A method for manufacturing a gun barrel with a cold spray process. The method includes the use of a mandrel having a tubular body and being made of a material with properties suited to use with gun barrel manufacture and materials and cold spray processes. The gun barrel includes a liner, one or more structural layers and an outer jacket. The mandrel is dissolved in a chemical process during manufacture of the gun barrel.

A method for manufacturing a gun barrel with a cold spray process. The method includes the use of a mandrel having a tubular body and being made of a material with properties suited to use with gun barrel manufacture and materials and cold spray processes. The gun barrel includes a liner, one or more structural layers and an outer jacket. The mandrel is dissolved in a chemical process during manufacture of the gun barrel.

A hybrid metal and composite barrel assembly for a firearm preferably includes a metal inner barrel liner and a composite outer barrel sleeve. The composite outer barrel sleeve preferably includes at least one layer of woven metal mesh material comprising a plurality of metallic fibers, and at least one layer of carbon fiber material comprising a plurality of carbon fibers. The composite outer barrel sleeve is preferably engaged around the metal inner barrel liner, and optionally incorporates a tensioning nut to retain the sleeve on the liner.

A hybrid metal and composite barrel assembly for a firearm preferably includes a metal inner barrel liner and a composite outer barrel sleeve. The composite outer barrel sleeve preferably includes at least one layer of woven metal mesh material comprising a plurality of metallic fibers, and at least one layer of carbon fiber material comprising a plurality of carbon fibers. The composite outer barrel sleeve is preferably engaged around the metal inner barrel liner, and optionally incorporates a tensioning nut to retain the sleeve on the liner.

A guide system for use in electro-processing a bore of a gun barrel includes a non-conductive external bore guide and a non-conductive internal bore guide. The external bore guide is an adapter that is configured to removably engage the outside of the gun barrel and includes a conduit formed therein. The conduit is disposed such that it is axially aligned with a bore of the gun barrel when the external bore guide is engaged with the gun barrel. The internal bore guide is elongated and includes an axial recess that is sized to seat an electro-processing electrode (an anode). A method for uniformly plating the bore includes moving an anode through the gun barrel at one or more rate(s) of travel to uniformly plate the bore is also disclosed. The plating is sufficiently uniform to conform to military specifications. The systems, methods, support structures, etc. described herein are particularly well-suited to plating small-bore gun barrels.

A guide system for use in electro-processing a bore of a gun barrel includes a non-conductive external bore guide and a non-conductive internal bore guide. The external bore guide is an adapter that is configured to removably engage the outside of the gun barrel and includes a conduit formed therein. The conduit is disposed such that it is axially aligned with a bore of the gun barrel when the external bore guide is engaged with the gun barrel. The internal bore guide is elongated and includes an axial recess that is sized to seat an electro-processing electrode (an anode). A method for uniformly plating the bore includes moving an anode through the gun barrel at one or more rate(s) of travel to uniformly plate the bore is also disclosed. The plating is sufficiently uniform to conform to military specifications. The systems, methods, support structures, etc. described herein are particularly well-suited to plating small-bore gun barrels.

A method for manufacturing a rifle barrel is provided. The method is attained by providing an inner barrel defining a rifle bore, and having an outside diameter of a selected first amount at room temperature. Further, by providing an outer sleeve defining a bore, and having a second diameter at room temperature less than the first amount. The outer sleeve is heated to a temperature above room temperature, and the inner barrel is inserted into the bore of the sleeve.

A method for manufacturing a rifle barrel is provided. The method is attained by providing an inner barrel defining a rifle bore, and having an outside diameter of a selected first amount at room temperature. Further, by providing an outer sleeve defining a bore, and having a second diameter at room temperature less than the first amount. The outer sleeve is heated to a temperature above room temperature, and the inner barrel is inserted into the bore of the sleeve.

Apparatus and associated methods relate to a gun barrel liner having circumferentially distributed radially yielding inserts. In an illustrative example, the inserts may be distributed along a longitudinal axis of a liner body. For example, each of the inserts may be urged radially inward against the liner by one or more coupling members. Each coupling member may, for example, circumscribe a circumference of the liner. Inserts may, for example, be individually assembled onto a liner. Inserts may, for example, be coupled to spacers such that an insert assembly may be assembled onto a liner as a single unit. For example, the inserts may yield to a radially outward force from a projectile such that an effective diameter of the gun barrel liner substantially conforms to the diameter of the projectile. Various embodiments may advantageously provide interchangeable radially yielding gun barrel liners.

Apparatus and associated methods relate to a gun barrel liner having circumferentially distributed radially yielding inserts. In an illustrative example, the inserts may be distributed along a longitudinal axis of a liner body. For example, each of the inserts may be urged radially inward against the liner by one or more coupling members. Each coupling member may, for example, circumscribe a circumference of the liner. Inserts may, for example, be individually assembled onto a liner. Inserts may, for example, be coupled to spacers such that an insert assembly may be assembled onto a liner as a single unit. For example, the inserts may yield to a radially outward force from a projectile such that an effective diameter of the gun barrel liner substantially conforms to the diameter of the projectile. Various embodiments may advantageously provide interchangeable radially yielding gun barrel liners.