A method making a gun barrel liner includes depositing material on a mandrel that has ribs or ridges corresponding to the rifling grooves in the liner. The material may be deposited using plasma spraying, with sprayed splats of material re-melted after deposition for at least part of the deposition process to reduce or eliminate porosity in the deposited material. The mandrel may be made of metal, such as a high thermal conductivity metal such as copper. The mandrel may have a channel therein or therethrough. The channel may facilitate flow of liquid though the mandrel, one example of such a liquid being a coolant (such as water), used to remove heat produced during the material deposition. Another liquid passed through the channel may be an etchant (or other fluid) that is used to dissolve or otherwise remove the mandrel after the material of the gun barrel liner has been deposited.

A method making a gun barrel liner includes depositing material on a mandrel that has ribs or ridges corresponding to the rifling grooves in the liner. The material may be deposited using plasma spraying, with sprayed splats of material re-melted after deposition for at least part of the deposition process to reduce or eliminate porosity in the deposited material. The mandrel may be made of metal, such as a high thermal conductivity metal such as copper. The mandrel may have a channel therein or therethrough. The channel may facilitate flow of liquid though the mandrel, one example of such a liquid being a coolant (such as water), used to remove heat produced during the material deposition. Another liquid passed through the channel may be an etchant (or other fluid) that is used to dissolve or otherwise remove the mandrel after the material of the gun barrel liner has been deposited.

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.

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.

A monolithic barrel for a weapon has an integral suppressor. The barrel and integral suppressor can be machined from a single piece of material, which can eliminate the need to attach separate components to the barrel. The monolithic barrel has a barrel bore for firing a projectile that produces discharge gas. To suppress the discharge, the barrel defines one or more baffles separating expansion chambers toward a distal end of the barrel. The barrel further defines one or more channels along the length of the barrel that provide extend flow paths for the discharge gas from the barrel's bore. Greater reductions in sound can be achieved relative to the overall barrel length due to the integral suppressor.

A monolithic barrel for a weapon has an integral suppressor. The barrel and integral suppressor can be machined from a single piece of material, which can eliminate the need to attach separate components to the barrel. The monolithic barrel has a barrel bore for firing a projectile that produces discharge gas. To suppress the discharge, the barrel defines one or more baffles separating expansion chambers toward a distal end of the barrel. The barrel further defines one or more channels along the length of the barrel that provide extend flow paths for the discharge gas from the barrel's bore. Greater reductions in sound can be achieved relative to the overall barrel length due to the integral suppressor.

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 method of making a continuous fiber barrel wrap sheath onto a steel riffled barrel liner of a gas-operated firearm is described. A wrap made up of composite fiber is wrapped onto a steel riffled barrel liner in a continuous fashion, with no interruption within the steel liner for the purpose of delivering high pressure gas through the steel liner. After joining the composite wrap to the steel barrel liner, either by mechanical or chemical procedure, a slot is formed by carving out a top and/or a bottom of the composite. A gas key insert is then placed in the made slots and retained by mechanical or chemical procedure. Finally, a gas port is drilled through the key insert.

A method of making a continuous fiber barrel wrap sheath onto a steel riffled barrel liner of a gas-operated firearm is described. A wrap made up of composite fiber is wrapped onto a steel riffled barrel liner in a continuous fashion, with no interruption within the steel liner for the purpose of delivering high pressure gas through the steel liner. After joining the composite wrap to the steel barrel liner, either by mechanical or chemical procedure, a slot is formed by carving out a top and/or a bottom of the composite. A gas key insert is then placed in the made slots and retained by mechanical or chemical procedure. Finally, a gas port is drilled through the key insert.