Experimental investigation of tungsten–nickel–iron alloy, W95Ni3.5Fe1.5, compared to copper monolithic bullets

Abstract

Introduction: The demand for improved small arms ammunition has led to exploring advanced materials and manufacturing techniques. This research investigates the machining characteristics of CM and WNF alloy bullets, aiming to enhance ballistic performance and durability.

Methods: Bullet profile-making trials were conducted to evaluate the impact of machining parameters such as cutting speed and feed. The study also considered variables including surface roughness, cutting temperature, and hardness, alongside a detailed morphological analysis, The evaluation utilized an orthogonal array and MCDM approach, incorporating the TOPSIS method for decision-making processes.

Results: The findings reveal that WNF alloy bullets exhibit 3.01% to 27.95% lower machining temperatures, 24.88%-61.85% reduced surface roughness, and 19.45%-34% higher microhardness compared to CM bullets. Moreover, CM bullets demonstrated higher machining temperatures, resulting in 47.53% increased tool flank wear. WNF bullets showed a 24.89% reduction in crater wear and a 38.23% decrease in compressive residual stress in bullet profiles, indicating superior machining performance.

Discussion: The superior machining performance of WNF alloy bullets suggests their potential to improve the ballistic performance and durability of small arms ammunition. The reduced tool wear and favorable machining parameters highlight WNF alloy's advantages for military and defense applications. A ballistic impact analysis using a finite element method (FEM) model in Abaqus software further supports the potential of WNF alloy bullets, providing a solid foundation for future advancements in bullet manufacturing technologies.