METHOD OF MAKING A RELIABLE GUN

Abstract

A gun has parts that slide past one another during operation. A coating is formed on at least a surface of a first part that contacts a second part. At least an upper layer of the coating is porous and comprises a thermoset polymer and a filler. One or both parts may be part of a gas-operated reloading mechanism. The coating prevents jamming by excluding particles, yielding to particles that still manage to intrude, and by providing a reservoir for lubricant. The coating reduces clearances, improves accuracy, and reduces operating temperatures. The coating excludes particles from the lubricant, effectively allowing a large volume of lubricant to be used without the drawback of trapping dirt and other contaminants in the lubricant.

Claims

1. A gun, comprising: a first metal part and a second metal part that slide past one another; and a coating over a surface of the first metal part; wherein the coating comprises a porous upper layer; the porous upper layer comprises a thermoset polymer and a filler; and the porous upper layer contains oil and expresses some of the oil under stresses induced by operating the gun.

2. The gun of claim 1, wherein the porous upper layer is operative to reabsorb some of the expressed oil after the stresses are relieved.

3. The gun of claim 1, wherein the coating is a product of a processes comprising: applying a liquid primer over the surface, wherein the liquid primer comprises a second thermosetting resin; applying a powder of particles individually comprising a thermosetting resin and the filler over the liquid primer prior to drying or curing the liquid primer; and curing the powder and the liquid primer; wherein the powder forms the porous upper layer and the second thermosetting resin forms a polymer matrix underneath the porous upper layer.

4. The gun of claim 1, wherein the filler is a solid lubricant.

5. The gun of claim 1, wherein the porous upper layer has a porosity in a range from 2%-80%.

6. The gun of claim 1, wherein the coating has a thickness of at least 250 μm.

7. The gun of claim 1, wherein the coating has a roughness Rvk of 2 μm or more.

8. The gun of claim 1, wherein the coating has a roughness Rsk of negative 0.5 or lower.

9. The gun of claim 1, wherein: the coating has an Rpk and an Rvk related to roughness; and the Rpk is half or less the Rvk.

10. The gun of claim 1, wherein the first metal part and the second metal part have a telescoping relationship.

11. The gun of claim 1, wherein one of the first metal part and the second metal part is part of a gas-operated reloading mechanism.

12. The gun of claim 1, wherein the first metal part and the second metal part are parts of a gas-operated reloading mechanism.

13. The gun of claim 1, wherein the first metal part and the second metal part are part of a bolt carrier group.

14. The gun of claim 1, wherein the first metal part and the second metal part are selected from the group consisting of a bolt, a bolt carrier, a receiver, and a firing pin.

15. A gun, comprising: a first metal part and a second metal part that slide past one another; and a coating over a surface of the first metal part; wherein the coating comprises a porous upper layer; the porous upper layer comprises a thermoset polymer and a filler; and the porous upper layer has an interconnectivity above a percolation threshold.

16. The gun of claim 15, wherein: the porous upper layer comprises particles that individually comprise the thermoset polymer and the filler; the particles are adhered to one-another; and spaces between the particles provide the porous upper layer with porosity.

17. The gun of claim 16, wherein the filler is present within the particles in an amount that is from 15% to 40% by volume.

18. A method of assembling a gun comprising a first metal part and a second metal part that slide past one another, the method comprising: applying a powder of particles over a surface of the first metal part, wherein the particles individually comprise a thermosetting resin having a cure temperature and a filler having a melting point above of the cure temperature; curing the thermosetting resin so as to form a coating on the first metal part, wherein the coating comprises a porous upper layer that has a roughness that results from a structure of the particles; and assembling the first metal part and the second metal part, wherein a thickness of the coating results in an interference fit between the first metal part and the second metal part.

19. The method of claim 18, applying a liquid primer over the surface, wherein the liquid primer comprises a second thermosetting resin and applying the powder of particles over the surface of the first metal part comprises applying the powder of particles over the liquid primer prior to drying or curing the liquid primer.

20. The method of claim 18, wherein the powder of particles is a product of a process, the process comprising: melt-mixing the thermosetting resin and the filler to form a composite; cooling the composite; and breaking up the composite to form the powder of particles.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a flow chart of a process for coating a gun part in accordance with some aspects of the present teachings.

[0014] FIG. 2 is flow chart of a process that may be used in accordance with some aspects of the present teachings to form a powder.

[0015] FIG. 3 is a sketch of a part surface with a coating in accordance with some aspects of the present teachings.

[0016] FIG. 4 is another sketch of a part surface with a coating in accordance with some aspects of the present teachings.

[0017] FIG. 5 illustrates parts of an AR-15, some of which may be coated in accordance the present teachings.

[0018] FIG. 6 is a plot showing an effect of a coating according to the present teachings on operating temperature

[0019] FIG. 7 is a plot showing an effect of a coating according to the present teachings on a jamming rate.

DETAILED DESCRIPTION

[0020] FIG. 1 is a flow chart of an example process 100 for forming a gun part with a coating according to the present disclosure. Act 101 is preparing the part that will receive the coating. Examples of parts that may be coated include, without limitation, a bolt, a bolt carrier, a firing pin, a barrel, a receivers, a gas key, a gas tube, any other part of the bolt carrier group, and any other moving part associated with a gas-powered reloading mechanism. The part can be of any material that can withstand the cure temperature of the coating. In some embodiments, the part is metal. The surface to be coated may already have a coating, porous or non-porous, of any suitable material.

[0021] Preparing the part surface is optional, although generally advisable. Any surface preparation process or combination of processes may be employed. Examples of surface preparation processes that may be used include physical and chemical processes. Examples of physical preparation processes include, without limitation, vibro-finishing, sanding, abrasive grit blasting, media blasting, plasma treatment, irradiative treatment, and the like. Examples of chemical preparation processes include, without limitation, washing, activating, sealing, and the like. The surface preparation process may form a coating on the surface by chemical, electrochemical, or other means. In some embodiments, surface preparation produces a conversion coating. Examples of conversion coatings include phosphate coatings, chromate coatings, black oxide, and the like. Surface preparation may include electroless plating or electroplating to form alloys of nickel, chrome, tin, or other metals. Surface preparation may include galvanizing.

[0022] Act 103 is applying a base coat to the part surface. The base coat is a liquid composition that includes a thermosetting resin. The thermosetting resin may be part of a resin system that includes one or more of a curing agent, a hardener, an inhibitor, and plasticizer. Any suitable thermosetting resin may be used. Examples of thermosetting resins that may be used include acrylic, allyl, benzoxazine, epoxy, benzoxy melamine formaldehyde, phenolic, polyamide, polyaryl sulphone, polyamide-imide, polybutadiene, polycarbonate, polydicyclopentadiene, polyester, polyphenylene sulphide, polyurethane, silicone, and vinyl ester resins and mixtures thereof. The thermosetting resin may make up 35% or more of the liquid by volume.

[0023] Optionally, the base coat includes a solvent. The solvent is present in at least an amount sufficient to make the composition liquid if a solvent is needed for that purpose. Low boiling point solvents are preferred as are organic solvents. Examples of solvents that may be suitable for the liquid primer include methyl ethyl ketone (MEK), N-Methyl-2-pyrrolidone (NMP), turpentine, xylene, mineral spirits, turpenoid, toluene, dimethylfomamide, glycol ethers, ethylbenzene, n-butyl acetate, alcohols, acetone and combination thereof. In some embodiments, the base coat includes one or more epoxy resins that remain liquid without solvent.

[0024] The base coat may include other components such as diluents, surfactants, modifiers, and other components that either contribute to the formation of the base layer or the functionality of the final coating. Examples of other components that may contribute to the formation of the base layer include, without limitation, curing agents, hardeners, inhibitors, and plasticizers. Examples of other components that may contribute the functionality of the coating include, without limitation, pigments and minerals of various types such as graphite, hexagonal boron nitride, talc, other clays, minerals between 1 and 10 on the scale of MOH's hardness, diamond, cubic boron nitride, metal flake, and the like.

[0025] The base coat may be formed by any suitable process. Depending on the composition of the base coat and the material of the gun part, suitable processes may include spraying, electrostatic deposition, silk screening, dipping, ink jet printing, brushing, dip spinning, pad printing, film transferring, wiping, and the like. In some embodiments, the process includes some type of spraying. Spraying may be electrostatic spraying. Also, the gun part may be spun during or after spray deposition. The base coat may be formed with multiple layers and the layers may be of different materials.

[0026] An additional process may take place after the initial application of the base coat to improve uniformity or coverage. The additional process may include wiping, rinsing, or flinging excess base coat material from the surface. In some embodiments, centripetal force is used to fling excess base coat material from the surface. Centripetal force can be effective in producing a highly uniform base coat.

[0027] Act 105 is depositing the powder over the liquid base coat. The powder includes a thermosetting resin and a filler. The thermosetting resin of the powder may be part of a resin system that includes one or more of a curing agent, a hardener, an inhibitor, and a plasticizer. Any suitable thermosetting resin may be used. A thermosetting resin is any polymer resin that can be irreversibly hardened by curing regardless of whether curing is induced by heat, radiation, pressure, catalysis, or any other mechanism. In some embodiments, the thermosetting resin is of a type that can be granulated into a powder. Examples of thermosetting resins that may be used include, without limitation, acrylic, allyl, allyl, benzoxazine, epoxy, melamine formaldehyde, phenolic, polyamide, polyaryl sulphone, polyamide-imide, polybutadiene, polycarbonate, polydicyclopentadiene, polyester, polyphenylene sulphide, polyurethane, silicone, and vinyl ester resins and mixtures thereof. In some embodiments, the powder has the resin in an amount that is 35 percent or more by volume.

[0028] The filler material preferably has a melting point above a cure temperature of the thermosetting resin. In some of these teachings, the filler material is a solid lubricant. Examples of solid lubricants that may be used as the filler material include graphite, PTFE, polyamide, polyamide imide, polyimide, boron nitride, carbon monofluoride, molybdenum disulphide, talc, mica, kaolin, the sulfides, selenides, and tellurides of molybdenum, tungsten, or titanium and combinations thereof. The mixture preferably has the filler material in an amount that is 15 to 40 percent by volume. In some of these teachings the filler is at least 60 percent graphite. In some of these teachings the graphite particles have lengths in the range from 7 to 30 micrometers. Some application benefit from the inclusion of clay in the filler. In some of these teachings, the filler is from 20% to 40% clay by volume. Examples of clays that are suitable for the filler include kaolin, mullite, montmorillonite, and bentonite.

[0029] The powder may be the product of a process 131, which is illustrated by FIG. 2. The process 131 includes act 133, melt-mixing the polymer resin and the filler to form a composite, act 135, cooling the composite, and act 137, breaking up the composite to form a powder. The composite may be broken up to form the powder by any suitable process such as milling or the like. The resulting powder preferably has a mean particle size in the range from 2 to 200 μm. For purposes of the present disclosure, particle sizes are the diameters of spheres having the same volume as the particles. More preferably, the mean particle size is in the range from 5 to 150 μm. Still more preferably the particle size is in the range from 10 to 80 μm. Smaller particles may be difficult to process. Larger particles may not adhere well when electrostatics are used. Preferably, the filler and the resin are both present in the individual particles of the powder.

[0030] The powder may be deposited over the liquid by any suitable process. In some embodiments, the coating process comprises electrostatics, e.g., electrostatic spray deposition. More generally, the coating process may include one or more of spraying the powder, fluidizing the powder, heating the powder, and heating the surface to be coated. If the surface is heated, it is not heated in a way that solidifies the base layer. It may also be feasible to apply the powder by dipping, rolling, screen printing, or other film transfer process. The powder may be formed into a slurry to facilitate use in one of the foregoing processes.

[0031] In some embodiments, act 105 includes depositing multiple layers. Each layer may comprise a different type of powder. The powders may vary in composition, size distribution, or any other characteristic. The different layers may be used in combination to provide desirable wear characteristics and the like. For example, differing powder composition may be used to provide a low wear resistance upper layer and a second that produces a higher resistance layer underneath. A variety of parameters may be adjusted to produce a desired degree of wear resistance. Useful parameters to adjust include the identity of the thermosetting resin, the cure temperature, the amount of filler, the composition of the filler including the amount of clay the filler contains, and the porosity of the coating, which may be controlled through the size distribution of the dry powder particles.

[0032] Act 107 is curing the base layer and the powder to form the coating. Curing evaporates any solvent from the base layer and hardens the base layer. Curing may be driven by any of heat, radiation, pressure, catalysis, combinations thereof, or any other mechanism. Where curing is driven by heat, heating may take place by convection, conduction, induction, radiative heating, combinations thereof, or any other mechanism. In some embodiments, curing causes the powder to sinter, but curing completes without the particles flowing sufficiently to lose their discrete identities. In some embodiments, curing takes place in a temperature range between 100° C. and 300° C. In some embodiments, curing takes place in a temperature range between 150° C. and 200° C. Curing solidifies the coating. Curing may also consolidate or densify the coating. The various layers of the coating may be cured simultaneously or sequentially.

[0033] FIG. 3 illustrates a coated part 200 that may be a product of the process of FIG. 1. The coated part 200 includes a metal part 201 and a coating 211 formed on a surface 209 of the metal part 201. The abradable coating 211 includes a base layer 203 formed from a liquid coat, an upper layer 207 formed from powder particles, and an interfacial area 205 formed from both the liquid coat and the powder particles.

[0034] The base layer 203 is generally non-percolating in the sense that neither liquid nor air can pass through it. In some embodiments, the base layer has 5% or less porosity. In some embodiments, the base layer has 2% or less porosity. In some embodiments, the base layer has no porosity. The base layer 203 includes a thermoset polymer matrix and may include one or more non-polymer materials dispersed within the thermoset polymer matrix. The base layer 203 adheres the coating 211 to the surface 209 and may serve other functions such as providing corrosion resistance, sealing, and the like for the surface 209.

[0035] In some embodiments, the upper layer 207 has an interconnectivity above a percolation threshold meaning that fluids can pass through it. The porosity of the upper layer 207 may be in the range from 2 to 80 percent. In some embodiments, the porosity of the upper layer 207 is in the range from 2 to 40 percent. In some embodiments, the porosity of the upper layer 207 is in the range from 2 to 20 percent. The porosity may facilitate the provision of controlled wear properties, desirable rheological properties, and a reservoir of lubricating fluid. The provision of porosity in the upper layer 207 is facilitated by curing without allowing excessive flow, whereby in some embodiments individual particles of the powder from which the upper layer 207 was formed remain identifiable within the upper layer 207. The upper layer 207 may provide the coating 211 with targeted characteristics such as, for example, friability, lubricity, clearance control capability, heat transport, and the like. In some embodiments, the upper layer 207 is two or more times thicker than the base layer 203.

[0036] The thickness of the coating 211 may vary over the coated part 200. The coating 211 may be very thick on the coated part 200. In some embodiments, at its thickest point, the coating 211 may have a thickness the coating has a thickness of 100 μm or greater. In some embodiments, the coating 211 has a maximum thickness of 300 μm or greater. In some embodiments, the coating 211 has a maximum thickness of 500 μm or greater. A thickness of 750 μm has been demonstrated and thicker coatings are possible. The thickness is generally at least about 25 μm.

[0037] In some embodiments, the upper layer 207 includes multiple strata (sublayers) composed of different types of particles. The different strata may be used to control characteristics of the coating. For example, the upper layer 207 may include an upper strata that wears relatively quickly and a lower strata that is comparatively wear resistant to provide a balance between easy break-in and long life.

[0038] The interfacial area 205 includes particles of the upper layer 207 partially surrounded or entirely surrounded, partially sunken or entirely sunken, into the polymer matrix of the base layer 203. Fluid-solid interactions may cause the formation of a complex interface. The interfacial area provides adhesion between the upper layer 207 and the base layer 203.

[0039] FIG. 4 is a sketch of a coated part 200A, which is an example of the coated part 200 and illustrates a possible structure. The coated part 200A includes the coated part 201 and an abradable coating 211A formed on the surface 209 of the coated part 201. The abradable coating 211A includes a non-porous base layer 203A formed from a liquid coat, a porous upper layer 207A formed from powder particles, and an interfacial area 205A formed from both the liquid coat and the powder particles.

[0040] The upper layer 207A includes particles 301 that have been sintered enough to flow and bind together to form a solid mass. An upper surface 315 of the mass may include peaks 313 and valleys 311. The base layer 203A includes a polymer matrix 305. The interfacial area 205A includes particles 301 that are bound by the polymer matrix 305. Some particles 301 may be completely immersed in the polymer matrix 305. Other particles 301 may be partially surrounded by the polymer matrix 305. The particles 301 and the polymer matrix 305 may have a complex interface due to interactions of the liquid base layer and particles of the powder. In some embodiments, those interaction result in a contact structure 303 that is partially determined by a contact angle between the liquid base coat and particles of the powder. FIG. 4 illustrates a structure that may form when the base coat is wetting with respect to the powder particles.

[0041] Returning to FIG. 1, the process 100 may continue with a break-in process that determines a final shape for the coating 211. Act 109 is assembling a gun with the part 200. The part 200 may form an interference fit with another part (not shown) of the gun. The coating 211 may initially be thicker than the clearance between the mating parts, whereby a portion of the coating 211 is necessarily shaved off when the gun is initially assembled.

[0042] Act 111 is operating the gun. Operation causes wear at high stress points on the coating 211. As the wear progress, a contact area between the mating parts tends to increase and clearances become optimized, which effects reduce local stresses until the shape of the coating 211 stabilizes.

[0043] Before break-in, the upper surface 315 has a roughness that is related to a structure of the particles 301. In particular, because the abradable coating 211 cures without the particles 301 flowing sufficiently to entirely loose their discrete identities, the upper surface 315 has peaks 313 that individually correspond to one or more of the particles 301. In some embodiments, before break-in, the upper surface 315 has a roughness Ra in the range from about 0.5 μm to about 20 μm. In some embodiments, before break-in, the upper surface 315 has a roughness Ra in the range from about 1 μm to about 10 μm. In some embodiments, before break-in, the upper surface 315 has a roughness Ra greater than about 2 μm.

[0044] After break-in, the upper surface 315 may be smoother. Nevertheless, in some embodiment the upper surface 315 continues to have roughness that relates to the particles 301 retaining a degree of separation. Asperities on the upper surface 315 may be reduced by wear and the surface 315 may recede, but in some embodiments valleys 311 between particles 301 continue to appear of the upper surface 315. In some embodiments, after break-in, the upper surface 315 has a roughness Ra in the range from about 0.2 μm to about 10 μm. In some embodiments, after break-in, the upper surface 315 has a roughness Ra in the range from about 0.5 μm to about 5 μm. In some embodiments, after break-in, the upper surface 315 has a roughness Ra greater than about 1 μm.

[0045] The removal of asperities from the upper surface 315 and the appearance of new values 311 as wear continues may result in the valleys 311 having a greater contribution to surface roughness than the peaks 313. This effect is captured by the Rsk of the surface, the Rsk being a roughness parameter that measures the skewness of the of a surface height distribution about a mean. In some embodiments, prior to break-in, the Rsk of the upper surface 315 is in the range from −0.5 to 0.5. In some embodiments, prior to break-in, the Rsk of the upper surface 315 is in the range from −0.25 to 0.25. After break-in these Rsk values are reduced. In some embodiments, after break-in reduces the Rsk be about −0.5 or more. In some embodiments, after break-in, the Rsk is less than about −0.25. In some embodiments, after break-in, the Rsk is less than about −0.50. In some embodiments, after break-in, the Rsk is less than about −1.0.

[0046] A structure of the upper surface 315 may also be characterized in terms of the roughness parameters Reduced Peak Height (Rpk) and Reduced Valley Depth (Rvk). Rpk relates to peak height over a surface mean height. Rvk relates to valley depth below the surface mean height. In some embodiments, prior to break in, both Rpk and Rvk are at least about 2 μm. In some embodiments, prior to break in, both Rpk and Rvk are at least about 3 μm. Rvk may remain nearly the same or even increase after break-in. Rpk, on the other hand, may be reduced. In some embodiments, after break-in, the Rpk is less than about 3 μm. In some embodiments, after break-in, the Rpk is less than about 2 μm. In some embodiments, after break-in, the Rpk is half or less than half Rvk. In some embodiments, after break-in, the Rpk is one fourth or less than one fourth Rvk.

[0047] The coating 211 can be applied to any type of gun. Examples of guns that may be coated include, without limitation, semi-automatic handguns, e.g., a Colt 1911 style pistol, a semi-automatic rifle, e.g., an AR-15, a machine gun such as an M249 light machine gun, an M60 machine gun, or a Browning .50 caliber heavy machine gun, a Gatling-style rotary cannon, e.g., an M61 Vulcan or even a heavier gun. In some embodiments, the gun has a gas-powered reloading mechanism.

[0048] FIG. 5 illustrates some parts of an AR-15 that are associated with the gas reloading mechanism. These parts include a bolt carrier 501, a gas key 503, a bolt 505, a bolt cam pin 507, a firing pin 509, a gas tube 511, a barrel 513, and a bolt ring 515. Any or all of these parts may receive the coating 211. During operation of the gas reloading mechanism, the following pairs of parts move in telescoping relationship: the bolt carrier 501 and the bolt ring 515, the bolt carrier 501 and the bolt 505, the bolt carrier 501 and a receiver (not shown), the bolt carrier 501 and the firing pin 509, the firing pin 509 and the bolt 505, the gas key 503 and the gas tube 511, and the bolt 505 and the barrel 513. There is also sliding movement between bolt cam pin 507 and the bolt 505 and between the bolt cam pin 507 and the bolt carrier 501.

[0049] The bolt carrier 501, the bolt 505, and the bolt cam pin 507 of an AR-15 were given a coating 211 according to the present teachings. The coating 211 varied in thickness from a minimum of 50 μm to a maximum of 750 μm, the maximum occurring on the rails (not shown) of the bolt carrier 501.

[0050] FIG. 6 compares the bolt and bolt carrier temperature of an AR-15 with the coating to one lacking the coating. The guns were fired one every second until the magazine was emptied. Firing continued about 15 seconds later after a magazine exchange. The plot 601 shows temperature as a function of rounds fired for the uncoated AR-15 and the plot 603 shows temperature as a function of rounds fired for the AR-15 with coated parts. The temperatures were substantially lower for the coated gun.

[0051] FIG. 7 is a bar chart showing the results of two trials in which a sand injection machine was used to shoot sand into the ejection port of the coated and uncoated AR-15s. In each case, firing continued until the gun jammed. Between trials, the guns were disassembled, cleaned, and lubricated. In both trials, the coated weapon was able to fire many more rounds before jamming.

[0052] The components and features of the present disclosure have been shown and/or described in terms of certain embodiments and examples. While a particular component or feature, or a broad or narrow formulation of that component or feature, may have been described in relation to only one embodiment or one example, all components and features in either their broad or narrow formulations may be combined with other components or features to the extent such combinations would be recognized as logical by one of ordinary skill in the art.