Lightweight Small Arms Technologies

Lightweight Small Arms Technologies (LSAT)

National Defense Industrial Association

Joint Services Small Arms Systems
Annual Symposium
May 2008

Ms. Kori Spiegel

US Army ARDEC
(973) 724-7912
[email protected]

Mr. Paul Shipley

AAI Corporation
(410) 628-3462
[email protected]
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LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies

Top 5 Soldier Weight Contributors
Lightweight Small Arms Technologies (LSAT)

For Automatic Rifleman:

1.
2.
3.
4.
5.

M249 Squad Automatic Weapon w/200 rds Ammo

5.56mm Ammunition (400 rounds)
Body Armor & Helmet
Communication Equipment
Canteen/Water

LSAT NDIA Small Arms

May 2008

Lightweight Small Arms Technologies

Goals
Lightweight Small Arms Technologies (LSAT)

Goals:

35% weapon weight reduction

40% ammunition weight reduction
Reduced training & maintenance
Maintain cost of current systems

Approach:

Clean Slate design

Reduced weight as the priority
In depth trade studies
Extensive modeling & simulation
LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies

Program Approach
Lightweight Small Arms Technologies (LSAT)

5.56mm Telescoped
Ammunition

Cased

Light Machine Gun

Demonstrator

Caseless

Focus is development of
technologies- not specific weapon
system
Demo via Light Machine Gun with
5.56mm ammunition
Spiral development approach

Achieve 50% overall weight reduction

Pursue parallel Cased Telescoped and
Caseless Ammunition design approaches
High commonality of design and function,
some action component differences
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LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies

Status vs Goals
Lightweight Small Arms Technologies (LSAT)

Capability
Weapon
Weight
Ammo Weight
600 rds Pkgd
Affordability
TRL
Effectiveness

Current LSAT Program

Current
(M249)

Threshold

Current Status

Objective

17.5 lbs

13.1 lbs (25%)

CT 9.8 lbs (44%)

CL 9.9 lbs (43%)

11.4 lbs (35%)

20.4 lbs

15.3 lbs (25%)

CT(2) 13.6 lbs (33%)

CT(3) 12.2 lbs (40%)
CL 9.8 lbs (51%)

12.2lbs (40%)

Gun $3600
Ammo $262

Gun $3600
Ammo $262

Equivalent

Gun $3600
Ammo $262

N/A

CT TRL 5
CL TRL 4

Baseline

Maintain
Baseline

Potential
Improvement

Improve
Baseline
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LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies

AAI Contractor Team Members
Lightweight Small Arms Technologies (LSAT)

TBD
Weapon Producer
Launc h Systems
Lake City

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LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies

Weapon Design and Performance Features
Lightweight Small Arms Technologies (LSAT)

Key Technologies
Use of telescoped ammocased and caseless
Lightweight materials &
structural configuration
Thermal management for
weight reduction
Barrel
Caseless chamber
components

Caseless chamber sealing

Human factors- firing
controllability
Integration of electronics

Muzzle Compensator
(option)

Rotating Chamber prov ides

In-line push thru feed/eject

Vented
Foregrip

Both M855 ball and M856

tracer bullets prov ide
lethality equivalent to M249

Long stroke, soft recoil

Improv es controllability

Fluted, Quick Change Barrel

High stiffness and heat capacity
No tools for barrel change

Rounds Counter
improv es maintainability
Rail attachment points

Full Loop
Polymer Links

Both cased telescoped

and caseless configurations

Multiple Sling
attach points for
mission tailoring

Semi or Full
Auto Fire @
100 Round Ammo 600 rd/min
Soft Pouch (150 for
Caseless)

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LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies

Ammunition Design Features
Lightweight Small Arms Technologies (LSAT)

Key Technologies
Telescoped cartridge
Cased Ammunition
Polymer cartridge case
and endcap
Compacted/consolidated
propellant

Caseless Ammunition
Weight 600 linked pkg'd rnds

M855
20.8 lbs

LSAT CT

LSAT CL

13.6 lbs (Sp2)

33% reduction
12.2 lbs (Sp3)
40% reduction

9.8 lbs
51 % reduction

High Ignition
Temperature Propellant
Booster assisted interior
ballistics

Demonstrate in 5.56mm

Muzzle velocity (78 ft)

3,020 ft/sec

3,020 ft/sec

3,020 ft/sec

Length

2.25 inches

1.6 inches

1.6 inches

Diameter

0.38 inches

0.35 inches

Primer

Percussion

0.45 in (Sp2)
0.38 in (Sp3)
Percussion

Address producibility
Consider scalability

Percussion

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LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies

Ammunition Features
Lightweight Small Arms Technologies (LSAT)

Cased Configuration

Conventional technology in
telescoped configuration
30 40% weight reduction
Lower Risk

Caseless Configuration

High Ignition Temperature

Propellant Technology
50%+ Weight Reduction
40% Volume Reduction
Higher Risk

LSAT NDIA Small Arms

May 2008

Lightweight Small Arms Technologies (LSAT)

Cased Telescoped System

Design and Development Status
- Ammunition - Weapon -

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LSAT NDIA Small Arms
May 2008

CT Ammunition Chronology
Lightweight Small Arms Technologies (LSAT)

2005

2006

2007 (May)

Spiral 1 Cartridge

Spiral 2 Cartridge

Spiral 2 Cartridge

24% wt red, 0.50 OD

Off the shelf
propellant
Demonstrated
concept and
performance
Used for initial
weapon development
testing and cartridge
geometry studies

Reduced size, weight

Custom LSAT powder
w/reduced flash
Material optimization
across temperatures
Supported integrated
weapon development

33% wt red, 0.46 OD

Continued
refinements
Baseline established
for materials, design,
tooling
Supported weapon
development, demos

Spiral 3 Cartridge
Initiated development

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LSAT NDIA Small Arms
May 2008

CT Ammunition 2007/08 Update

Lightweight Small Arms Technologies (LSAT)

Spiral 2- Fabricated
ammunition to support
weapon testing
Spiral 3- Conducted initial
performance testing

Compacted propellant
Consolidated propellant
0.38 diameter
40% Weight Reduction

CT
Spiral 1

CT
Spiral 2

CT
Spiral 3

CL
Spiral 2

Over 9,000 rounds fired

Mann Barrels and Machineguns
Temperatures ranging
from -65F to +160F

Preparing 2,000 rd contract

delivery
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LSAT NDIA Small Arms
May 2008

CT Weapon Chronology
Lightweight Small Arms Technologies (LSAT)

2005

SN 1

Action function
assessed using
dynamic test fixture
Spiral 1 ammo
Validated kinematic
model

Lubricious coating
assessment

2006

SN 1

Integrated weapon/action
Conducted functional
assessments, incorporated
design refinements
Fixture and shoulder firings
TRL 5 demo with Spiral 1 ammo

SN 2

Initiated design updates

Fabricated hardware
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LSAT NDIA Small Arms
May 2008

CT Weapon Chronology
Lightweight Small Arms Technologies (LSAT)

2007 (May)

SN 1
SN 2

SN 1

Fired approx 3,000 rds

Converted weapon to Spiral 2 ammo
Army DTC limited safety release for
manned fire
Conducted shootability assessment
Confirmed TRL 5 with Spiral 2 ammo

SN 2

Weapon Action in test, approx 750 rds fired

Integrated weapon components ready
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LSAT NDIA Small Arms
May 2008

CT Weapon 2007/08 Update

Lightweight Small Arms Technologies (LSAT)

SN1
Fired approx 6,500 total rds
Conducted 4 major live fire demos
Measured system characteristics

Single Shot Char acter ist ics M249 vs. LSAT

(Pro n e fro m b ipo d )

M 24 9 3 Rou nd Bu rst
L SAT Si ng le Sh ot Avg

1 20

1 00
Forc e (lbs )

Aim disturbance/compensation
Recoil
Barrel thermal/ablator heat reduction

1 40

80

60

40

20

Incorporated design refinements

-1 0 0

-50

50

100
Tim e (m s )

150

20 0

2 50

300

SN2
Fired approx 2,000 rds
Integration complete
TRL 5 verification underway
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LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies (LSAT)

Caseless System
Design and Development Status
- Ammunition - Weapon -

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LSAT NDIA Small Arms
May 2008

CL Cartridge Components & Technologies

Lightweight Small Arms Technologies (LSAT)

Key Technologies
Telescoped configuration
High Ignition Temperature
Propellant (HITP)
Internal Primer assisted
interior ballistics
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LSAT NDIA Small Arms
May 2008

CL Ammunition Chronology
Lightweight Small Arms Technologies (LSAT)

2005
Characterize HITP

2006
Replicate 4.92mm ACR

2007 (May)
Begin Scale-up to 5.56mm

Fabricate
Fabricate initial
initial Spiral
Spiral 11
5.56mm
5.56mm ammo
ammo using
using
lab-scale
lab-scale process
process

Design
Design and
and equip
equip
process
process scale-up
scale-up facility
facility

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LSAT NDIA Small Arms
May 2008

CL Ammunition 2007/08 Update

Lightweight Small Arms Technologies (LSAT)

Spiral 2 Process scale-up facility complete and in use

Located at ATK Launch Systems (Utah)
Equipment includes

50 ton transfer mold

Dry material feed and handling
Solvent processing
Horizontal mixer

Several Design-of-Experiments process studies

Dedicated primer fabrication facility nearing

completion at ATK Lake City AAP
Spiral 2

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LSAT NDIA Small Arms
May 2008

CL Ammunition 2007/08 Update

Lightweight Small Arms Technologies (LSAT)

Refined Spiral 2 Ammunition

Several Design-of-Experiments HITP process studies
FNGUN interior ballistics model updated
Primer (internal and external) material studies
Preparing contract deliverable ammunition

Initiated Spiral 3 Development

Replace energetic binder
Improve cost/environmental considerations
Reduce production facility impact

Reduce thermal load on weapon

Burn rate modifiers- reduce flame temperature, improve barrel life
Exterior coatings- reduce heat transfer rate
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LSAT NDIA Small Arms
May 2008

CL Weapon Chronology
Lightweight Small Arms Technologies (LSAT)

2005

2006

Burst fire analysis

temperature profi le

Component Studies

Chamber sealing
Firing pin interface
Characterize thermal loads
Utilized residual 4.92mm ACR
ammo
Maximize CT commonality

Thermal Focus

Initial material studies

High temperature
High heat capacity
Insulating materials
Thermal configuration studies
Ablator heat reduction assessment
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LSAT NDIA Small Arms
May 2008

CL Weapon Chronology
Lightweight Small Arms Technologies (LSAT)

2007 (May)

Design Finalization
3D models, kinematics
Subsystem test fixtures

Matl Thermal Investigations

Insulating materials
Laser pulse heating apparatus
Ballistic fixture
Automatic fire barrel heating/model

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LSAT NDIA Small Arms
May 2008

CL Weapon 2007/08 Update

Lightweight Small Arms Technologies (LSAT)

Conducted Weapon Subsystems Tests

Ballistic interfaces
Firing pin
Chamber volume
Seals

Weapon/Cartridge interfaces (via CT wpn)

Rammer loads
Cross feed loads
Free belt dynamics
Validated kinematic model

Weapon action tests underway

Continued thermal tests
Insulating materials
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LSAT NDIA Small Arms
May 2008

Rifle Design Activity

Lightweight Small Arms Technologies (LSAT)

Initiated in 2008
Requirements analysis
Concept development and tradeoffs
Both CT and CL designs (ctg same as LMG)
17 rifle concepts- various mechanisms and overall
configurations
Two magazine approaches- weapon powered, spring
powered. Focused on high capacity.
Evaluated, downselected to two each CT and CL

Detailed design
Nearing completion
Full detail 3D models
Structural analysis, kinematic analysis
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LSAT NDIA Small Arms
May 2008

Ongoing Supportability Activities

Lightweight Small Arms Technologies (LSAT)

Supportability Focus
Evaluate technology implementation considerations
Fully integrated with development effort

Key Activities Nearing Completion

Logistics Support Analysis- Level of Repair analysis
(COMPASS), Life Cycle Cost analysis (ACEIT), O&M task
identification (new Army maintenance concept)
Reliability, Availability, Maintainability- Failure modes, effects,
and criticality analysis, reliability tracking, mean time to repair
Training analysis and materials- Training concept, training task
analysis
Human System Integration- Human factors design support,
system safety evaluations, fightability assessments (2
complete), shootability assessment (1 complete)
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LSAT NDIA Small Arms
May 2008

Lightweight Small Arms Technologies

Summary
Lightweight Small Arms Technologies (LSAT)

System design meets all program requirements:

Weight reduction exceeds goals

Improves lethality
Improves logistics
Improves ergonomics

Maintaining parallel, synergistic Cased Telescoped and Caseless

development plan
Emphasizes commonality
Reduces program risk
Initiated Rifle design activity- requirements, concepts, detailed designs

Scalable design provides significant modularity and commonality

Cohesive Government/industry team ensures success in
development, user acceptance, and production
Comments/Questions?
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LSAT NDIA Small Arms
May 2008