The primary goal of this project is to demonstrate the ability to create lightweight and long life ceramic barrels that will function satisfactorily in the M4 Carbine weapon system. The basic objectives are development and fabrication of a ceramic barrel that will yield a 25% weight saving compared with the M4 SOCOM Heavy Barrel, conform to standard fixture requirements for the M4 Carbine system and a have a composite overwrap that will establish and sustain compressive stresses on the ceramic bore surface during all M4 operational firing schedules.In this study a HiPed Y-TZP (Yttria Tetragonal Zirconia Polycrystal) was selected as the ceramic bore material and is wrapped with a PEEK/IM7 Towpreg composite at high tension. A number of design iterations are carried out to determine the optimal winding conditions so as hoop compression in the ceramic is maintained under high pressure firing conditions. Parametric studies are carried out to study the effect of tension profiles on ceramic and composite hoop and radial stresses under zero loads and during firing conditions. Results show that a successful design of a composite overwrapped HY-TZP ceramic barrel is possible if adequate tension is applied and maintained on the ceramic bore.
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