A Plasma Process to Produce Refractory Metal Clad Continuous Lengths of Copper Alloy Gun Rails

An electromagnetic launcher also known as a rail gun is a major gun system the Navy is developing for long range fire support. A refractory metal cladding on a copper rail is enabling for the successful high fire rate and long life of the electromagnetic launcher. Heretofore, a successful process for adherently cladding/coating a refractory metal onto a copper rail that withstands the rigors of an electromagnetic launcher has not been demonstrated. In Phase I it was demonstrated a plasma transferred arc (PTA) process was capable of producing a refractory metal clad copper gun rail which withstood bending and thermal shock testing. The Phase II is to further develop PTA cladding processing and produce experimental gun rails for multiple shot testing at the University of Texas. The PTA system is capable of processing non-planer gun rail cross-sections in continuous lengths which will also be demonstrated in the Phase II program.