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| Jeff, Eugene Stoner designed the Ar-15 to be used with IMR propellents---------not ball type powders.
{partial Quote} With these requirements in mind, Stoner began. To meet the 500 meter standard, Stoner had the Remington Arms Company increase the capacity of their .222 Remington cartridge to fire a 55-grain bullet at 3300 feet per second. With the new round, known as the .223 Remington, Stoner started work on the rifle. His first attempt was of a conventional design that was uncontrollable when fired fully-automatically, so he created a scaled-down AR-10.6 The new Stoner rifle took ideas and other smaller details from many rifles and combined them into one design: the locking system from the M1941 Johnson rifle, the use of a hinged receiver and the buffer system from the FAL, the straight in-line stock from the T-25 and the direct gas system of the Swedish M42 Ljungman rifle, which eliminated several moving parts and made the rifle simpler to operate and cheaper to manufacture.7 Because the new cartridge allowed him to use aluminum alloys and plastics, Stoner's new rifle, the AR-15, weighed only 6.35 pounds(2.89 kilograms) empty. But Stoner also made some mistakes. Stoner did not feel a need to have the AR-15's barrel chrome-plated, especially since ArmaLite didn't possess the capability to plate the barrel, but Army research after World War II had shown the benefits of having a chrome-plated barrel and chamber on rifles designed for automatic fire and Army declared after the M14's adoption that all subsequent rifles would have chrome-lined barrel and chambers.8 In developing the AR-15's cartridge, Stoner used a type of gunpowder known as IMR powder. With the IMR powder, the AR-15 was highly reliable, but the Army was now in the process of converting to the use of ball type powder in its cartridges, which was cheaper to produce and had wholly different ballistic characteristics.9 The only major problem with the prototype AR-15 design was that it wasn't fully developed before Army testing began nine months later on 31 March 1958. Ordnance engineers and ArmaLite designers didn't see eye-to-eye from the start, but the AR-15 proved to be a workable design and the Infantry Board report stated a fully-developed AR-15 would be a suitable replacement for the M14 rifle. But later tests showed some problems. Rainwater in one AR-15 barrel cause it to burst when fired. Stoner redesigned and strengthened the barrel, but Ordnance engineers said the problem still remained, due to the .22-caliber size of the barrel. It was also at this time when Stoner learned several of his rifles were set to the Army Arctic Test Board and reliability problems were noted there. Stoner went to Alaska to find the problems with the AR-15 were caused by Army personnel, who disassembled the rifle and reassembled it improperly. Stoner asked for a new test trial because of the way the AR-15 had been mishandled.10 The Army then began to stonewall Stoner over the suitability of the AR-15, but said if the AR-15 was built to fire a new .258 caliber round which the Ordnance department now stated was the best cartridge, it may be suitable. Additionally, the Army Chief of Staff, General Maxwell Taylor, did not favor the AR-15 and recommended continued production of the M14. Because of this treatment and its desire to recoup its $1.45 million development expense, Fairchild sold its rights to the AR-15 to Colt's Patent Firearms Manufacturing Company for $75,000 cash and a 4.5% royalty on subsequent rifle sales in December, 1959. In 1960, ArmaLite was reorganized and Stoner left ArmaLite during this reorganization.The use of ball gunpowder left a very sticky residue in the barrel and the gas tube of the M16. Since the barrel wasn't chrome-plated and no cleaning equipment and/or lubricants were available, it hardened quickly and soon made the rifle inoperable. The residue also caused spent casings to become stuck in the chamber and the rifle suffered a rim shear extraction failure, where the bolt's extractor tore off a portion of the end of the spent casing, leaving the rest of the case stuck in the chamber. Because of the ball gunpowder's ballistic characteristics and the rifle's buffer's light weight, the M16 fired fully automatically with a cyclic rate of between 850-1000 rounds per minute, well in excess of the normal 750-850 rounds per minute. Compounding this comedy of errors was the lack of training and instruction given to those troops who were issued the M16.22
Beginning on 15 May 1967, the problems were investigated by a Congressional subcommittee, headed by Representative Richard Ichord, a Democrat from Missouri. After seeing the M16 malfunction firsthand during tests at Fort Benning and Camp Pendleton and traveling to Vietnam to assess the problems, the Ichord Subcommittee report, issued in late June, 1967, stated "the much-troubled M16 rifle is basically an excellent weapon whose problems were largely caused by Army mismanagement."23 To correct the M-16's fouling problems, the formulation of the ball gunpowder used in the 5.56mm M193 Ball cartridge was changed by reducing the level of calcium carbonate(CaCO3 - limestone, used as an acid neutralizer to extend shelf life) from 1% to .25%, less than half the amount shown to clog the M16's gas tube. A new heavier weight buffer was developed to reduce cyclic rates back to normal. A cleaning kit was developed, along with a new buttstock able to store the cleaning kit in the rifle. Finally, a massive training program on how to properly maintain the M16 was instituted and made use of a rifle maintenance comic book.24 With the major operational problems finally solved, the next most pressing problem was how to get more rifles into the hands of troops needing them. Two additional contractors, Harrington & Richardson and the Hydramatic Division of General Motors Corporation, were awarded contracts to produce the M16/M16A1. With the operational and production problems resolved, the M16/M16A1 began to operate with great reliability. [ 12-28-2002, 18:36: Message edited by: TBS ] |