CONTENTS

PAGE

SECTION I - INTRODUCTION

1. Purpose 1

SECTION II - TERMINOLOGY

2. Cartridge 3
3. Caliber or Millimeter 3
M-. Type 3
5. Model 3
6. Cartridge Case 3
7. Primer 5
8. Propellant 5
9. Bullet 6
10. Cartridge Identification 6

SECTION III - MANUFACTURE

11. General 7
12. Case and Bullet Jacket Cup 7
13. Cartridge Case 8
Ik. Case Operations 9
15. Primed Case l6
16. Cartridge Operations 17
17. Bullet 20
18. Bullet Jacket Operations 21
19. Bullet Operations 22
20. Slug, Point Filler, and Base Filler
Operations 23'
21. Primer Operations 24^
22. Cores for Armor Piercing Cartridges .... 273
23. Closure Cups and Closure Discs for 3
Tracer Cartridges 28,
24. Incendiary and Tracer Manufacture 28'
25. Incendiary and Tracer Charging 28_
26. Packaging 29

.cues
r\»(tu a.d/or
Dit Special

ÖHWWOÜNCÖJ /)-(
 CONTENTS

PAGE

SECTION IV - THE CONTROL OF QUALITY

27. General 31
28. Definition 31
29. Inspection 3^
30. Control Tests 35
31. Work Tests 36
32. Statistical Quality Control 36

SECTION V - QUALITY ASSURANCE

33. General 39
34. Function 39
35- Nonconforming Material 41
 SECURITY CLASSIFICATION OF THIS
! PPDnOT IWII RKAD INSTRUCTIONS
j RCrUK 1 IAJV.U '.FORE COMPLETING FORM
ll. REPORT NUMBER m mm± m f\g* f* 1 /\ O IF-N T'S C AT ALOG NUMBER

1« TITLE (tnd Subllllt) OF REPORT t PERIOD COVERED

INTRODUCTORY HAHDBOOK FOR SMALL ARMS AMMUNITION
1
I 6. PERFORMING ORG. REPORT NUMBER
1-9
I?. AUTHORf'i B. CONTRACT OR GRANT NUMBER^»

19. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT, PROJECT, TASK
AREA ft WORK UNIT NUMBERS
FRANKFORD ARSENAL
PHILADELPHIA, PA 1910U

111. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE

JUL 6?
13. NUMBER OF PAGES

1 U. MONITORING AGENCY NAME A ADDRESSf// dlllmrmnl from Conlrolllnt Olllct) IS. SECURITY CLASS, (ot Ml raport)

UNCLASSIFIED
15a. DECLASSIFICATION/DOWNGRADING
SCHEDULE

1 IS. DISTRIBUTION STATEMENT (ol thlt Rmporl)

j DISTRIBUTION UNLIMITED

1 IT. DISTRIBUTION STATEMENT (ol lha abalracl acilarad In Black 20, II dllltrtnt Inm Report)

1 IB. SUPPLEMENTA'RY NOTES

119. KEY WORDS fConfinu« on ravsrao midm It nacaaaaiy and identity by block number) 1
CARTRIDGES, SMALL ARMS AMMUNITION, 7.62MM CARTRIDGES, 5,56MM CARTRIDGES, .50
CALIBER CARTRIDGES, .Uj CALIBER CARTRIDGES, .30 CALIBER CARTRIDGES, .30 CALIBER
| CARTRIDGES (CARBINE)

120. ABSTRACT fCarttau. an ra«i-a. .«. »n^M.arr and (dao/itr Sy Dloclc num6aO j
A brief description of the manufacturing of small arms ammunition. 4— |
:
1 ' ' ' <J ^ i

' 1

DO t j AM*7S 1473 EDITION OF I MOV 65 IS OBSOLETE

SECUBITV CLASSIFICATION OF THIS PAGE fWhan Data Entered)
 INTRODUCTORY HANDBOOK

SECTION I

INTRODUCTION

1. PURPOSE

a. This handbook Is Intended to provide a gen-

eral narrative description of the processes and
problems Involved In the manufacture of small arms
ammunition. Additional detailed technical data can
be found In the Descriptions of Manufacture, Ma-
chinery Handbook, Adjuster's Handbooks, Technical
Data Packages, Operations Control Procedures, and
Quality Control Inspection Plans.

b. The preceding paragraph me ntlons that the

small arms ammunition process Invol ves "problems",
At the outset It should be emphasize d that the pro-
ductlon of a small arms cartridge 1 s not as simple
as might be Indicated by a casual study of compo-
nents and drawings, or a visit t o a production
line. A lipstick container Is not unlike a car-
trldge case In form. It Is blanked cupped , drawn
and trimmed by the same general pro cess and equlp-
ment. However, the lipstick tube s erves only as a
container while the cartridge case is a component
of a very powerful "engine".

c. In the firing of a 7'^2mm cartridge, the

charge of propellant weighing slightly more than
1/10 ounce develops 4880 horsepower In the
11/10,000 second that elapses between the firing of
the primer and the emergence of the bullet from the
muzzle of the weapon. This Is the energy required
to propel a bullet weighing approximately 1/3 oz.
at a speed 2 1/2 times that of sound. The bullet
Is capable of traveling up to 2 1/2 miles. The
energy at work Is so tremendous and the masses and
time Intervals are so minute that the effect of
physical and dimensional variables in the compo-
nents and assembly of the cartridge is exceedingly
complex.
SECTION I

INTRODUCTION

d. Since the beginning of the production of

metallic center-fire military rifle cartridges
circa 1870, the process has constituted an Indus-
trial art. Science has been of great assistance in
lessening the importance of personal "know-how" but
that element remains essential.

•
 INTRODUCTORY HANDBOOK

SECTION II

TERM"'NOLO Y

2. CARTRIDGE

Th is t er m is us ed t o de si na t e a comp le t e as -
sembly consisti of a ll the cartridge components
ne cess ary t o fire the weapon once ; that i s , the
b~ l let , case , pr op l ent, and primer. Terminol ogy
is illustrated i n Fi r e 1 .

3. CALI BER OR MI LLlt'!ETER

In small arms ammunition, the size of the car-

trid e is des cribed by the use of "calibe r (ca l ,) "
or "millimeter (mm )" . Calibe r r epresent s the ap -
pr oximate diamete r of the bulle t as the de cimal
fraction of an inch . Millimete r r epresents t he ap-
pr oximate di ameter of t he bulle t as expressed in
the metr ic system .

4. TYPE

The "type " of cartridge or bulle t is des crip-

tive of its pr i ncipal military charac teristi c .

5. MODEL

The "model" des i nation r ef e r s t o a s pec ifi c

desi n . The f oll owing are examp les of s tandard no-
menclatur e :

Item MM or Calibe r Model

Cartridge 7. 62mm , NATO Ba ll M80
Cartri d e 5. 56mm Ball Ml 93
Cartridge Calibe r . 30 Ball M2

6. CARTRIDGE CASE

The cartridge case hol ds the primer, propellant

3
Sl'CTION II

Figure 1
A Sectioned Cartridge and Terminology of Components
 SECTION II

INTRODUCTORY HANDBOOK

and bullet in a fixed unit. It Is usually made of

brass although steel has been used as a substitute
material. When a cartridge Is fired In the chamber
of a weapon, the case expands tightly against the
wall of the chamber and thus prevents the hot gases
from escaping rearward, damaging the weapon and
possibly Injuring the gunner. After expanding (ob-
turating) at firing the case must then shrink away
from the chamber walls to permit easy extraction.

7. PRIMER

The primer Is an assembly consisting of a brass

cup, a pellet of primer composition, a paper disc
and a brass anvil. The pr'imer composition deto-
nates under the Impact of the firing pin. The re-
sulting flame is forced through the vent in the
bottom of the primer pocket and ignites the propel-
lant in the case.

PROPELLANT

The propellant charge of a cartridge consists

of a quantity of smokeless propellant, either a
single base (nitrocellulose) type or a double base
(nitrocellulose-nitroglycerin) type. The geometry
of small arms ammunition propellants is generally
confined to spherical, cylindrical or flake config-
uration. The propellant charge weight is measured
in "grains" (avoirdupois) and is controlled to pro-
duce the required bullet velocity within the pre-
scribed pressure limits. The propellant is manu-
factured by commercial or government owned contrac-
tor operated facilities. Small arras propellants
are relatively stable, usually of uniform quality
and reasonably safe to store and handle. The cur-
rent propellant types as manufactured to the tech-
nical data requirements, present no serious produc-
tion problem to the ammunition manufacturer.
SECTION II

TERMINOLOGY

BULIET

The term "bullet" is applied only to small

arms ammunition projectiles. The various types of
bullets are Illustrated in Figures 2, 3 and 4.

10. CARTRIDGE IDENTIFICATION

Figures 5, 6, 7, 8, 9, 10 and 11 illustrate

the various types of 7.62mm, 5.56mm, caliber .30,
caliber .30 carbine, caliber ,k^ and caliber ,50
cartridges. The painted tips on certain bullets
are for purposes of identification.
 1
—SLUG

—BULLET JACKET

BULLET, 7.62 MM, NATO, BALL, M80

TRACER COMPOSITION-

CLOSURE CUP
POINT FILLER
IGNITER COMPOSITION

SUB-IGNITER COMPOSITION^ BULLET JACKET

BULLET, 762 MM, NATO, TRACER, M6Z

POINT FILLER
BASE FILLER
BULLET JACKET

BULLET, 7.62 MM, NATO, AP, MS!

EXAMPLES OF BULLETS, 7.62 MM (SECTIONED )

Figure 2

■
 SLUG

-BULLEi JACKET
BULLET, 5S6 MM, BALL, MI93
ICAlf 4

TRACER COMPOSITION-

CLOSURE BASE-
-POINT FILLER
IGNITER COMPOSITION-

SUBI6NITER COMPOSITION- -BULLET JACKET

BULLET, 5.56 MM, TRACER, MI96

TRACER COMPOSITION- -TRACER COMPOSITION

IGNITER COMPOSITION-, INCENDIARY COMPOSITION

n
CLOSURE CUP- ^—PRIMER,STAB,M2€

TRACER CONTAINER- -INCENDIARY CONTAINER

SLUG BULLET JACKET

BULLET, CALIBER.SO, SPOTTER TRACER, M4eAl

9€Mie:-f-

EXAMPLES OF BULLETS, 5.56MM AND CALIBER.50

SPOTTER TRACER (SECTIONED)

Figure 3

'
•
 SLUG
BULLET JACKET
BULLET, CALIBER 30, BALL. M2

BASE FILLER-
POINT FILLER
CORE
BULLET JACKET
BULLETt CALIBER.30. A P. M2

CLOSURE CUP

IGNITER — POINT FILLER

SUB-IGNITER BULLET JACKET
TRACER
BULLET. CALIBER 30. TRACER. M25

| •]-ALUMINUM

BASE FILLER
INCENDIARY COMPOSITION
CORE
BULLET JACKET
BULLET, CALIBER.30. API. Ml4

EXAMPLES OF BULLETS, CALIBER 30 (SECTIONED)

Figure U
 BALL,M59 AND M80

HIGH PRESSURE TEST (MPT),M6C

ARMOUR PIERCING (A P), M61

TRACER, H62

DUMMY, M63

.«—■» i \«$m i«*111 w

RIFLE GRENADE, M64

f Cartridges, 7.62mm
Figure 5 " Examples o
 BLANK, M82

MA TCH, Ml 18

6AL L , FRANGIBLE, MI60

DUMMY, INEf?T LOADED, MI72

DUPLEX, Ml9d

Figure 6 - Examples of Cartridges, 7.62mm

 BALL,MlSt3

RIFL E 6 RENA DE, X VI95

TRACER, MI96

Ml

HIGH PRESSURE TEST (HPT)MI97

DUMMY MI99

BLANK,XMZUi.

DUMMY, INERT LOADED, M232

Figure 7 - Examples of Cartridges, 5,56nim

 BLACK
>■> H

ARMOR-PIERCING, M2

ALUMINUM COLORv

ARMOR-PIERCING-INCENDIARY, M14

3.34 MAX-

I BALL, M2

ORANGE>

TRACER, M25
ORD D91

Figure 8 - Examples of Cartridges, Caliber .30

 •1.68 MAX-

BALL, Ml

DUMMY: M13

H TIN COATED ^

&
TEST, HIGH-PRESSURE, M18

ORANGE

i TRACER, M27
6> ORD D89

Figure 9 - Examples of Cartridges,

Caliber .30 Carbine
 Ch

>
Z
5
ca
Q

A
UJ

LU

CO K
UJ <
C£ U
Q.
i
I m

h
tn
UJ
<
o
CM
Os

i of
LU
U
<
<
CO

Figure 10 - Examples of Cartridges, Caliber .45

^
DUMMY M2 BLANK, Ml

HIGH PRESSURE TEST, MI

Figure 11 - Examples of Cartridges, Caliber .50

 INTRODUCTORY HANDBOOK

SECTION III

MANUFACTURE

11. GENERAL
a. The manufacturing process as described in
paragraphs 12 through 21 is based on the manufac-
ture of Cartridge, 7.62mm, NATO, Ball, M8o. A sim-
ilar process is used for the manufacture of other
cartridges with variations as necessary to accommo-
date the type and caliber of cartridge being manu-
factured. This description omits the inspection,
control and test opera.tions except for those few
instances where a 100% : nspection operation is per-
formed. The general description of inspection,
test and control operation is presented in Section
IV.
b. Fi ure 12 is a flow chart of the process
f or the manufa cture of Cartridge, 7.62mm, NATO,
Ball, M80.

12. CASE AND ULLET JACKET CUP

a. The c nventional draw pr ocess for fabrica-
t i n cart r i e cases and bul let j ackets starts with
a di s c which i s bl anke f r om strip and formed into
a cup. The bl ank and cup operation is accomplished
in ne operat ion on a double action vertical crank
pr ess. Cups are usually purchased from cup manu-
f ac turers.

b. Fol lowi ng the Blank and Cup Operation, the

cups are processed through a Wash Operation and
then through an Anneal, Pickle, Rinse, Rinse, Neu-
tralize and Rinse Operation. The anneal operation
imparts the require d workability to the cup and the
pickle through rinse operations remove oxide, scale
and di r t.

c. It is imperative that case cups and bullet

7
 i
is-

»-
5 s
k

■ i &
i ii
1 ii@ liiii iiil
Hi ii
5!
mm
5
I« Cl I ffl 1
:
.5;
i
ilil

it
2

an i
it

1 Ji

Figure 12
SECTION III

MANUFACTURE

j acket cups conform to the dimensional and physical

requirements of the drawings and cup specifica-
tions; however, during times of emergency it may be
necessary to accept substandard cups and make com-
pensations in tbe process to overcome the deficien-
cies in the cup.
d . Wall thickness variations are particularly
critical i n bullet j acket operations where exces-
s iv e wall t hi ckness variations will have a direct
effect upon the accuracy of the bullet.

e. Cups from various manufacturers must be

segregated from each other to decrease the possi-
bi lity of variations from batch to batch of cups.

13. CARTRIDGE CASE

a. A cartri dge case not only must be formed

to the di mensions shown on the drawing, it must
ha ve the necessary metallurgical properties "built
in" dur ing the process. The mouth of the case must
be hard enough to retain the bullet and soft enough
that it will not "season crack" under the tension
of the bullet fit and mouth crimp. The head of the
case must be hard enough to contain the primer det-
onat i on and resist without deformation the high
pressures generated by the pro ~ ellant. Figures 13
and 14 show the location points at which readings
are taken to check the hardness of the various fam-
ilies of cartridge cases.

b. The several operations in the case process

shown on the flow chart (Figure 12) are relatively
simple. However, the tooling, adjustments and
process controls are complex and require skilled
"know-how" and vigilant attention.

8
 << ^ cvi<Vi
"i—

/
^^VJQUJ

's—
^—

t\jC\j C\j *) *rj

^—
k—
to-

k— ^
^i
kj— 3
Q—

O—

Hi—
'S?—

ff

Figure 13 - Hardness Location Points

(Caliber .45, .30 Carbine, 7.62mm)
I 85§
• • •

^^

gjajd

I
k-i

5
h
^i-
V^

Figure 14 - Hardness Location Points

(Caliber ,30 and .50)
 SECTION III

INTRODUCTORY HANDBOOK

14. CASE OPERATIONS

a. Wash and Neutralize

This operation is required to ascertain

that the cups are clean prior to the draw opera-
tion. The cups may be in storage either at the
manufacturer's plant or at the ammunition plant for
some period of time before being processed through
the draw operations.

b. Dry

The cups are dried prior to the First Draw

Operation.

c. Draw

(1) Cartridge cases for the 7.62mm family

are fabricated in three successive draws with a
Wash, Rinse and Dry Operation; an Anneal, Pickle,
Rinse, Rinse, Neutralize and Rinse Operation; and
another Wash, Rinse and Dry Operation between
draws.

(2) The draws differ principally in the

tooling, e.g., the punch and die combination and
die block assembly. The presses operate at speeds
between 85 and 120 strokes per minute. Each press
draws two to four components on each stroke.

(3) Tooling, adjustment of tooling, and

proper lubrication of punches, dies and draw pieces
are of critical importance to the operation.

(4) A single action vertical crank press

is used at each operation.
SECTION III

MANUFACTURE

d. Anneal, Pickle, Rinse, Rinse, Neutralize

and Rinse

(1) The anneal may be accomplished In an

oil, gas fired or electric continuous furnace. The
anneal process restores the draw piece to approxi-
mately the same degree of hardness that prevailed
before the "work hardening" caused by the preceding
draw operation.

(2) The annealing operation is critical

and must be closely controlled with reference to
time and temperature. Underannealed components may
he salvaged by further annealing, but overannealed
components must be scrapped.

(3) The pickle solution removes oxidation

caused by the anneal operation.

(4) The two rinse operations remove the

pickle solution.

(5) Tiie neutralizing solution removes any

remaining pickle solution.

(6) A four section conical drum with a

rinsing attachment is utilized in conjunction with
the annealing furnace for this operation.

e. 1st Trim

(1) Before trimming, the final draw piece

must be thoroughly washed, rinsed and dried. The
spindle of the trim machine will not operate prop-
erly unless the pieces are clean and free of lubri-
cation.

(2) The Trim Operation is conducted on a

hopper fed, single spindle horizontal bench type
machine. While the case component is positioned on

10
 SECTION III

INTRODUCTORY HANDBOOK

the rotating spindle, a free, circular cutter

presses Into the case and causes a radial separa-
tion of the excess uneven material from the open
end of the work piece. Both portions are then
forced off the spindle; the trimmed draw piece
falling upon a conveyor and an air jet directing
the lighter scrap material into a scrap chute. As
a consequence of this operation, all pieces become
a uniform length which aids in the automatic feed-
ing of components in subsequent operations.

f. Sort and Inspect

After the Trim Operation all pieces are

visually inspected on a conveyor. Any scrap and
all untrimmed or defective pieces are removed.

g. Pocket

(1) In this operation, a deep indent,

which the subsequent heading operation will form
into a finished pocket, is swaged in the head of
the case. Alignment and adjustment of punch, die
and ejecting stem are critical.

(2) The operation is conducted on a hop-

per fed, horizontal crank and toggle press. The
work piece is held in the die and restricted from
movement as the punch swages the head.

h. Head and Identify

(1) This operation is performed on the

same type of press as used at the preceding opera-
tion; however, the punch and die are different.
The head of the case and the primer pocket are
given their final form with the exception of the
head turn operation. The punch in addition to per-
forming the heading operation also stamps the iden-
tification or manufacturing plant's symbol and year

11
SECTION III

MANUFACTURE

of manufacture on the head face.

(2) The head as now formed must not be

subsequently annealed. The cold working which the
head has received during this and previous opera-
tions must have produced the required hardness.

1. Wash, Rinse and Dry

Since the cases have been lubricated in

the hopper at the Pocket Operation, it is necessary
to remove the lubricant prior to the Head Turn Op-
eration; therefore, a Wash, Rinse and Dry Operation
is performed. Any trace of lubricant or dirt will
prevent the collet from holding the case at the
Head Turn Operation.

J. Head Turn

(1) At this operation burrs or excess

metal are removed from the head face, the head di-
ameter Is turned and the extractor groove is cut to
size.

(2) Adjustment of the form cutting tools

is critical if excessive dimensional and visual de-
fects are to be avoided.

(3) The operation is performed on a hop-

per fed, horizontal single spindle machine; I.e., a
lathe design.

k. Body Anneal

(1) The case, having been work hardened

in the final draw operation, must be annealed on
the sldewalls or body to permit the tapering of the
case, and forming of the shoulder and neck in the
next operation. The Body Anneal Operation is per-
formed on a hopper fed Induction or gas heating

12
 SECTION III

INTRODUCTOror HANDBOOK

machine. With the induction machine, the cases are

rotated axially through the machine on a conveyor
worm as an alternatinc current in the inductor es-
tablishes an alternating magnetic flux that creates
heat to body anneal the cases. With the gas an-
nealer, the case is rotated axially through a se-
ries of open gas flames. With both systems, the
head of the case is submerged in water to prevent
the anneal from extending down into the head.

(2) Care must be exercised in handling

the cases after this operation since the cases are
in a softened condition and are easily dented.

1. Taper and Plug

(1) At this operation the case is taper-

ed, the shoulder and neck are formed, and the in-
side neck diameter is sized.

(2) The operation is performed on a hop-

per fed double action vertical crank press.

m. Wash, Rinse and Dry

The cases are thoroughly washed, rinsed

and dried to remove the lubrication applied at the
Taper and Plug Operation.

n. Final Trim

(1) At this operation, the cases are

trimmed to final length. Since this affects over-
all length of the assembled cartridge, the opera-
tion must be controlled to close limits.

(2) A hopper fed single spindle vertical

machine is used at this operation.

o
SECTION III

MANUFACTURE

o. Stress Relief

(1) Because stresses have been Induced at

prior operations due to cold working, a stress re-
lief operation must be performed. The operation is
performed by subjecting the cases to a temperature
of approximately 4750F for a predetermined period
of time. Close control of time and temperature is
of utmost importance since cases that are subjected
to excessive periods of stress relief or to too
high temperature are damaged beyond salvage.

(2) This operation is performed in a sta-

tionary electric recirculating air furnace.

p. Pickle and Rinse

Following Stress Relief the cases are sub-

jected to a Pickle and Rinse Operation. The pickle
solution removes oxidation caused by the stress re-
lief and the rinse operation removes the pickle so-
lution.

q. Neutralize and Lubricate

At this operation a soap solution is used

to neutralize any traces of acid that remain from
the pickle solution at the preceding operation. A
residual film of soap remaining on the sidewall of
the primer pocket facilitates insertion of the
primer at the Pierce, Prime and Waterproof Opera-
tion. The cases are processed through a Dry Opera-
tion after this operation.

r. Mouth and Neck Anneal

(1) The cases are mouth and neck annealed

at this operation to soften the mouth and neck suf-
ficiently to ease bullet insertion and crimping.
Otherwise the stresses caused by bullet insertion
14
 SECTION III

INTRODUCTORY HANDBOOK

would result In "season cracks" of the mouth and

neck.

(2) The operation is accomplished on a

hopper fed horizontal straight line twin screw con-
veyor open gas flame machine. The cases are rotat-
ed axlally through the series of open gas flames.

(3) The adjustment of the gas jets Is

critical and must be maintained to Insure the re-
quired physical metallurgical properties.

s. Inspect

(1) Prior to the Pierce, Prime and Water-

proof Operation a 100^ visual inspection is per-
formed on the cases.

(2) The operation is performed on a hop-

per fed horizontal straight line twin screw convey-
or machine. The pieces are conveyed and rotated
past two mirrors which aid the operator to observe
the inside of the case and the head of the case.
Bar attachments detect for cases which exceed mini-
mum or maximum length limits. A bushing located in
the feed tube prevents the passage of a case with a
large head diameter,

t. Completed Component

(1) At this point in the process, the

cartridge case is complete as a component and ready
for partial assembly by piercing the primer vent,
inserting and seating the primer, and applying the
waterproofing compounds.

(2) In the Interest of continuity, this

narrative will proceed with a description of the
assembly operations and thereafter discuss the
manufacture of bullets and primers.

15
SECTION III

MANUFACTURE

15. PRIMED CASE

a. Pierce, Prime and Waterproof

(1) This Is a semlhazardous operation In

which explosive safety precautions must be observ-
ed. Primers In close contact with each other may,
by the explosion of one primer, cause mass detona-
tion. The severity of the explosion will depend
largely upon the number of primers Involved and the
degree of their confinement.

(2) The operation Is performed on a hop-

per fed multistation straight line vertical crank
and rocker press or dial type vertical crank and
lever press.

(3) In addition to detect stations for no

case, foreign matter, no vent, Inverted or no prim-
er, and inverted or missing anvil, the following
operations are performed:

(a) Deburr the primer pocket.

(b) Vent (a hole is punched in the

pocket in the head of the case).

(c) Insert and seat the primer.

(d) Crimp the metal around the prim-

er joint.

(e) Primer and mouth waterproofing.

(4-) After the mouth waterproofing has

dried, the primed case is ready for the loading op-
eration.

16
 SECTION III

INTRODUCTORY HANDBOOK

16. CARTRIDGE OPERATIONS

a. Loading

(1) The loading operation consists of

putting a measured charge of propellant In the car-
tridge case, inserting the bullet in the mouth and
neck * to the proper depth, and crimping the case
mouth into the bullet cannelure.

(2) The propellant charge must be one

which will produce the required velocity and devel-
op a pressure that is within the established limit.

(3) In the 7.62mm cartridge, a deviation

of one grain of propellant from the established
charge will affect velocity to the extent of ap-
proximately 60 feet per second (fps) and pressure
to the extent of approximately 1,000 pounds per
square inch (psi). Obviously, the weight of the
propellant charge from cartridge to cartridge must
be very uniform. Careful verificatlon and control
testing of the loading process is necessary.

Cl) In the processes used In the United

States, the charge is loaded by volumetric measure-
ment although determined by weight. The propel-
lants are sufficiently uniform in density to permit
this. The propellant charge in 7.62mm cartridges,
once established, can usually be held within a tol-
erance of plus or minus 0.3 grains under mass pro-
duction, volumetric loading.

(3) The loading operation is conducted

on a hopper fed multistation automatic vertical
straight line cam machine. The following opera-
tions are performed:

(a) No case detect and spread mouth.

17
SECTION III

MANUFACTURE

(b) Load (Insert propellant).

(c) Detect for high, low or no

charge,

(d) Bullet insert and detect for no

bullet.

(e) Seat bullet.

(f) Case eject for high, low or no

propellant charge or no bullet.

(g) Crimp.

NOTE: This same type of machine can be used with a

lacquering attachment to point identify bul-
lets requiring such identification.

(6) Another method of loading is known as

"plate loading". This unit consists of several
presses, machines and plates. Plate loading accom-
plishes the same operation as the straight line ma-
chine ; however, it requires more pieces of equip-
ment. The production rate for plate loading far
exceeds the straight line machine.

(7) Propellant weight and bullet pull

(force required to extract the bullet from the
mouth of the case) are the characteristics directly
established in the loading process. The former and
to some extent the latter characteristics may af-
fect velocity and pressure. However, velocity and
pressure are also affected by variables in the com-
ponents such as primer brisance, case volume, bul-
let diameter, propellant moisture, etc.

b. Gage and Weigh

(1) A 100^ gage and weigh operation is

18
 SECTION III

INTRODUCTORY HANDBOOK

performed after the Load and Assemble Operation.

(2) The following gaging inspections are

performed:

(u) Profile and alignment.

(b) Length, head to shoulder.

(c) Length, total.

(d) Diameter, extractor groove.

(e) Depth, primer.

(f) Diameter, head.

(g) Thickness, head.

(3) As the cartridge reaches the end of

the gaging transfer bar. It drops into a sensitive
weighing pan which weighs the cartridge and rejects
underweight cartridges.

(4) Cartridges are automatically rejected

at the gaging operations If they are not within
limits. Rejected cartridges are processed through
another machine. If rejected again they are hand
gaged. If such rejects are found to be acceptable
they are included with acceptable cartridges. De-
fective cartridges are segregated for verification
of causes end scrapped.

(5) This operation Is performed on a man-

ual or hopper fed seven station automatic lever ac-
tion machine with a weighing attachment.

c. Inspect

A 100^ visual inspection is performed on

19
SECTION III

MANUFACTURE

the cartridges after the Gage and Weigh Operation.

The cartridges which have been divided into lots
are then submitted to the Government Quality Assur-
ance Representative in Charge (QARIC) to ascertain
that they comply with the requirements of the Tech-
nical Data Package. Upon acceptance the cartridges
are returned to the manufacturer for packaging.
After packaging the wirebound boxes are submitted
to the QARIC for Inspection of packaging.

17. BULIET

a. A bullet for a Ball, MSO cartridge is an

assembly of a pointed bullet jacket and a lead
slug. Other types of bullets are composed of a
combination of a bullet jacket with various compo-
nents such as core, point filler, base filler, clo-
sure cup, tracer composition, incendiary composi-
tion, igniter composition, and/or sub-igniter com-
position. For example, a Tracer, M62 bullet is
composed of a pointed buxlet jacket, a point fill-
er, a closure cup, tracer composition, igniter com-
position and sub-igniter composition.

b. The required accuracy as well as the spe-

cial performance characteristics must be "built in"
the components and assembly. Compliance with draw-
ings and an established production manual will not
alone guarantee performance In firing tests. Bul-
let manufacture calls for highest skills and spec-
ialized "know-how". For example, matching of tools
is not limited to matching a punch to a die but in
matching a series of tools throughout the various
stages of manufacture, particularly the bullet as-
sembly operation.

20
 SECTION III

INTRODUCTORY HANDBOOK

18. BULLET JACKET OPERATIONS

a. Bullet Jacket Draw

(1) Bullet Jackets for the 7.62inm family

of bullets are formed in one or two draws depending
upon the type of material that is used (gilding
metal clad steel or gilding metal). Ihe draw oper-
ations are similar to the case draw operations.
The major differences in the operations are the
size of the tools and the smaller capacity (ton-
nage) of the press. A vertical crank press is used
at this operation.

(2) Prior to the First Draw Operation the

bullet jacket cups are subjected to a Wash and Neu-
tralize Operation and a Dry Operation. These oper-
ations are necessary to ascertain that the cups are
clean and dry. The cups may be in storage at the
manufacturer's plant or at the ammunition plant for
some period of time before being processed through
the draw operations.

b. Wash, Pickle and Neutralize

(1) A Wash, Pickle and Neutralize Opera-

tion is performed after the First Draw Operation.
The wash operation removes foreign matter; the
pickle solution removes oxidation and the neutral-
ize solution removes the pickle solution.

(2) A Dry Operation follows the preceding

operation.

c. Wash and Dry

When a two draw process is used, separate

wash and dry units perform these operations prior
to the Trim Operation.

21
SECTION III

MANUFACTURE

d. Trim

(1) The bullet Jacket is trimmed on a

hopper fed horizontal single spindle (lathe) ma-
chine .

(2) The trim length of the bullet Jacket

is controlled to meet requirements expressed in
weight (grains),

e. Completed Component

(1) At this point in the process the bul-

let jacket is complete as a component and ready for
assembly into a bullet.

(2) In the interest of continuity, this

narrative will proceed with a description of bullet
assembly and thereafter discuss the manufacture of
the lead slug.

19. BULLET OPERATIONS

a. Bullet Assembly

(1) A multistation straight line vertical

crank press is used at this operation to perform
the bullet assembly operation on the Ball, M80 bul-
let. The Jackets are fed by a pin wheel hopper and
the lead slugs by means of a profile hopper.

(2) The bullet Jacket is fed to the press

in the form of a trimmed, cylindrical, closed end
tube and the slug is fed as a cylindrical piece
that is pointed on one end.

(^) This press can be set up as a single

or duplex press. When the duplex setup is uti-
lized, two pieces are completed with each stroke.
The following operations are performed when either
22
 SECTION III

INTRODUCTORY HANDBOOK

method is used :

(a) Insert and Inspect bullet jack-

et.

(b) Ist point.

(c) 2nd point.

(d) Insert, Inspect and seat slug.

(e) 1st boattail, cone and base.

(f) Finish boattail.

(g) Size.

(h) Cannelure and resize - A dis-

tinct attachment to the bullet assembly press.

(U) The set up of the bullet assembly

press is very complex since the adjustment of each
station is interdependent.

b. Clean and Polish

Following bullet assembly the bullets are

cleaned and polished in a horizontal rotary barrel
containing ground corncobs.

20. SLUG, POINT FILLER, AND BASE FILLER OPERATIONS

a. The lead slug for the Ball, M80 bullet and

the point fillers and base fillers for other types
of bullets are manufactured by a similar process.
Only the tools are different.

b. Extrude

A hydraulic vertical press is used at this

23
SECTION III

MANUFACTURE

operation to extrude lead cylinders having required

lead antimony composition Into wire of a predeter-
mined dimension.

c. Form

A horizontal crank press Is used to cut

predetermined lengths of wire and feed these seg-
ments Into a die and swage them to the required
shape and weight.

d. Inspect

The components are 10.0^ visually Inspected

on a conveyor belt after the Form Operation. The
pieces are Inspected for short piece, deep nick or
scratch, embedded foreign matter or bent piece.

e. Wash, Rinse and Dry

(1) A scoop type reversible rotary cylin-

der two section machine is used to Wash, Rinse and
Dry the components. A helix propels the pieces
through the machine.

(2) An alkaline solution removes foreign

matter from the pieces and rinse water removes the
alkaline solution. A drying compartment dries the
pieces.

21. PRIMER OPERATIONS

a. Composition

(1) The formulation and preparation of

primer composition is a batch process described on
the drawing for the particular primer composition
-and In the Operations Control Manuals or Standard
Operating Procedures used by the various ammunition
producers.
21+
 SECTION III

INTRODUCTORY HANDBOOK

b. Cups and Anvils

(1) Gups are blanked and cupped by a

stamping process on high speed double action verti-
cal crank presses while anvils are blanked and
formed by a stamping process on high speed single
action vertical crank presses. The tolerance on
the outside diameter of the anvil is 1/1,000 of an
inch. Considering that these components are made
in a high speed stamping operation with crank
speeds of approximately 350 spm, this tolerance may
seem to be amazingly close. However, given strip
material of proper thickness and hardness and prop-
er tools, the physical operation is not difficult.
Tool adjustments to assure production of acceptable
components is critical.

(2) After a wash-water polish-dry opera-

tion, the primer cups and anvils are ready for as-
sembly.

(3) Dimensional variations in the cup and

anvil may affect the function of the assembled
primer. Blunt anvil points, thick or high crowned
cups may cause misfires. The whole primer manufac-
turing process is critical, requiring skilled,
careful personnel. Some modern plants successfully
and consistently produce one hundred million or
more primers for varied calibers and types of ammu-
nition per month.

c. Charge and Assembly

(1) Primers are charged in one of two

ways, either with wet or dry priming composition.

(2) Wet priming is accomplished by the

manual compression of wet primer composition into
volumetrlcally controlled holes of a stainless
steel charging plate. Dry charging is accomplished
25
SECTION III

MANUFACTURE

in a somewhat similar fashion except remote mechan-

ical means are used to charge the dry primer compo-
sition Into the charging plate holes.

(3) The Increments (pellets) of volumet-

rlcally measured primer composition are then trans-
ferred from the charging plate to primer cups pre-
viously oriented In a transfer plate.

(4) The plate of charged primer cups Is

then placed on a multiple punch press where treated
paper foil Is cut and Inserted In the charged prim-
er cups followed by consolidation of the foiled
primer composition. It Is noteworthy to mention;
however, that some producers of some primers do not
employ paper foil.

(5) Shaker plates filled with anvils and

foiled charged cups respectively, are placed to-
gether under a power operated vertical action tog-
gle press which presses the anvils to the desired
depth Into the cups.

(6) A drop of either lacquer or liquid

shellac Is placed on top of the anvil of each wet
primer immediately after assembly. Dry charged
primers have a drop of either lacquer or shellac
placed directly Into the cup prior to charging or
on top of the pellet prior to assembly.

d. 100^ Visual Inspection

(1) After assembly, the primers are given

a 100^ visual inspection. Since the cost of a
primer is so small and the function so vital, it is
a recognized practice in conducting the 100^ visual
Inspection to remove and scrap any primer that ap-
pears defective.

26
 SECTION III

INTRODUCTORY HANDBOOK

e. Drying and Storage

(1) Primers may be dried by various meth-

ods -- In a vacuum oven, by exposure to Infrared
light, In a heated air dryer or controlled dry-
house .

(2) Primers are stored In a temperature-

humidity controlled area conforming to local safety
regulations.

f. Invert

(1) When primers are released from stor-

age to cartridge production. It Is necessary that
they be Inverted; I.e., arranged anvil side up in a
small flat tray for feeding Into the magazine of
the primer Insert machine.

(2) This operation may be accomplished by

a special Inverting machine or by manual means.

(3) Ihe operator of the Inverting machine

or the manual operator conducts an additional visu-
al Inspection of the anvil side of the primer and
scraps any primer that appears defective.

g. Safety

Immaculate housekeeping, personnel and

quantity limits, and handling procedures must be
respectfully and strictly followed. Some of the
large plants have accomplished the production of
billions of primers without serious accidents.

22. CORES FOR ARMOR PIERCING CARTRIDGES

Armor piercing (AP) cores are manufactured on

an automatic screw machine. Experience has shown
that a core conforming to drawing dimensions and

27
SECTION III

MANUFACTURE

having a correct hardness will, if properly assem-

bled in a bullet, possess the required armor pierc-
ing characteristics.

23. CLOSURE CUPS AND CLOSURE DISCS FOR TRACER CAR-

TRIDGES

The cup or disc is used to seal the base of

the tracer bullet and protect the composition from
moisture. The thin cup ruptures when the cartridge
is fired.

24. INCENDIARY AND TRACER MANUFACTURE

The manufacture of incendiary and tracer com-

positions is described in the drawing for the par-
ticular composition and In the Operations Control
Manuals or Standard Operating Procedures used by
the various ammunition producers.

25. INCENDIARY AND TRACER CHARGING

a. These are semihazardous operations requir-

ing vigilant observance of safety regulations.

b. The charging of these compositions is sim-

ilar in principle. The bullet jacket is seated in
a die. The pyrotechnic powder is automatically
placed In the jacket and compressed or consolidated
by mechanical means. Depending on the type of bul-
let and the pyrotechnic composition, the charging
is accomplished on several types of multistation
machines and in one or two operations.

c. Charges of incendiary and tracer composi-

tions are established by weight, but the charging
operation is accomplished volumetrlcally. Varia-
tions in the volume available in the bullet as well
as variation in the density of the compositions re-
quire careful control and adjustment. Further, in-

28
 SECTION III

INTRODUCTORY HANDBOOK

cendiary and trace performance are directly affect-

ed by the compression, which must be uniform and
carefully adjusted.

d. The performance is also affected by: the

length of time the compression punch dwells on the
compressed charge; the relationship of the punch
diameter to the bullet Jacket inside diameter; the
configuration of the working end of the compression
punch; the interrelationship of the charging die
dimensions, tolerances, and configuration to those
of the bullet jacket; the bullet Jacket material;
the dimensions, tolerances, and configuration of
the coning punches, basing dies , and sizing dies
used for the final bullet assembly operation; the
distributions of particle sizes in the basic chemi-
cals used to blend the pyrotechnic compositions;
the humidity and temperature when the composition
was blended; the humidity and temperature when the
composition was charged and compressed.

26. PACKAGING

a. The same degree of control must be main-

tained over the packaging process as is maintained
over the cartridge manufacturing process.

b. Small caliber ammunition must be packaged

In such a manner:

(1) That it will be properly Identified.

(2) That it will be functionally service-

able when it arrives at its destination. The ammu-
nition must be packed to withstand conditions nor-
mally encountered in shipping, in storage, and in
the field. Waterproof ammunition boxes and suita-
ble wirebound boxes are used to provide this pro-
tection.

29
SECTION III

MANUFACTURE

c. Many Items of automated or semlautomated

equipment exist for the cartoning, clipping and
linking of cartridges, bandoleer packing, and the
marking of ammunition and wlrebound boxes; however,
a considerable amount of hand labor Is also requir-
ed.

30

.*
 INTRODUCTORY HANDBOOK

SECTION IV

THE CONTROL OF QUALITY

27. GENERAL

The adage "Quality must be built Into a prod-

uct, It cannot be Inspected Into It" Is particular-
ly applicable to the manufacture of small arms am-
munition. Ammunition must be manufactured dimen-
slonally and functionally conforming the first time
to avoid excessive scrap and rework costs. Small
arms ammunition production is inherently high speed
and a defective machine condition can be respon-
sible for producing thousands of scrap components
within an hour. Furthermore, completed lots of
ammunition must not contain any "critical" type
defects, almost no "major" and very few "minor"
types. The incidence of as few as one (1) critical
defect in a million rounds can affect the safety of
personnel using the malfunctioning cartridge, and
Jeopardize the success of his individual mission.
For these reasons there is a continuous striving
for highest ammunition quality. This quality is
controlled and assured through application of a
modern management tool, Quality Control.

28. DEFINITION

a. Quality Control has been defined as "an

effective system for coordinating the quality main-
tenance and quality improvement efforts of the var-
ious groups of an organization to enable production
at the most economical levels which allow for full
customer satisfaction".

b. The word quality in "quality control" does

not have the popular meaning of "best" in any abso-
lute sense. Rather, it is the ability of the prod-
uct to conform to its specifications and control is
simply the business of assuring that conformance.
Effective small arms ammunition control is accom-
31
SECTION IV

THE CONTROL OF QUALITY

pllshed through the following procedures :

(1) Interpreting Requirements - Prepar-

ing such documents as "Quality Assurance Provi-
sions" for Inspection of Incoming material, "Qual-
ity Control Instructions" and "Detail Inspection
Plans" for process Inspection guidance.

(2) Appraising Conformance - Comparing

the conformance of the manufactured product to
standards. Process Inspection and proof testing
actions are vital In accomplishing the appraisal.
Statistical methods are employed to measure quality
and determine action.

(3) Acting When Necessary - Taking cor-

rective action when appropriate, e.g., when stan-
dards are not attained, trends toward defective
conditions are discovered, "assignable causes"
(variation beyond the stable predicted pattern) and
erratic, unstable conditions are exhibited.

(4) Recommending Improvements - Analyzing

quality data and submitting proposals for modifica-
tion of processes to achieve more efficient opera-
tion and to resolve quality difficulties.

c. From the administrative point of view,

quality control enters into all phases of the small
arms ammunition production process. It starts with
the customer's specification and moves into produc-
tion engineering, materials purchasing, methods
planning, manufacturing, inspection, proof testing,
packaging, shipping and back to the customer, whose
needs must be satisfied with quality ssidll arms am-
munition. Figure 15 illustrates this "Quality Con-
trol Cycle".

32
 SECTION IV

INTRODUCTORY HANDBOOK

.CUSTOMER.

PACKAGING PRODUCTION
SHIPPING ENGINEERING

PROOF QUALITY PURCHASING

TESTING CONTROL

METHODS
INSPECTION
PLANNING

MANUFACTURING

QUALITY CONTROL CYCLE

Figure 15

33
SECTION IV

THE CONTROL OP QUALITY

29. INSPECTION

a. Operator Inspection - The machine operator

is the first line of defense against the occurrence
of defective work. He continuously Inspects the
production obtained from the machine. The adjuster
and line foreman also check the work under their
charge at random Intervals,

b. Process Inspection - Process inspection is

vital to the effective functioning of the small
arms ammunition quality control system. As the ma-
jor arm of the system, it serves in data collec-
tion, material identification and all Inspection
activities. The process inspection element ap-
praises conformance by performing the following:

(1) First Piece Inspection - This inspec-

tion is performed on production from all small arms
ammunition component and assembly machines when an
operation is initially set up and after every major
tool change.

(2) Machine Inspection - The process in-

spector visits every machine in his area a sched-
uled number of times per shift. He Inspects a
small sample. If it is satisfactory, all produc-
tion since his last visit is considered acceptable
and is added to the day's production. If the sam-
ple contains a defective(s), corrective action is
taken immediately.

(3) 100^ Inspection - Process inspection

performs certain 100^ visual and dimensional in-
spections to insure that no critical defects will
be processed and shipped to the field In small arms
ammunition lots.

(4) Lot Sampling Inspection - The visual

and dimensional quality of lots is assessed by
3^
 SECTION IV

INTRODUCTORY HANDBOOK

using sampling procedures. Sampling is performed

to verify that good manufacturing practice and the
machine and 100^ Inspections have, in fact, com-
bined to produce small arms ammunition of accepta-
ble quality.

30. CONTROL TESTS

a. The primary goal is to manufacture ammuni-

tion that functions properly and exhibits accept-
able ballistic characteristics. Therefore, during
the manufacturing cycle, In addition to dimensional
and visual inspections, proof testing is conducted
to assure conformance to functional and ballistic
requirements. Small samples, identified to a par-
ticular machine, machine group, or lot of material,
are taken at specified Intervals, identified, proc-
essed into finished cartridges and fired. The re-
sults of these tests are utilized to verify proc-
esses, make necessary process adjustments or con-
firm the effectiveness of new material. The tests
are called dally production control tests and they
Include :

(1) Accuracy tests from bullet assembly

machine production.

(2) Velocity, chamber pressure, and port

pressure tests from loading machine production.
Bullet pull tests and propellant charge weight
checks are performed at this stage, also.

(3) Primer sensitivity tests.

(k) Tracer bullet performance tests from

tracer bullet charging and basing operations.

(5) Function and casualty tests repre-

senting dally case line production. This includes
the evaluation of metallurgical charac'terlstlcs
SECTION IV

THE CONTROL OF QUALITY

such as case hardness and grain size.

31. WORK TESTS

Work tests are conducted under controlled con-

ditions to determine the performance of new or im-
proved tools, equipment or material.

32. STATISTICAL QUALITY CONTROL

a. Statistics are used in the overall small

arms ammunition quality control program whenever
it may be useful. But statistics are only one
phase in the program; they are not the program it-
self.

b. Statistical methods have been employed

with great success in inspecting small arms ammuni-
tion materials, parts and cartridges to test their
conformance to appropriate quality levels, and in
controlling the production process itself. They
have made possible the diagnosis and correction of
many production problems, brought improvements in
quality and reduced scrap and rework.

c. Statistical methods have had a profound

effect upon the entire area of small arms ammuni-
tion quality control. The following four statisti-
cal tools may be used separately or in combination
to achieve quality goals :

(1) The Frequency Distribution - The fre-

quency distribution is a tabulation or tally of the
number of times a given quality characteristic oc-
curs within the sample of product being checked.
As a picture of the quality of the sample, it may
be used to show:

(a) The average value of the charac-

teristic
36
 SECTION IV

INTRODUCTORY HANDBOOK

(b) The spread of the characteristic

(c) The coiuparlson of the character-

istic results with specification requirements (ca-
pability study)

(2) The Control Chart - The control chart

is a chronological (hour by hour, day by day)
graphical comparison of a quality characteristic
with special limits. It allows the user to main-
tain statistical control over a process. The con-
cept of the control chart briefly is: Measured
quality of manufactured product is always subject
to a certain amount of variation as a result of
chance. Some stable "system of chance causes" is
inherent in any particular scheme of production and
Inspection. Variation within this stable pattern
is inevitable. The reason for variation outside
this stable pattern may be discovered and correct-
ed. The power of the control chart technique lies
in its ability to separate the assignable causes of
quality variation which should receive corrective
engineering attention. Moreover, by Identifying
certain variations as inevitable chance variations,
the control chart tells when to leave a process a-
lone.

(3) Sampling Techniques - Sampling tech-

niques are utilized to judge the quality of an en-
tire lot by examining only a small portion of it.
Admittedly, there is alwayc a chance that a sample
will fail to truly describe its lot by Indicating
acceptable quality when poor quality is present or
vice versa. However, the errors involved in sam-
pling are predictable and well worth the risks in
view of the advantages over 100^ inspection. Sam-
pling is more efficient than 100^ inspection (in-
dustrial studies show U-00% inspection is necessary
to achieve 98^ efficiency); it is more economical
and provides potential process control information
37
SECTION IV

THE CONTROL OF QUALITY

more readily than end-of-the-line 100^ sorting.

(4) Special Methods - Some of the special

methods are: analysis of variance, analysis of
means, "t" test, "F" test, "chl-square", regression
and correlation techniques and designed experi-
ments. They are utilized to solve such problems
as :

(a) Determination of ballistic (ac-

curacy, velocity, pressure) capabilities of ammuni-
tion lots.

(b) Comparison of ammunition lots or

special groups, for ballistic differences.

(c) Establishment of daily produc-

tion control group acceptance criteria,

(d) Establishment of daily produc-

tion control group combination criteria to deter-
mine composition of ammunition lots.

(e) Comparisons among processes or

machines to determine best performers.

38
 INTRODUCTORY HANDBOOK

SECTION V

QUALITY ASSURANCE

33. GENERAL

a. The manufacturers of military small arms

ammunition, whether a government arsenal, a govern-
ment-owned contractor-operated plant, or a private
commercial plant, are required to submit the ammu-
nition to the Government Quality Assurance Repre-
sentative In Charge (Q,ARIC) for acceptance.

b. The manufacturer is also required to pro-

vide the QARIC access to all parts of his produc-
tion facility.

3^. FUNCTION

a. The function of the QARIC in a small arms

ammunition plant and the purpose of his presence
are as follows :

(1) Process Observation

(a) The manufacturer when he signs

the contract will have agreed to make the ammuni-
tion by an approved process and in accordance with
applicable drawings and specifications. The reason
for the government's interest in the process is the
fact that acceptance examination and testing are
performed on a relatively small sample of each am-
munition lot. Since the effective application of
such sampling inspection assumes homogeneity of the
cartridges within the lot, it is most Important
that the ammunition be produced by an effective,
established, uniform, proven process.

(b) The QARIC, in observing the

process, will not interfere with production or con-
duct any process inspection as such. If he detects
any Irregularity or deviation, he will , bring the

39
SECTION V

QUALITY ASSURANCE

matter to the attention of the manufacturer and

will request that corrective action be effected.
Continued occurrence of cited deficiencies will be
cause for discontinuance of government acceptance.

(2) Official Acceptance

(a) Current cartridge specifications

contain a statement to the effect that the manufac-
turer Is responsible for the performance of all In-
spections prescribed therein. However, the govern-
ment reserves the right to perform any of the In-
spections set forth In the specification where such
Inspections are deemed necessary to assure that am-
munition conforms to prescribed requirements. The
amount and nature of product verification to be
performed by the QARIC are delineated In the "Qual-
ity Assurance Letter of Instructions" generated by
the Army Materiel Command Quality Assurance Repre-
sentative (Key Inspector), The QARIC formally and
officially accepts or rejects ammunition, based
upon objective evidence that the ammunition either
compiles or does not comply with the specification.
The actions required to obtain such evidence are
outlined in the above mentioned "Quality Assurance
Letter of Instructions", and normally include both
government product Inspection and evaluation of the
manufacturer's inspection records.

(3) Assistance

The QARIC has the function of assist-

ing the manufacturer whenever possible, particular-
ly in presenting engineering problems through prop-
er channels to the responsible technical agency.

(U) Protection

The presence and activity of the

QARIC in a manufacturer's plant operates as a sub-
 SECTION V

INTRODUCTORY HANDBOOK

stantial protection to both the government and

manufacturer. Monitoring of the manufacturer's in-
spection system by the QARIC enables detection and
correction of deficiencies on a timely basis,
thereby preventing the manufacture of sizeable
quantities of unacceptable ammunition. Product
verification by the QARIC provides additional as-
surance that the ammunition being submitted by the
manufacturer to the government is of acceptable
quality.

35. NONCONFORMING MATERIAL

The QARIC will not have authority to waive the

specification requirements. However, procedures
for the submission and processing of "Requests for
Waiver" for consideration for approval to accept
nonconforraing material are provided in the "Quality
Assurance Letter of Instructions" or in established
regulations.

41