Caseless Ammunition Small Arms.

The Good, The Bad,

and The Ugly.
Presented by

Jim Schatz
during the

2012 NDIA Joint Armaments Conference

Seattle, Washington
1
 Purpose
◘ Discuss the common misperceptions and
“perceived” merits of caseless ammunition
for use in rapid-fire military small arms.
◘ Learn from past experiences in numerous
US and foreign efforts to “crack the
caseless ammunition nut”.
◘ Escape the “10% Bridge Too Far” trap. (1)

(1) Ref. LSAT Briefing, NDIA May 2010 Page 10, 12 (CL = 50%, CTA = 41%)
2
 Caveats
◘ The contents and opinions expressed in this
presentation are those of the presenter and
are based on available information and actual
hands on experience.

◘ Applicable organizations were contacted for

input. That input was considered and is
included as received.
3
 About the Presenter
◘ Life long student in modern small arms and
ammunition technology.

◘ 35 years in the international small arms arena serving

in numerous capacities from user and trainer to
developer and provider.

◘ Caseless Technology PM and Contractor Trainer

for the Caseless Ammunition G11 Rifle during the
“successful” US Advanced Combat Rifle (ACR)
program. 3+ years “living with” caseless ammo.
4
 What is Small Arms
Caseless Ammunition?
◘ Ammunition missing THE most important
cartridge component – the Exoskeleton
Pressure Vessel (EPV)
◘ Having a fully combustible propellant body
“I can hold my gas and naughty
bits together with little help!”
(Cased Round)

“I got nothing!”
(Caseless Round)
5
 Not to be confused with…
“Semi-Caseless” or “Rocket”
a.k.a.
“Self-propelled”
Propellant
located
within a hollow
projectile

.41 Smith & Wesson Volcanic Gyrojet

(USA - 1860) (USA - 1965)
6
 Caseless Ammo = Teddy

Caseless Ammo “Teddy” on Vacation

No stuffed animals were hurt during the compilation of this presentation 7
 Things are good…while all goes well

Beware of
hidden
dangers!

No stuffed animals were hurt during the compilation of this presentation 8

 But if the foundation is weak,
bad
things
can
happen
(to Teddy!)
Beware of
hidden
dangers!
Caused by
a poor
foundation

No stuffed animals were hurt during the compilation of this presentation 9

 And things go bad…and fast!

OKAY, stuffed animals WERE hurt during the compilation of this presentation
10
 Why should I covet my EPV?
◘ Because it –
1. Holds all your components together in one solid
piece that is easily transportable and
“discardable”.
2. Is not readily or easily influenced by chamber
heat, solvents or rough handling.
3. Can be pull versus push-through extracted.
4. Contains its own initial pressure irrespective to
the weapon mechanism around it.
5. Prevents a degree of spark/flame propagation
between rounds if struck by incoming fire.
It is a strong and the key foundation for complete
“system” integrity, safety and reliability!
11
 Brief Caseless Ammo History
◘ 1346 - First “hand cannon” – fired “caseless” ammo

◘ 1570 – 1st “cartridge” (paper case) – BIG NEWS!

◘ 1830 – 1st “metallic cartridge” – BIGGER NEWS!
◘ WWII – Germans experiment with caseless
ammunition – Formed Nitrocellulose (NC) employed
to save “strategic materials” (brass)
Lesson Learned: Steel cases were used instead.
12
 Caseless Ammo History (cont.)
◘ Various commercial caseless firearms developed
-Daisy VL .22 Caseless Ammunition Rifle (1967-1969)
ATF-
forced
“demise”

NC “pellet” ignited by compressed air. Novelty.

- Russian VAG-73 Semi-Caseless Ammo Pistol (1973)
High
Capacity
48 round
dual column
(front, rear)
magazine 7.62mm Semi-caseless
VAG-73 rounds 13
 Caseless Ammo History (cont.)
◘ 1959-1975 - US Ordnance Department
-Ground-breaking efforts to develop Same technical
5.56mm, 7.62mm and 25mm caseless challenges:
ammunition (and weaponry) to reduce: -Sealing
1. Ammo weight (50%) and volume (30%) -Cook-off
-Propagation
2. Critical case material reliance
-Involved AAI, AC Electronics, GE, GM,
Hercules, Hughes Tool Co., others.
-Formed NC, HITP, even caseless flechette
rounds were developed and tested. AC Electronics Model 68
Caseless bull-pup rifle
Hughes 5.56mm Caseless LMG

5.56x30mm Telescoped Caseless Rounds

7.62mm Caseless Developed by Hercules, Inc. @ 1969
14
 Caseless Ammo History (cont.)
◘ 1970-1990 – German 4.92x34mm Caseless G11/US
ACR, LSW, PDW developed at the cost of
100M’s of $ and DM’s. HITP

90K rds fired through 20 prototype weapons in 18 months

by US troops - all weapons “survived”
BUT only under close supervision!
Increased pH through “Salvo Launch” of multiple projectiles 15
 Caseless Ammo History (cont.)
◘ Various commercial caseless firearms (cont.)
- Benelli Armi CB-M2 SMG
9x25mm AUPO (1980’s)
“semi-caseless”
round

NC “stacked” ammunition. Improved reliability.

- Austrian Voere VEC91 hunting rifle and 5.7mm
and 6mm NC caseless ammunition (1994)

Electrically-fired to reduce lock-time.

Improved accuracy. 16
Caseless Ammo History (cont.)
◘ 2000’s – US LSAT LMG and Carbine under
development in polymer CTA and Caseless
Ammunition variants. Employs reformulated
DNAG-developed HITP caseless propellant (of
the German G11/ACR) in a cylindrical profile.

LSAT Carbine LSAT LMG

Reduction
of combat load
LSAT Caseless Ammo 17
 “Failed” Caseless Attempts
(1)

Austria-Swiss 1983 USA 1869 Germany 1975-78

Austria 1994 USA 1969 Germany 1974-78

Germany 1974-78
USA 1963
France 1980-86

France USA 1968-70 Germany/USA 1989-90

France USA (Hercules) - 1975 Unknown

Italy
Belgium 1987
USA mid-1960’s Spain
(1) – Not fielded in an
auto-loading weapon. 1869 through 2012 18
THE GOOD

19
 Principle of Operation
HITP Caseless Round

“LACQUER”
SEALANT

*Molded propellant body must be

fractured for proper function by primer/booster

Booster
Plastic Cap Cup

DNAG 4.92x34mm HITP round pictured Remnants - Unique

“Battlefield Spores” 20
 THE GOOD
Weight Reduction
◘ Demonstrated Reduction:
-Cartridge Weight > 50% vs. M855 (vs. 41% poly CTA) (2)

+ 525 %

+ 138 %

(2) Ref. LSAT Briefing, NDIA May 2010 Page 10, 12 (CL = 50%, CTA = 41%) 21
 THE GOOD
Reduced Bulk
-Bulk: 37% < M855 ◘◘◘◘◘ ●●●●●
* Smaller packaging, storage.
* Less expensive to transport ($1K-3K/pallet)
* Square round cross section allows 7.62x51mm, 5.56x45mm,
more stowed rounds in a given space. 4.92x34mm

*More stowed round

on/in weapon. Caseless
LMG shown with 300
round “box” of
ammunition inside stock.

16,000 rds M855 (L),

4.92mm Caseless (R)
4,000 cu. ft. vs. 2,533 cu. ft.
22
 THE GOOD
Increased Combat Load
◘ On Soldier - 510 rounds versus 240 rounds
◘ On Weapon – 135+ rounds versus 30 rounds

7.35 kg =
16.2 lbs.

23
 THE GOOD
Increased Rate of Fire
(Higher pH, BA Defeat)
A Double Edged Sword!
◘ Elimination of Extraction and Ejection steps (25% less)
allows for higher rates of fire (> 2,200 rpm) BUT requires
novel, high risk mechanisms with a poorly demonstrated
down-range pH and body armor defeat benefits.
Includes a complex HITP Caseless Ammunition firing
muzzle compensator G11/ACR “Interior Operating
Floating System” (IOFS)
mechanism
HK G11 IOFS
Conventional Cased Ammunition
Russian AN-94 Assault Rifle
“Shifted Pulse” mechanism

“Hyper Burst” - Worth the complexity? 24

 THE GOOD
Use of “Non-strategic”
materials to lower cost
◘ Can caseless propellant, production and assembly
procedures (mixing, molding, milling) compare with
the cost of cased ammunition manufacturing?
Especially if compared to inexpensive polymer cases?
◘ Requires all new machinery
and processes, which would
make the cost of a caliber
switch seem cheap by
comparison!
◘ No cases to be recycled.
Caseless ammunition production machinery
25
 THE GOOD
Reduced Operator Cleaning
◘ Caseless HITP propellant creates
almost zero fouling BUT enough
exists that can inhibit high-tolerance
sealing component function. 2-part
“expanding”
G11 chamber
◘ No brass to police up, control, dispose of.
-Firing “remnants” are however
created and must be expelled during
operation and represent unique
battlefield “spores” left behind.
Post-misfire remnants of
an HITP caseless round
26
 THE GOOD
Reduced Fire Hazard
◘ The absence of the EPV (case) reduces the
risk of secondary missiles and eliminates
hazardous case fragments as a result of fire.

Propellant body burns, booster pops, launches projectile @ 18” up.

Lands within 10” of “launch site”. No fragments.
However round to round propagation is still a serious concern. 27
THE BAD

28
 THE BAD
Obturation a.k.a Chamber Sealing
The caseless ammunition “bogeyman!”
It is very likely an insurmountable technical
obstacle to successful military fielding.
3 Key Chamber Sealing Areas – All “sealed” by the Cased Round

1. Chamber

3. Bore 2. Firing Pin Opening

Gas Jet cutting can be game over for the mechanism!

Cased Ammunition 29
 THE BAD
Chamber Sealing (cont.)
3 Key Chamber Sealing Areas – 1. 2-part Expanding Chamber
Only 1 “sealed” by the Caseless
Round until Complete Ignition
“Cork Screw”
firing pin with
flared base seal

Unsealed bore
Seals chamber front, rear
2. Rotary “corkscrew”
3. Plastic “Shoot thru” Cap Just one example Firing Pin
of sealing methods
illustrated here

Projectile Seals Bore after “Launch”

Caseless Ammunition Seals firing pin opening

30
 THE BAD
Fragile Propellant Body
◘ Not for use in legacy weapon mechanisms.
◘ Cannot easily/effectively be pull-extracted.
◘ Fragments are difficult to clear from weapon!
◘ Rough handling must be avoided.
Ruptured Propellant Body Cracked Propellant Body

Can inhibit transport/clearing.

A Clearing Nightmare for the operator! 31
 THE BAD
Cook Off
◘ No expendable cartridge case
“heat sink” (@ 10%) to eject
from the weapon
5.56x45mm, 4.92x34mm

◘ 210 rounds – Maximum cook off rate from

a single-chamber mechanism. Multiple-
chamber mechanism required for high
sustained rate of fire employment (LMG’s,
AR’s).
32
 THE BAD
Miscellaneous
◘ Correct weapon function and cartridge ballistics
fully dependant on propellant body weight and
the presence of all propellant at ignition.
◘ Propellant charge variances (i.e. custom loads)
difficult to make. No user hand-loading.
◘ Interoperability within NATO.
◘ Operator field sustainability is questionable.
◘ Regulatory controls (ATF and the Daisy VL)
and cartridge case “micro-stamping”.

33
THE UGLY

34
 Caseless Ammunition Failures
◘ Unlike anything you have seen before!

◘ Many are unique to Caseless Ammunition!

◘ Remember why we love that case (EPV)?!

Broken propellants pieces make

great field chow warmers though!
35
 Caseless Ammunition Failures (cont.)
Class I
SCRAPPED LACQUER COATING Stoppage

Clearable by
Cause: Rough Handling operator in
less than 10
seconds
NOTE: Failures shown are
weapon, ammo dependent.
36
 Caseless Ammunition Failures (cont.)

Class I
Stoppage

Clearable by
operator in
Cause: High Weapon Temperature less than 10
seconds
NOTE: Failures shown are
weapon, ammo dependent.
37
 Caseless Ammunition Failures (cont.)
Class I
Stoppage

Clearable by
operator in
Cause: Mechanism Failure
less than 10
Missing in the photo
are the propellant
seconds
fragments that NOTE: Failures shown are
cause stoppages. weapon, ammo dependent.

Why pull-type extractors don’t work on caseless rounds. 38

Caseless Ammunition Failures (cont.)

Class I
◘ Stoppage

Clearable by
operator in
Cause: Operator Error less than 10
seconds
NOTE: Failures shown are
weapon, ammo dependent.
39
Caseless Ammunition Failures (cont.)

Class I
Stoppage

Clearable by
Cause: Ammunition Failure operator in
less than 10
Where are the
fragments?
seconds
NOTE: Failures shown are
weapon, ammo dependent.
40
 Caseless Ammunition Failures (cont.)

Class II
Stoppage

Clearable by
Booster Cup

Cause: Sealing Failure

operator in
◘ Requires detailed operator cleaning
of the weapon to remove fouling. less than 10
minutes
NOTE: Failures shown are
weapon, ammo dependent.
41
 Caseless Ammunition Failures (cont.)

Class II
Stoppage
◘Propellant pieces become a major problem
in weapon function, chamber clearing.
Clearable by
Cause: Ammunition Failure operator in
◘Partial projo tip penetration of plastic cap
can impede chamber clearing (rotary type).
less than 10
Where are the
fragments?
minutes
NOTE: Failures shown are
weapon, ammo dependent.
42
 Caseless Ammunition Failures (cont.)

Class III
Stoppage

◘ Bore Obstructed by
Projectile
Not
clearable by
Cause: Ammunition Failure
operator.
Where are the
fragments?
NOTE: Failures shown are
weapon, ammo dependent.
43
 THE END
◘

“Blue Smoke” incident. Sealing failure of chamber.

Gas jet destroys the weapons’ breech.
The weapon is inoperable (FUBAR).
Note: Images are of a caseless G11 rifle mechanism. 44
 Summary
◘ “10% Bridge Too Far” – is the cartridge
weight savings of 50% versus 40%(3) worth:
-Unavoidable additional weapon complexity,
weight(4) and sealing challenges?
-Unique ammunition failures/stoppages?
-Complete retooling cost for
caseless ammo production?
-The demise of poor Teddy!
(3) Ref. LSAT Briefing, NDIA May 2010 Page 10, 12 (CL = 50%, CTA = 41%)
(4) Ref. LSAT Briefing, NDIA May 2010 Page 6 (LMG: CL 9.9 lbs., CTA 9.2 lbs)
45
 Questions?
Contact Information
Jim Schatz
[email protected]

Thank you for your

time and interest! 46