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An open single-cavity bullet mold and a closed two-cavity mold. A cast bullet is made by allowing molten metal to solidify in a mold.Most cast bullets are made of lead alloyed with tin and antimony; but zinc alloys have been used when lead is scarce, and may be used again in response to concerns about lead toxicity.
Cast bullets as cast (left), with gas check (center) and lubricated (right). A gas check is a gasket type component of firearms ammunition. Gas checks are used when non-jacketed bullets are used in high pressure cartridges. The use of a gas check inhibits the buildup of lead in the barrel and improves accuracy. [1]
With a mold, bullets can be made at home for reloading ammunition, where local laws allow. Hand-casting, however, is only time- and cost-effective for solid lead bullets. Cast and jacketed bullets are also commercially available from numerous manufacturers for handloading and are most often more convenient than casting bullets from bulk or ...
A full metal jacket (FMJ) bullet is a small-arms projectile consisting of a soft core (often lead) encased in an outer shell ("jacket") of harder metal, such as gilding metal, cupronickel, or, less commonly, a steel alloy. A bullet jacket usually allows higher muzzle velocities than bare lead without depositing significant amounts of metal in ...
A hunting flat nosed cast bullet will hold together without expanding and carry a large amount of air envelope with it causing a great amount of cavitation and wounding. Since it is cavitation that does most of the damage when a bullet strikes a game animal this means the flat nose bullet is an extremely effective hunting design.
It does not apply to jacketed or gas-check cast bullets. Below is a chart containing various bullet alloys, the BHN, and the PSI required to expand a bullet to the bore: Pure lead is very soft, and can be expanded or upset by most firearm cartridges, but the pressures required are higher than those encountered in most airguns.
Handgun bullets made entirely of lead have less penetration ability than jacketed bullets at similar velocity. In the 1930s, Western Cartridge Company introduced .38 Special ammunition capable of firing a 158-grain (10.2 g) copper-tipped lead-alloy bullet at 1,125 feet (343 m) per second to penetrate sheet-metal automobile doors. [4]
HBWC rounds are best used at only the lowest velocities, as by being hollow at the rear end, they can split under heavy loads. DEWC rounds are best suited for automatic press reloading uses, as they may be used when loaded with either end pointed forward. BBWC have been developed to permit easier bullet insertion into the case when reloading.