursor selection, degree of mixing, relative amounts of metal and ceramic phases, forming method, and thermal and mechanical processing parameters.

Abstract: To produce lead-free projectiles, iron and copper are melted at a predetermined ratio and rapidly quenched to yield a fine-grained microstructure with uniformly distributed copper and iron phases. The iron-copper alloy may be made into a powder through atomization, with the iron-copper molten metal being dispersed using a rapidly moving gas, liquid stream, or via mechanical dispersion. The step of forming the bullet may include solid-state sintering of the atomized powder, including heating at a temperature below 1083° C., the melting point of copper. Alternatively, the step of shaping the mixture into a bullet-shaped form may include casting and/or unixially pressing the mixture into a mold. A ceramic powder may be added to the copper-iron mixture prior to forming to produce a frangible projectile. Chromium, including chromium from recycled stainless steel, may be added to increase corrosion resistance and/or reduce manufacturing cost.

Abstract: To produce lead-free projectiles, iron and copper are melted at a predetermined ratio and rapidly quenched to yield a fine-grained microstructure with uniformly distributed copper and iron phases. The iron-copper alloy may be made into a powder through atomization, with the iron-copper molten metal being dispersed using a rapidly moving gas, liquid stream, or via mechanical dispersion. The step of forming the bullet may include solid-state sintering of the atomized powder, including heating at a temperature below 1083° C., the melting point of copper. Alternatively, the step of shaping the mixture into a bullet-shaped form may include casting and/or uniaxially pressing the mixture into a mold. A ceramic powder may be added to the copper-iron mixture prior to forming to produce a frangible projectile. Chromium, including chromium from recycled stainless steel, may be added to increase corrosion resistance and/or reduce manufacturing cost.

Abstract: To produce lead-free projectiles, iron and copper are melted at a predetermined ratio and rapidly quenched to yield a fine-grained microstructure with uniformly distributed copper and iron phases. The iron-copper alloy may be made into a powder through atomization, with the iron-copper molten metal being dispersed using a rapidly moving gas, liquid stream, or via mechanical dispersion. The step of forming the bullet may include uniaxially pressing and solid-state sintering of the atomized powder, including heating at a temperature below 1083° C., the melting point of copper. Alternatively, the step of shaping the mixture into a bullet-shaped form may include casting the molten mixture into a mold. A ceramic powder may be added to the copper-iron mixture prior to forming to produce a frangible projectile. The method may further include the step of adding another elemental powder to enhance strength, toughness, density, or hardness.

Abstract: To produce lead-free projectiles, iron and copper are melted at a predetermined ratio and rapidly quenched to yield a fine-grained microstructure with uniformly distributed copper and iron phases. The iron-copper alloy may be made into a powder through atomization, with the iron-copper molten metal being dispersed using a rapidly moving gas, liquid stream, or via mechanical dispersion. The step of forming the bullet may include uniaxially pressing and solid-state sintering of the atomized powder, including heating at a temperature below 1083° C., the melting point of copper. Alternatively, the step of shaping the mixture into a bullet-shaped form may include casting the molten mixture into a mold. A ceramic powder may be added to the copper-iron mixture prior to forming to produce a frangible projectile. The method may further include the step of adding another elemental powder to enhance strength, toughness, density, or hardness.

Abstract: This disclosure generally relates to high-volume and cost-effective methods for producing non-spherical metal particles, particularly methods for producing metal cubes having rounded edges. The metal cubes having rounded edges are useful as ballistic shot in shotshell loads for hunting, where the particle shape imparted by the disclosed process packs to a higher density than spherical shot in the same volume.

Abstract: This disclosure generally relates to high-volume and cost-effective methods for producing non-spherical metal particles, particularly methods for producing metal cubes having rounded edges. The metal cubes having rounded edges are useful as ballistic shot in shotshell loads for hunting, where the particle shape imparted by the disclosed process packs to a higher density than spherical shot in the same volume.

Abstract: In making frangible objects, including lead-free bullets and other projectiles, powdered metal primary and powdered ceramic secondary phases are mixed and densified at an elevated temperature such that the ceramic phase forms a brittle network. Any combination of metal and ceramic phases may be used to achieve desired chemical and physical properties. Any appropriate mixing, forming, and/or thermal processing methods and equipment may be used. Degrees of frangibility, strength, and toughness can be adjusted to suit a given application by precursor selection, degree of mixing, relative amounts of metal and ceramic phases, forming method, and thermal and mechanical processing parameters.

Abstract: In making frangible objects, including lead-free bullets and other projectiles, powdered metal primary and powdered ceramic secondary phases are mixed and densified at an elevated temperature such that the ceramic phase forms a brittle network. Different combinations of metal and ceramic phases may be used to achieve desired chemical and physical properties. Any appropriate mixing, forming, and/or thermal processing methods and equipment may be used. Degrees of frangibility, strength, and toughness can be adjusted to suit a given application by precursor selection, degree of mixing, relative amounts of metal and ceramic phases, forming method, and thermal and mechanical processing parameters.

Abstract: This disclosure generally relates to high-volume and cost-effective methods for producing non-spherical metal particles, particularly methods for producing metal cubes having rounded edges. The metal cubes having rounded edges are useful as ballistic shot in shotshell loads for hunting, where the particle shape imparted by the disclosed process packs to a higher density than spherical shot in the same volume.

Abstract: In making frangible objects, including lead-free bullets and other projectiles, powdered metal primary and powdered ceramic secondary phases are mixed and densified at an elevated temperature such that the ceramic phase forms a brittle network. Any combination of metal and ceramic phases may be used to achieve desired chemical and physical properties. Any appropriate mixing, forming, and/or thermal processing methods and equipment may be used. Degrees of frangibility, strength, and toughness can be adjusted to suit a given application by precursor selection, degree of mixing, relative amounts of metal and ceramic phases, forming method, and thermal and mechanical processing parameters.

Abstract: In making frangible objects, including lead-free bullets and other projectiles, powdered metal primary and powdered ceramic secondary phases are mixed and densified at an elevated temperature such that the ceramic phase forms a brittle network. Any combination of metal and ceramic phases may be used to achieve desired chemical and physical properties. Any appropriate mixing, forming, and/or thermal processing methods and equipment may be used. Degrees of frangibility, strength, and toughness can be adjusted to suit a given application by precursor selection, degree of mixing, relative amounts of metal and ceramic phases, forming method, and thermal and mechanical processing parameters.

Abstract: In making frangible objects, including lead-free bullets and other projectiles, powdered metal primary and powdered ceramic secondary phases are mixed and densified at an elevated temperature such that the ceramic phase forms a brittle network. Any combination of metal and ceramic phases may be used to achieve desired chemical and physical properties. Any appropriate mixing, forming, and/or thermal processing methods and equipment may be used. Degrees of frangibility, strength, and toughness can be adjusted to suit a given application by precursor selection, degree of mixing, relative amounts of metal and ceramic phases, forming method, and thermal and mechanical processing parameters.