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SMCAR-ES-94-1

AD-A285 699

External Barrel and Handguard Temperatureof the 5.56mm M4 Carbine

DTIC Final Report

R- 10Origia contains color

This docmn ha been aprvdplates: All DUOC reprotluct-fo pblcrelecse and sale; ift long W1ll be In black An

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Preae By:Jeff Windham

Small Arms BranchEngineering Support Directorate

Rock Island, Illinois

September 1994

94-32904.1. !)_______________________________4___________y____ 1111111 UPllItl 111111 lE thu 1 llf ll 1111

External Barrel and Handguard Temperatureof the 5.56mm M4 Carbine

Final Report

Accesion For

NTIS CRAMI

U,-,arnounced5

DistributionI

Availability Codes

Prepared By: jAvail and/orJeff Windham Dit Special

Small Arms BranchEngineering Support Directorate

Rock Island, Illinois-

September 1994

SECURITY CLASSIFICATION OF THIS PAGE c1hon Date EntOr0)

REPORT DOCUMENTATION PAGE BEFORE MSTIN FORM1. REPORT NUMBER 2. GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER

SMCAR-ES-94-1

4. TITLE (and Subtitle) 5. TYPE OF REPORT & PERIOD COVERED

External Barrel and Handguard Temperature of Final Report

the 5.56mm M4 Carbine Sept. 1994S. PERFORMING ORG. REPORT NUMBER

SMCAR-ES-94-17. AUTHOR(@) S. CONTRACT OR GRANT NUMBER(*)

Jeff WindhamSMCAR-ESW-SRock Island, IL 61299-7300

S. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT. PROJECT, TASKAREA & WORK UNIT NUMBERS

U.S. Army Armament Research, Development andEngineering Center (ARDEC), SMCAR-ESW-SRock Island, IL 61299-7300

11. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE

Sept. 199413. NUMBER OF PAGES

14. MONITORING AGENCY NAME & ADDRESS(f dilferent from Controlling Office) IS. SECURITY CLASS. (of this report)

15o. DECL ASSIFI CATION/ DOWN GRADINGSCHEDULE

16. DISTRIBUTION STATEMENT (of this Report)

Distribution Statement A: Distribution is unlimited Ihz. uh cunracrors Lude

17. DISTRIBUTION STATEMENT (of the abstract entered In Block 20, if different from Report)

Il. SUPPLEMENTARY NOTES

19 KEY WORDS (Continue on revere side if nec...., and Identify by block number)

5.56mm Small ArmsM4 Carbine TemperatureHandguard M16A2 RifleBarrel

24L AWTVI ACT (Cintheae o w werw N emm~enw modtI~ftY by block mmber)

This test report examines the external barrel temperature of the5.56mm H4 series Carbines as a function of time and as a functionof longitudinal location on the barrel. It also compares theeffects of the handguard on barrel temperature and measures thetemperature of the X4 Carbine handguard external surface andinternal liners.

SE UR 473 EDITION OF T 0G, " IS OEOLETE

SECU~IrY CLASSIFICATION OF THIS PAGE (When Des Entered)

0 TECHNICAL REPORT NO. SMCAR-ES-94-1

EXTERNAL BARREL AND HANDGUARD TEMPERATUREOF THE 5.56=m M(4 CARBINE

Final Report

EP E 1994

PRZPAV- !,BY

t" JZPW WINDHAM

General Engineer

APPROVEDBy

Acting Ch, Cmbt apt & Sm Cal Wpn Sys Div

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

ENGINEERING SUPPORT DIRECTORATEARMAMENT RESEARCH, DEVELOPMENT AND ENGINEERING CENTER

ROCK ISLAND, IL 61299-7300

Disclaimer: The findings of this report are not to be construed as anofficial Department of the Army position unless so designated by otherauthorized documents.0

. ABSTRACT:

This test report examines the external barrel temperature of the5.56mm M4 series Carbines as a function of time and as a functionof longitudinal location on the barrel. It also compares theeffects of the handguard on barrel temperature and measures thetemperature of the M4 Carbine handguard external surface andinternal liners.

TABLE OF CONTENTS

STITLE PAGE oe...... . .. . .. . .. . . ................ i

ABSTRACT ... ... ... ... ..............*.............. ii

TABLE OF CONTENTS .................................... iii

INTRODUCTION ........................................ 1

BACKGROUND ... * ..... . o...... .. .. ................. 1

OBJECTIVE .- o o...... o.... o oo... - o...... . .. . .. . .. . . ... 2

TEST PROCEDURE .... .... ....... .... ..................... 2

TEST RESULTS . ...... . ..... .............. ........... 3

ANALYSIS OF TEST RESULTS ... .......... .. ..... ..... 4

CONCLUSIONS ................. o- ............... 6

APrENDIX A o............. ..... o....................... Al

LIST OF ILLUSTRATIONS

FIGURE 1 - Test Setup .. .... .. ..... .... ............... 8FIGURE 2 - Barrel Thermocouple Location ................ 9FIGURE 3 - Barrel Thermocouple Location ............. 10FIGURE 4 - Handguard Thermocouple Location ........... 10FIGURE 5 - Deformed Handguard Liner .................. 11FIGURE 6 - Deformed Handguard Liner .................... 12FIGURE 7 - Barrel Temp. for Bare Barrel .............. 13FIGURE 8 - Barrel Temp. for Small Handguard ......... 14FIGURE 9 - Barrel Temp. for Large Handguard ......-... 15FIGURE 10 - Maximum Barrel Temp. at TC 3 -... o....... 16FIGURE 11 - Maximum Barrel Temp. at TC 4 ............. 17FIGURE 12 - Maximum Barrel Temp. vs Barrel Location .. 18FIGURE 13 - Handguard Temp. for Large Handguard ...... 19FIGURE 14 - Handguard Temp. for Large Handguard ...... 20

LIST OF TABLES

TABLE I - Test Matrix ............................... 4

1.0 INTRODUCTION01.1 This report describes the test methods, analysis and

results used to examine the M4 and M4A1 Carbine barrel andhandguard temperatures during firing. It evaluates and comparesthe barrel temperature for a carbine when fired without handguards,with Colt commercial handguards, and with M4 Carbine handguards.The Colt commercial handguard is a small diameter, single aluminumliner handguard which hereafter will be referred to in this reportas the "small" handguard. The M4 Carbine handguard is a relativelylarge diameter, double aluminum liner handguard which willhereafter be referred to in this report as the "large" handguard.In addition, the temperature of the large, double liner M4 Carbinehandguard is evaluated in the top and bottom position.

1.2 Other reports which are related to this effort:

a. External Barrel Temperature of the M16AI Rifle, R-TR-75-045, July 1975, Rodman Laboratory, Rock Island Arsenal, IL.

b. XM4 Carbine Development Program, AD-E401 627, Sept 1987,Colt Firearms, Hartford, CT.

c. M4 Carbine Initial Production Contract Pre-ProductionEngineering Report, Colt Mfg. Co. Hartford, CT. (Report notformally released as of September 1994).

1. 3 All testing described in this report was conducted by theWare Simulation Laboratory, Rock Island Arsenal, Rock Island, IL.

2.0 BACKGROUND:

2.1 Short barreled carbine versions of the 5.56mm M16 seriesrifles have been in existence since the 1960's. These shortbarreled weapons have been used commercially and by variousmilitary services since that time. One complaint with earlierversions of these carbines was handguard overheating during severefiring schedules. The handguard used on these weapons is arelatively small diameter, round, single aluminum liner handguard.During development of the M4 Carbine in 1984, Colt Mfg. Co.developed several handguard prototypes in an attempt to remedy thisoverheating problem. The design that was adopted consisted of alarge diameter, round, double aluminum liner handguard withresistance welded aluminum tabs. This double liner configurationproved very successful in improving resistance of the handguard tooverheating.

2.2 During the Pre-Production Engineering Phase of the initialproduction contract for the M4 Carbine (June through Dec. 1993),Colt Mfg. Co. developed several alternatives to the handguard

configuration in an attempt to improve producibility. Handguardtemperature profiles were developed during this effort showing thehandguard temperature for the small Colt commercial handguard, thelarge M4 Carbine handguard, the M16A2 rifle handguard and severalother prototype configurations.

2.3 The temperature profile developed in the Pre-ProductionEngineering Phase of the M4 Carbine contract indicated the large,double liner handguard performed well in insulating the firer'shand from the heat of the barrel. Because the large M4 handguardremained relatively cool compared to the small, Colt commercialhandguard, concerns were raised that the large, double liner M4handguard might be insulating the barrel of the weapon too well,thereby causing a significant increase in the temperature of thebarrel. Part of this testing examines this condition.

3.0 OBJECTIVE:

3.1 The objectives of this testing were as follows:

a. Determine the temperature profile of the M4 and M4A1barrels.

b. Determine the effects of the handguard on barreltemperature and compare barrel temperature differences between thesmall, Colt commercial handguard and the large, M4 handguard.

0c. Determine the large, M4 handguard temperature profile inboth the top and bottom handguard position.

4.0 TEST PROCEDURE:

4.1 This test was conducted in four phases. Each phaseconsisted of two firing schedules. The first firing scheduleconsisted of 280 rounds fired in full automatic as fast as possible(approximately 140 to 160 rounds per minute). The second firingschedule consisted of firing 280 rounds in semi-automatic fire asfast as possible (approximately 100 to 120 rounds per minute). Thetemperature at each thermocouple was recorded during the firing andfor approximately 10-12 minutes thereafter (for a total elapsedtime of 14 minutes). The test setup is shown in Figure 1. Thefour phases of firing are outlined below:

4.2 PHASE I. One M4A1 Carbine barrel was modified by theattachment of six thermocouples located in the positions shown inFigures 2 and 3. The weapon was then fired with no handguard onthe weapon using the firing schedules described in paragraph 4.1.The temperature at each thermocouple location was recorded.

4.3 PHASE II. The thermocoupled M4A1 barrel was fired with

the small handguards on the weapon, using the firing schedulesdescribed in paragraph 4.1 above. The temperature at eachthermocouple location was recorded. During the semi-automaticportion of this test, a weapon malfunction occurred during firingwhich took approximately 30 seconds to clear. The test wab refiredwithout malfunction. The temperature profila of the firingsequence with the malfunction is shown in appendix A, charts II-S-1-a through II-S-6-a, in order to show the amount of cooling whichcan occur during such a brief firing interruption.

4.4 PHASE III. The thermocoupled M4A1 barrel was fired withthe large, M4 Carbine handquards installed on the weapon, using thefiring schedules described in paragraph 4.1 above. The temperatureat each thermocouple location was recorded.

4.5 PHASE IV. One large, M4 Carbine handguard was modifiedwith five thermocouples as shown in Figure 4. Thermocouple 7 waslocated on the inner liner next to one of the two rear tabs.Thermocouple 8 was located on the outer liner next to one of thetwo rear tabs. Thermocouples 9, 10, and 11 were located on theoutside of the handguard at the rear, middle and front of thehandguard respectively. These thermocouples measure thetemperature the firer's hand will encounter. This test was firedin two parts, once with the thermocoupled ha:idguard in the toppo3ition on the weapon and once with the thermocoupled handguard inthe bottom position on the weapon.

5.0 TEST RESULTS:

5.1 Graphs of each thermocouple temperature vs. time for eachfiring sequence and test phase are showr in appendix A. A testmatrix of each test and the corresponding temperature profile graphnumber is shown in Table I. The graph numbers are coded in thefollowing manner:(Test Phase No.) - (Firing Schedule, F=Full Auto, S=Semi Auto) -(Thermocouple No.) - (Suffix if applicable: a=additional test dueto malfunction, T=Top handguard position, B=Bottom handguardposition)

5.2 During test firing of the large handguard, severedeformation of the inner aluminum liner occurred. This deformationoccurred during firing of 280 rounds in full automatic mode on thetop handguard only. Photographs of the deformed handguard linerare shown in Figures 5 and 6. The thermocouples on the handguardliner show the inner liner on the top handguard reachedapproximately 700 degrees at the rear tab location (the temperatureof the inner liner directly above the gas tube is likelysignificantly higher) during the severe 280 round/full auto firingschedule.

6.0 ANALYSIS:

6.1 Due to the difficulty in deriving useful information fromthe individual thermocouple graphs, the graphs were rescaled andcombined via computer software. The following combined graphs areshown:

6. 1. 1 The barrel thermocouple temperature for full automaticfire for a bare barrel is shown in Figure 7. It can be seen fromthis graph that the highest temperature location measured was atthermocouple 4 approximately midway between the chamber and thefront sight. The coolest point on the barrel is at thermocouple 6and is due to the upper receiver and barrel nut acting as a heatsink.

6.1.2 Barrel thermocouple temperature for full automatic firefor a barrel with the small handguards attached is shown in Figure8. The highest temperature location is also thermocouple 4 withthe coolest being at thermocouple 6.

6.1.3 Barrel thermocouple temperature for full automatic firefor a barrel with the large handguards attached is shown in Figure9. The highest temperature location is also thermocouple 4 withthe coolest being it thermocouple 6.

6.1.4 Maximum barrel temperature comparison at thermocouple 3for the bare barrel, small handguard barrel and large handguardbarrel is shown in Figure 10. As expected, the bare barrel maximumtemperature is less than that of the barrel with handguardsattached and the cooling rate of the bare barrel is greater thanthat of the barrels -ith handguards. This is due to the maximumamount of convective cooling on a barrel without handguard3. Thedifference in maximum temperature and cooling rate between thesmall and large handguards is insignificant. (As can be seen fromthe graph, there was a slight delay in firing of the largehandguard that caused the time to fire the 280 rounds to beincreased about 20 seconds. This would have an impact on themaximum temperature achieved, however this effect is consideredsmall).

6.1.5 Maximum barrel terperature comparison at thermocouple 4for the bare barrel, small handguard barrel and large handguardbarrel is shown in Figure 11. This graph shows the same results asdescribed in paragraph 6.1.4 above.

6.1.6 Maximum barrel temperature vs. location on the barrel isshown in Figure 12 for each firing condition (i.e. bare barrel;small handguard; and large handguard.)

M4 Carbine Barrel Temperature Test Matrix

0 THERMOCOUPLE LOCATION* Inner Outer

TEST Barrel Liner Liner Handguard

* 1 2 3 4 5 6 7 8 9 10 11

Full :F-i F-2 F-3 F-4 F-5 F-6 N/A N/A N/A N/A N/APhase I Auto:B are B rl. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Semi : I- I- I- I- I- I-Auto : S-1 S-2 S-3 S-4 S-5 S-6 N/A N/A N/A N/A N/A

Full F-i F-2 F-3 F-4 F-5 F-6 N!/A N/A N/A N/A N/APhase II Autosm all - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Handguard Semi : II- II- II- II- II- II-

Auto :S-i S-2 S-3 S-4 S-5 S-6 N/A N/A N/A N/A N/A

*Semi II- 11- 11- 11- 11-' 11Auto S-1 -;-2 S-3 S-4 S-5 S-6 N/A N/A N/A N/A N/AHalf.: -a -a -a -a -a -aRnd

Full : F-i F-2 F-3 F-4 F-5 F-6 N/A N/A N/A N/A N/APhase III Auto:0Large 14 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Handguard Semi : III- III- III- III- III- III-

Auto : S-1 S-2 S-3 S-4 S-5 S-6 N/A N/A N/A N/A N/A

IV- IV- IV- IV- IV-Phase IV Full : N/A N/A N/A N/A N/A N/A F-7 F-8 F-9 F-10 F-liLarge Hand- Auto : -T -T -T -T -TGuard and - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Liner Temp Semi : IV- IV- IV- IV- IV-in Top Auto : N/A N/A N/A N/A N/A N/A S-7 S-8 S-9 S-10 S-i1Position -T -T -T -T -T

IV- IV- IV- IV- IV-Phase IV Full : N/A N/A N/A N/A N/A N/A F-7 F-8 F-9 F-10 F-ilLarge Hand- Auto : -B -B -B -B -Bguard &-- - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - -Liner Temp semi : Iv- IV- IV- IV- IV-in Bottom Auto : N/A N/A N/A N/A N/A N/A S-7 S-8 5-9 S-10 S-liPosition :-B -B -B -B -B

* A malfunction occurred in magazine 12. Charts are provided toshow the temperature drop in the time it took to clear thestoppages.

TABLE I

6.1.7 Handguard thermocouple temperature for full automaticfire for the large handguard in the top position is shown in Figure13. As shown in this graph, the temperature of the inner liner isby far the hottest portion of the handguard. The temperature ofthe outside of the handguard plastic reached a point at which itcould not be comfortably held with the bate hand in about twominutes, with the temperature being highest near the front of thehandguard. (A handguard temperature of 150 degrees Fahrenheit isconsidered the temperature at which the handguard could not becomfortably held.) It can also be seen the maximum temperature ofthe outer portion of the handguard occurs after about 6 minutes orabout 4 minutes after the firing has ended and maximum barreltemperature has been achieved.

6.1.8 Handguard thermocouple temperature for full automaticfire for the large handguard in the bottom position is shown inFigure 14. In the bottom position on the weapon, all thermocoupleslocations are significantly cooler than when the handguard is inthe top position. The outside of the handguard never reached the150 degree Fahrenheit threshold.

6.2 The deformation of the inner handguard liner appears to1 ,e been caused by the thermal expansion of the liner inside thehandguard plastic. As the aluminum liner heats, it will attempt toexpand inside the plastic. Because the coefficient of thermalexpansion of the plastic is much less than the aluminum liner, andthe plastic is much cooler than the aluminum, the liner will beconstrained inside the handguard plastic and kept from expanding.From the liner thermocouple readings, the inner liner will reachtemperatures of approximately 700 degrees F. The thermalcoefficient of expansion of aluminum is 12.6 inches/(inch)(dcgreeF) x 10-0 . The length of the liner is 5.825 inches. If ambienttemperature is assumed to be 80 degrees F, the thermal expansion ofthe handguard liner is (700 OF - 80 OF) ((12.6 inches/(inch) (degreeF)) x 10-6)(5.825 inches) = .046 inches. Because the liner cannotexpand it will buckle and deform. Once the liner has cooled, itcontracts and is pulled away from the ends of the handguard causingthe condition shown in figures 5 and 6.

7.0 CONCLUSIONS:

7.1 The maximum temperature on the M4 Carbine barrel occurs atapproximately 4 inches forward of the breech face on the barrel.Due to the spacing of the thermocouples during this test, the exactlocation of the maximum temperature could not be determined. Basedon the previous test reports referenced in paragraph 1.2, thelocation of the maximum barrel temperature changes with rate offire. It is also likely the exact location of maximum temperatureof the barrel would change slightly with different types ofhandguards.

7.2 Although the bare barrel heats less rapidly and cools morerapidly than a barrel covered by a handguard, this difference isconsidered small.

7. 3 There is no significant difference in barrel heating andcooling rates between the small handguard and the large handguard.

7.4 Under severe firing schedules the inner liner of the M4Carbine large handguard in the top position will likely deform andbuckle. Because the liner of the handguards is not a replaceableitem, this condition will require replacement of the entirehandguard. Because the firing schedule used in this test is muchmore severe than that expected in field service, this should notpose a significant field problem. However, this is an undesirablecondition and efforts to improve the heat resistance of the linersshould be considered.

7.5 The large M4 Carbine handguard greatly reduces the problemof handguard overheating as has been reported by field units whenusing small Colt commercial handguards.

FIGURE 3 FGRBarrl ThrmocupleLocaionHandguard Thermocouple Location

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APPENDIX A

Individual thermocouple temperature charts for each phase ofthe testing.

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