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MIL-C-9963F
15 October 1976
SUPERSEDING
MIL-C-9963E
12 May 1970

MILITARY SPECIFICATION
CARTRIDGE, 5.56MM, BALL, M193

This specification is approved for use by all Departments and Agencies of the
Department of Defense.

1. SCOPE

1.1 This specification covers Cartridge, 5.56MM, Ball, M193 for use in the
5.56MM weapons.

2. APPLICABLE DOCUMENTS

2.1 The following documents of the issue in effect on date of invitation

for bid or request for proposal, form’s part of this specification to the extent
specified herein.

SPECIFICATIONS

Military

MIL-I-45607 - Inspection Equipment, Acquisition,

Maintenance and Disposition of

STANDARDS

Military

MIL-STD-105 - Sampling Procedures and Tables for

Inspection by Attributes
MIL-STD-109 - Quality Assurance Terms and Definitions
MIL-STD-636 - Visual Inspection Standards for Small
Arms Ammunition through Caliber .50
MIL-STD-644 - Visual Inspection Standards and Inspection
Procedures for Inspection of Packaging,
Packing and Marking of Small Arms Ammunition
MIL-STD-1168 - Lot Numbering of Ammunition

FSC 1305
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MIL-C-9963F

DRAWINGS

Armament Command
D10523632 - Cartridge, 5.56mm, Ball, M193
C7643674 - Classification of Cartridge Case Defects
F10535858 - Packing and Marking, Cartridges, 5.56mm;
Cartons; Box, Ammunition, M2A1; Box,
Wirebound
F10534605 - Packing and Marking, Cartridges, 5.56mm;
Cartons; Bandoleers; BOX, Ammunition,
M2A1; Box, Wirebound
F10542258 - Packing and Marking, Cartridges, 5.56mm;
10 Rd. Clips; Cartons; Bandoleers; B OX,
Ammunition, M2A1; Box, Wirebound
F11735709 - Packing and Marking, Cartridges, 5.56mm;
10 Rd. Clips; Cartons; Bandoleer M8; BOX,
Ammunition, M2A1; BOX, Wirebound
LI10523632 Index of Inspection Equipment List for
Cartridge, 5.56mm, Ball, M193

PUBLICATIONS

SCATP-5.56 - Ammunition Ballistic Acceptance Test Methods,

Test Procedures for 5.56mm Cartridges

(Copies of specifications, standards, drawings, and publications required

by suppliers in connection with specific procurement functions should
be obtained from the procuring activity or as directed by the contracting
officer.)

2.2 Other publications.-The following document forms a part of

this specification to the extent specified herein. Unless otherwise
indicated, the issue in effect on date of invitation for bid or request
for proposal shall apply.

ASTM Method E 92 - Method of test for Vickers Hardness of

Metallic Materials

(Application for copies should be addressed to the American Society

for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.)

3.1 General. - The cartridge shall comply with Drawing D10523632,

referenced specifications and the following:

3.2 Bullet extraction. -The force required to extract the bullet

from the cartridge case shall be not less than 35 pounds.
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MIL-C-9963F

3.3 Residual stress. -The cartridge case shall not split when subjected
to a 1% mercurous nitrate solution for 15 minutes.

3.4 Wate rproof.-The cartridge shall not release more than one bubble
of air when subjected to an internal pressure differential of 7½ pounds per
square inch (psi) for 30 seconds.

3.5 Accuracy. -The average of the mean radii of all targets of the
sample cartridges, fired at 200 yards, shall not exceed 2.0 inches.

3.6 Velocitv.-The average velocity of the sample cartridges,

conditioned at 70° ± 2° Fahrenheit (F), shall be 3165 feet per second
(ft/sec) plus or minus 40 ft/see, at 78 feet from the muzzle of the weapon.
The standard deviation of the velocities shall not exceed 40 ft/sec.

3.7 Chamber pressure.

3.7.1 Measurement by copper-crush cylinder.-The average chamber pres-

sure of the sample cartridges, conditioned at 70° ± 2°F, shall not exceed
52,000 pounds per square inch (PSI). The average chamber pressure plus
three standard deviations of chamber pressure shall not exceed 58,000 PSI.

3.7.2 Measurement by piezoelectric transducer.-The average chamber

pressure of the sample cartridges, conditioned at 70° ± 2°F, shall not
exceed 55,000 PSI. The average chamber pressure plus three standard
deviations of chamber pressure shall not exceed 61,000 PSI.

3.8 port pressure.

3.8.1 Measurement by copper-crush cylinder. -The average port pressure

of the sample cartridges, conditioned at 70° ± 2°F, shall be 15,000 PSI ±
2000 PSI,

3.8.2 Measurement by piezoelectric transducer. -The average pore

pressure of the sample cartridges, conditioned at 70° ± 2°F, shall be
14,400 PSI ± 2000 PSI.

3.9 Temperature stability.-When the sample cartridges are subjected

to the following storage conditions, the average velocity shall not
decrease by more than 250 ft/sec and the average chamber pressure by
either method used in 3.7 shall not increase by more than 5000 PSI.
the average port pressure by either method used in 3.8 shall neither Also ,
increase nor decrease by more than 2000 PSI with respect to the average
velocity, chamber pressure and port pressure of the sample cartridges of
the same lot, conditioned at 70° ± 2°F for a minimum of twenty minutes.
Any increases in velocity and decreases in chamber pressure of the sample
cartridges under these temperature conditions are acceptable.

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3.9 (Cont’d)

Stored at 125° ± 2°F for not less than one hour and fired at that
temperature.
Stored at -65° ± 5°F for not less than one hour and fired at that
temperature.

3.10 Function and casualty.-The cartridge shall function without

casualty at ambient temperature and under the conditions specified in 3.9.

3.11 Stripping.-The jacket of the bullet, or any part thereof, shall

not separate from the slug when the cartridge is fired.

3.12 Fouling. -The fouling accumulated In the weapon during the firing
of 1000 sample cartridges shall not cause failure of the weapon to function.

3.13 Workmanship. -The requirements for workmanship are as specified

on the applicable drawings, referenced specifications and the following:

3.13.1 Metal defects.-The cartridge shall be free of folds, wrinkles,

deep draw scratches, scaly metal, dents and other defects.

3.13.2 Foreign matter.-The cartridge shall be free of corrosion, stains,

discolorations, dirt, oil, and smears of lacquer.

4. QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for inspection. -Unless otherwise specified in the

contract or purchase order, the supplier is responsible for the performance
of all inspection requirements as specified herein. Except as otherwise
specified in the contract or order, the supplier may use his own or any
other facilities suitable for the performance of the inspection requirements
specified herein, unless disapproved by the Government. The Government
reserves the right to perform any of the inspections set forth in the
specification where such inspections are deemed necessary to assure supplies
and services conform to the prescribed requirements.

4.1.1 Quality assurance terms and definitions .-Reference shall be

made to MIL-STD-109 for definitions of quality assurance terms.

4.2 First article sample.

4.2.1 Initial production sample.-At the beginning of regular production,

a sample of 3500 cartridges shall be submitted in accordance with contract
requirements. In addition, 100 bullets shall be submitted for visual and
dimensional examinations. The sample shall be manufactured using the same
materials, equipment, processes and procedures as will be used in regular
production. All parts and materials, including packaging and packing,
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MIL-C-9963F
4.2.1 (Cont’d)

shall be the same as used for regular production and shall be obtained
from the same source of supply.

4.2.1.1 Examination and test. -After inspection and provisional

acceptance at source, the sample shall be inspected for all requirements
of the drawings and specifications at a Government laboratory or such
other facility specified in the contract.

4.2.1.2 Initial production sample failure.-Failure of the sample to

comply with requirements of the drawings and specifications shall result
in sample disapproval. Determination as to acceptability of any initial
production sample shall be based upon results of initial tests only, and
no second tests shall be permitted on that initial production sample.

4.3 Inspection provisions.

4.3.1 Lot.

4.3.1.1 Submission of product. -The product shall be submitted in

accordance with MIL-STD-105.

4.3.1.2 Lot identification. -Each lot of ammunition shall be identified

as to type, caliber and model, as well as with a lot number in accordance
with MIL-STD-1168. Each lot shall be further identified by a Federal
Stock Number assigned by the procuring activity.

4.3.2 Examination.- One hundred percent examination shall be performed

for all critical defects. Examination for major and minor defects shall
be performed on a class basis in accordance with the classification of
defects, Table I, using applicable sampling plans and acceptance criteria
of MIL-STD-105. The Acceptable Quality Level (AQL) for the major class
shall be 0.25 percent and the AQL for the minor class shall be 1.50
percent. All non-conforming cartridges shall be rejected.

4.3.2.1 Classification of defects .-The classification of defects shall

be as specified in Table I.

TABLE I

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4.3.2.1 (Cont’d)

Major
or
No. Defect and Method of Inspection Critical Major Minor Minor

2 Corroded or stained, if etched X

Case
4 Round Head X
5 Dent X
6 Split case
in K, L, or M location X
in I, S, or J location X
7 Perforated case X
8 Draw scratch X
9 Scratch X
10 Beveled underside of head X
11 Case mouth not crimped in cannelure X
12 Scaly metal X
13 No chamfer on head (rim) X
14 Fold X
15 Wrinkle X
16 Buckle X
17 Bulge X
18 Illegible or missing head stamp X
19 Defective head X
20 Defective mouth X
21 No visible evidence of mouth anneal X

Bullet
22 Dent X
23 Scratch X
24 Split bullet jacket X
25 Loose bullet X
26 Missing cannelure X
27 Scaly metal (bullet) X
28 Upset (crooked) point, X
29 Exposed steel (clad jacket) X
30 Blunt point X
31 Defective cannelure X

Primer
32 No primer X
33 Cocked primer X
34 Inverted primer X
35 Loose primer X
36 Nicked or dented primer X
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4.3.2.1 (Cont’d)

Major
or
No. Defect and Method of Inspection Critical Major Minor Minor
37 No waterproofing material (primer
pocket joint) X
38 Defective crimp x
Gaging
39 Total length x
40 Cartridge profile and alignment
failure x
41 Diameter of extractor groove, max. x
42 Diameter of extractor groove, min. X
43 Diameter of head x
44 Thickness of head x
45 Length to shoulder datum x
46 Depth of primer x
Weighing
47 Weight, min. X

“Refer to MIL-STD-636 (NATO caliber 7.62mm section) for visual defect

standards for defects 1 through 38.

Each lightweight cartridge shall be disassembled and the propellant

weighed. Each such cartridge found to contain 10 grains or more of
propellant shall be classed as a major defect. Any cartridge containing
less than 10 grains of propellant shall be classed as a critical defect.

4.3.3 Tests.-The tests listed in Table II shall be conducted in

accordance with the methods and procedures specified in 4.4.

4.3.3.1 Test samples.-The quantities for the various tests shall be

as specified in Table II. Only cartridges having met the visual, dimensional
and weight requirements shall be used in the ballistic tests,
and shall
have been selected in such a manner that the sample is representative of
the entire lot. The cartridges shall be thoroughly mixed before being
divided into samples for the various tests.

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4.3.3.1 (Cont’d)

TABLE II

Number of Cartridges

Ambient Low Temp. High Temp. Requirement

Test Temp. 70° ± 2°F (4.4.8.1) (4.4.8.2) Para.

Bullet extraction &/ 25 3.2

Residual stress
(Mercurous Nitrate) ~/ 50 3.3
Waterproof ~/ 50 3.4
Accuracy ~/ 90 3.5
Velocity ~/ 20 20 20 3.6 & 3.9
Chamber pressure ~/ 20 20 20 3.7 & 3.9
Port pressure ~/ 3.8 & 3.9
Function & Casualty ~/
Rifle, M16 or M16A1 480 480 480 3.9 & 3.10
Stripping &/ 1 00 3.11
Fouling ~/ 1000 3.12
Hardness d
Head ~/ 10 Drawing
Sidewall ~/ 10 Drawing

Failure of two or more cartridges to comply with the applicable

requirement shall be cause for rejection of the lot. If one cartridge
fails in the first test, a second sample consisting of double the number
of cartridges in the first sample may be tested. If any failing cartridges
are found in the second sample, the lot shall be rejected.

Failure of ten or more cartridges to comply with the applicable

requirement shall be cause for rejection of the lot. If more than three
but less than ten cartridges fail in the first test, a second sample
consisting of double the number, of cartridges in the first sample shall
be tested. The lot shall be rejected if in the combined first and second
sample, ten or more cartridges fail to comply with the applicable
requirement.

Failure of the cartridges to comply with the applicable requirement

shall be cause for rejection of the lot subject to testing of a second
sample consisting of double the quantity of cartridges used in the first
test. Failure of the cartridges in the second sample to comply with the
applicable requirement shall be cause for rejection of the lot.

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4.3.3.1 (Cont’d)

Failure of the cartridges in any sample to comply with the applicable

requirement shall be cause for rejection of the lot subject to testing
of a second sample consisting of double the quantity of cartridges used
in the first test for the temperature or temperatures at which the failure
occurred. Failure of the cartridges of the second sample to comply with
the applicable requirement shall be cause for rejection of the lot.
Chamber pressure and port pressure tests shall be conducted simultaneously.

The lot shall be rejected when function and casualty defects plus
firing defects observed in all other firing tests exceed the acceptance
number for the cumulative sample of Table III. If the number of defects
found in the first tests exceeds the acceptance number for the first sample,
but is equal to or less than the acceptance number for the cumulative sample,
a second sample, consisting of double the quantities specified under function
and casualty test, shall be fired in the service weapon specified therefor.
This procedure shall apply regardless of the weapon or weapons in which
the firing defects occurred in the first test. If the total number of
defects in the combined first and second sample exceeds the acceptance
number for the cumulative sample, the lot shall be rejected. If, in
testing a second sample, defects other than those for which the second sample
is being tested should occur to the extent that they exceed the acceptance
number for the cumulative sample, the lot shall be rejected.

Any evidence of stripping, as indicated by any irregular perforations

on the paper screens, shall be cause for rejection of the lot subject
to testing of a second sample consisting of double the quantity of
cartridges used in the first test. Any evidence of stripping in the
second sample shall be cause for rejection of the lot.

The test shall be conducted on the initial production sample only.

Failure of one or more cartridges to comply with the applicable require-

ment shall be cause for rejection of the lot. No second sample permitted.

4.3.3.2 Firing defects. -Firing defects and acceptance numbers shall

be as specified in Table III.

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4.3.3.2 (Cont’d)

TABLE III

Acceptance
First Cumulative
Defects Sample (1st & 2nd Sample)
1. Misfire
a. No vent hole 0 --
b. Other 1 2
2. Bullet remaining in bore 0 --
3. Primer leak:
a. Perforation in firing pin indent in primer
cup (Rifle M16 or M16A1 only) 0 --
b. Escape of gas through primer cup other
than 3a. above 2
Escape of gas around primer cup 105
d. Loose primer 2
e. Blown primer 1
f. Dropped primer 1
4. Case casualties
a. Longitudinal split
(1) Neck and shoulder (I or S) 28 66
(2) Body (J) 2 4
(3) Body (K) 0 1
(4) To head (L) 0 1
(5) Through head (M) 0 1
b. Circumferential rupture
(1) Partial, shoulder or body (J & S) 1 2
(2) Partial, body (K) 0 1
(3) Partial, head (L) 0 1
(4) Complete 0 1
5. Failure to extract 0 1
6. Weapons stoppage 0 1

No second sample permitted. Lot shall be rejected.

If one or more defects are found in the first sample, a second sample
consisting of double the quantity of cartridges specified under Function
and Casualty of Table II shall be fired. Prior to the testing of the
second sample, the firing pin of the specific rifle(s) in which the
defect originally occurred shall be replaced with a new firing pin. If
an additional primer perforation is found in the second sample, the lot
shall be rejected.

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4.3.3.2 (Cont'd)

For location of defects indicated by letters in parentheses, see

Drawing C7643674.

All stoppages attributable to the ammunition, with the exception of

misfire, complete rupture or failure to extract, observed in all tests
shall be included.

Of the cartridges in which this defect occurs, nor more than 14 in the
first sample nor more than 30 in the cumulative sample shall exhibit escape
of gas around 50% or more than 50% of the periphery.

Each cartridge that misfires shall be disassembled and examined for

presence of vent hole in primer pocket. If vent hole is missing, the
lot shall be rejected with no second sample permitted.

Loose primer.- Looseness, but not so as to permit the fired primer to fall
from the primer pocket.
Blown primer.- A primer which, when the cartridge is fired, is separated
completely from the head of the cartridge case, and both the head of the case
and the primer pocket are grossly distorted and deformed. The severity of
this condition is such that it is readily detectable with the naked eye.
Dropped primer.- A primer which falls from the primer pocket after the
cartridge is fired.

4.3.4 Packaging, packing and marking inspection. -During or immediately

prior to the packaging operation, 100% examination of the cartridges shall
be performed to ascertain that the cartridge type conforms to the drawing.
Occurrence of a high pressure test, dummy or blank cartridge shall be
classed as a critical defect. Occurrence of any type other than those
listed shall be classed as a major defect. All nonconforming cartridges
shall be rejected. Inspection for packaging, packing and marking shall
be in accordance with MIL-STD-644 as applicable to the drawing.

4.3.5 Inspection equipment .-The examinations and tests shall be made

using the equipment prescribed in Equipment Lists listed on LI-10523632.
Unless otherwise specified, acquisition, maintenance and disposition of
inspection equipment shall be in accordance with MIL-I-45607. Simulated
assessment of reference cartridge shall be in accordance with SCATP-5.56

4.4 Test methods and procedures.

4.4.1 Bullet extraction. -The test shall be conducted in accordance

with SCATP-5.56. The rate of travel of the test head shall be not less
than three nor more than six inches per minute.

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MIL-C-9963F

4.4.2 Residual stress Mercurous nitrate) .-The test shall be conducted

in accordance with SCATP-5.56.

4.4.3 Waterproof. -The test shall be conducted in accordance with

SCATP-5.56.

4.4.4. Accuracy. -The test shall be conducted in accordance with

SCATP-5.56, except that the Mean Radius shall be recorded to the nearest
one-tenth of an inch.

4.4.5 Velocity. -The test shall be conducted in accordance with

SCATP-5.56 ‘8.

4.4.6 Chamber pressure.-The test shall be conducted in accordance

with SCATP-5.56 and 4.4.8 simultaneously with the port pressure tests.

4.4.7 Port pressure. -The tests shall be conducted in accordance with

SCATP-5.56 and 4.4.8 simultaneously, with the chamber pressure tests.

4.4.8 Temperature.-The test shall be conducted in accordance with

SCATP-5.56. The weapon In which these tests are fired shall be at room
temperature. Velocity and pressure differences shall be determined by
firing twenty cartridges, conditioned at 68° to 72°F for a minimum of
20 minutes, from the same lot of ammunition, immediately prior to firing
the cartridges conditioned as specified below.

4.4.8.1 Low temperature test.-The test sample shall be stored at minus

65 degrees F, plus or minus 5 degrees, for not less than 1 hour and shall
be fired at that temperature.

4.4.8.2 High temperature test. -The test sample shall be stored at

125 degrees F, plus or minus 2 degrees, for not less than 1 hour and
shall be fired at that temperature.

4.4.9 Function and casualty.-The test shall be conducted in accordance

with SCATP-5.56 and 4.4.8. Two rifles shall be used and the following
number of cartridges shall be fired in each:

First Second Sample

Sample (if required)

Ambient temperature 240 490

Low temperature 240 480
High temperature 240 480

4.4.10 Stripping.-The test shall be conducted in accordance with

SCATP-5.56 and the following: Five magazines, 20 cartridges each, shall
be fired alternately, i.e. full automatic, semi-automatic, full automatic,
etc. After firing each magazine, the paper screen shall be inspected, and
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MIL-C-9963F

4,4.10 (Cont’d)

if necessary, be replaced, to assure observations. Test weapons shall be cooled

to ambient temperature after firing 60 cartridges. Cooling cycle shall be the
same for retests.

4.4.11 Fouling. -The test shall be conducted in accordance with SCATP-5.56.

4.4.12 Hardness testing. -The bullets shall be extracted, the pro-

pellant removed and the primers extracted. Each cartridge case of the
sample shall be prepared and placed on the appropriate test fixture for
testing in accordance with ASTM Method E 92.

4.4.12.1 Case sidewall.-The average of the hardness values of the

sample cases for each prescribed point along the sidewall exterior
surface shall be computed and charted in accordance with the drawing
requirements.

4.4. 12.2 Case head.-The individual hardness value for each prescribed
point on the head section of each sample case shall be recorded. Any value
failing to meet the drawing requirement at a prescribed point(s) shall be
cause for measurement of hardness at the corresponding point(s) on the
opposite side of the primer pocket of the same head section from which
the initial value was obtained. The higher of the two measurements shall
be recorded as the value of record for determination of conformance to
drawing requirements.

4.4.13 Defect penalty.-In any ballistic test, except function and

casualty, in which the occurrence of a firing defect prevents the obtaining
of a reliable result for the characteristic being tested, an additional
shot shall be fired. That particular test shall not be penalized, but
the acceptance or initial production sample shall be penalized for such
defects in accordance with Table III.

5. PREPARATION FOR DELIVERY

5.1 Packing - Level A (Worldwide shipment) .-The cartridges shall

be packed in accordance with Drawing F10535858, F105346O5, F10542258 or
F11735709.
5.2 Marking and labeling. -Packing boxes shall be marked and labeled
in accordance with applicable drawing cited in 5.1.

6. NOTES

6.1 Ordering data. -Invitation for bids and contracts or orders will
specify the following:

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MIL-C-9963F

6.1.1 Title, number and date of this specification.

6.1.2 Type and level of packing.

6.1.3 Provisions for the supply, maintenance and disposition of

mandatory ballastic test equipment for acceptance inspection purposes.

6.1.4 Provisions for the submission of acceptance inspection reports

containing final inspection results for each lot on ammunition presented
to the Government.

6.1.5 Requirement for contractor to provide and maintain an inspection

system in accordance with MIL-I-45208, Inspection System Requirement.

6.2 Hazard notice. The cartridge described herein and certain of its
components are flammable and /or explosive and consequently present hazards
in manufacture, handling, storage and shipment. The contractor should
recognize these hazards and take appropriate measures to guard and protect
against fire, explosion, adverse environment, corrosive atmosphere, rough
handling, and electrically induced incidents.

Custodian: Preparing activity:

Army -MU Army-MU

Air Force - 99 Project Mo. 1305-0800

Review activities:

Air Force - 99

User activity:

Navy - OS, MC
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