Manufacturing of a Composite Tailcone for 

an XM-1002 Training Round 

by James M. Sands, Uday Vaidya, George Husman, 

Juan Serrano, and Robert Brannon 

ARL-TR-4381 February 2008 

Approved for public release; distribution is unlimited. 
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Army Research Laboratory 

Aberdeen Proving Ground, MD 21005-5069 

ARL-TR-4381 February 2008 

Manufacturing of a Composite Tailcone for 

an XM-1002 Training Round 

James M. Sands 

Weapons and Materials Research Directorate, ARL 

Uday Vaidya, George Husman, and Juan Serrano 

University of Alabama at Birmingham, AL 

Robert Brannon 

National Composite Center, Kettering, OH 

Approved for public release; distribution is unlimited. 
ii

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1. REPORT DATE (DD-MM-YYYY)

February 2008 

2. REPORT TYPE 

Final 

3. DATES COVERED (From - To) 

2004–2005 

5a. CONTRACT NUMBER 

5b. GRANT NUMBER 

4. TITLE AND SUBTITLE 

Manufacturing of a Composite Tailcone for an XM-1002 Training Round 

5c. PROGRAM ELEMENT NUMBER 

5d. PROJECT NUMBER 

W911NF-04-2-0018 

5e. TASK NUMBER 

6. AUTHOR(S) 

James M. Sands, Uday Vaidya,* George Husman,* Juan Serrano,* 

and Robert Brannon†

5f. WORK UNIT NUMBER 

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 

U.S. Army Research Laboratory 

ATTN: AMSRD-ARL-WM-MD 

Aberdeen Proving Ground, MD 21005-5069 

8. PERFORMING ORGANIZATION 

 REPORT NUMBER 

ARL-TR-4381 

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11. SPONSOR/MONITOR'S REPORT 

 NUMBER(S) 

12. DISTRIBUTION/AVAILABILITY STATEMENT 

Approved for public release; distribution is unlimited. 

13. SUPPLEMENTARY NOTES 

*

University of Alabama, Birmingham, AL 

†

National Composite Center, Kettering, OH

14. ABSTRACT 

Recent work on the cost-effective manufacturing of an extrusion-compression molded, long-fiber thermoplastic (LFT) 

XM-1002 tailcone for training rounds of military ammunition is compiled in this technical report. During the last decade, the 

engineering community has expanded the use of thermoplastic composites due to their inherent advantages over traditional 

thermoset composites including: high toughness, inexpensive resin systems, short processing cycle times, recycling potential, 

excellent environmental resistance, and damage tolerance. Thermoplastic composites have a wide range of applications in the 

automotive and transportation industry for replacement of heavy metal components and/or structures. LFT composites are a 

family of compounds with reinforcing fiber strands (fiber lengths typically range from 6 to 24 mm) combined with a 

thermoplastic matrix (which can be any commodity or engineering thermoplastic polymer). LFTs have the ability to be molded 

into complex geometries featuring ribs, knock-outs, and thickness variations within the parts. LFT parts/components can be 

processed by extrusion-compression, injection-compression, and/or injection-molding processes. 

15. SUBJECT TERMS

long fiber thermoplastics, compression molding, resins/materials – thermoplastics, applications – military, XM-1002, 

manufacturing, composite 

16. SECURITY CLASSIFICATION OF: 

19a. NAME OF RESPONSIBLE PERSON

James M. Sands 

a. REPORT 

UNCLASSIFIED 

b. ABSTRACT 

UNCLASSIFIED

c. THIS PAGE 

UNCLASSIFIED

17. LIMITATION 

OF ABSTRACT 

UL 

18. NUMBER 

OF PAGES 

 22 19b. TELEPHONE NUMBER (Include area code) 

(410) 306-0878 

Standard Form 298 (Rev. 8/98) 

Prescribed by ANSI Std. Z39.18
Contents 

List of Figures iv

List of Tables iv

Acknowledgments v

1. Thermoplastic Composite Manufacturing 1

2. Kinetic-Energy Penetrator 3

3. Material Selection 4

4. Manufacturing 4

5. Molding 6

6. Summary 10

7. References 11

Distribution List 12 

iii
List of Figures 

Figure 1. Effect of glass fiber length on composite properties.......................................................1 

Figure 2. Hot-melt impregnation line for production of thermoplastic composite pellets and 

tape (courtesy: National Composite Center).............................................................................2 

Figure 3. Extrusion compression molding line for LFT (courtesy: National Composite 

Center)........................................................................................................................................3 

Figure 4. Molding concept for manufacturing of plastic tailcones: (a) exploded view and (b) 

cross section...............................................................................................................................5

Figure 5. Cross section of LFT composite tailcone showing detail on inserts used during 

molding trials of hollow-back thermoplastic composite tailcones: (a) threaded insert and 

(b) beaded insert.........................................................................................................................5 

Figure 6. Back-filled LFT composite tailcone cross section. .........................................................6 

Figure 7. Molded thermoplastic composite tailcone, aluminum inserts, and aluminum 

tailcone.......................................................................................................................................7 

Figure 8. (a) Back-filled cones produced during second molding trials using neat nylon 66 

(white cone), 10% (right) and 40% W glass LFT (left). (b) Detail showing as produced 

hollow-back tailcone (first molding) and back-filled version (second molding).

f

.....................8 

Figure 9. Cross-section image of neat nylon 66 tailcone and detail on thermally induced 

cracks. ........................................................................................................................................8 

Figure 10. Cross-section image of 10% W nylon 66 tailcone and detail on porosity and 

thermal stress induced crack.

f

.....................................................................................................9 

Figure 11. Cross-section image of 40% W nylon 66 tailcone and detail on minor crack 

formation at the edge of the tailcone.

f

.........................................................................................9 

List of Tables 

Table 1. Physical, mechanical, and thermal properties of nylon 66 (PA) long glass fiber.............7 

iv
Acknowledgments 

Support provided by the U.S. Army Research Laboratory (ARL), Aberdeen Proving Ground, 

MD, under a cooperative agreement ARL contract no. W911NF-04-2-0018 is gratefully 

acknowledged. The authors are grateful to James Garner and Peter Dehmer of ARL for helpful 

discussions. 

v
INTENTIONALLY LEFT BLANK.

vi
1. Thermoplastic Composite Manufacturing 

Long fiber-reinforced thermoplastics (LFTs) have received a lot of attention in the automotive 

industry due to the improved mechanical properties that can be achieved and the relative ease of 

fabrication and handling of these materials (1). The global use of LFTs is expected to grow from 

around 18 million kg (40 million lb) in 2001 to 34 million kg (75 million lb) in 2007 (2). Long 

fibers (fiber lengths between 12 and 50 mm) provide elastic modulus and the tensile strength 

close to 90% of that obtained using continuous fibers (3) (figure 1). The main advantage of 

LFTs is that unlike continuous fiber reinforced composites, they can be processed using 

traditional plastics molding equipment and therefore parts can be manufactured at medium 

volume rates with excellent consistency and repeatability. The use of a thermoplastic matrix 

gives the molder the ability to modify and enhance the properties of the resin by blending 

additives, fillers, and fire retardants depending on the nature of the application (4). 

0.0

0.2

0.4

0.6

0.8

1.0

1.2

0.1 1 10 100 Length (mm)

Relative Property Lev

Modulus

Strength

Impact

Processibility

Figure 1. Effect of glass fiber length on composite properties (3). 

LFTs can be manufactured using conventional extrusion-compression molding and/or injectionmolding techniques. Most of the applications in which LFTs have been commercialized include 

a polypropylene (PP) matrix and E-glass fiber reinforcement. In the last few years, there have 

been interesting innovative developments focused on automation of these processes that increase 

the output rate, such as D-LFT, S-LFT and E-LFT (1). Variations of these processes have also 

been used to produce sheets starting with neat resins and fiber rovings (4). Advances have also 

led to the utilization of a wide variety of engineering thermoplastics as matrix materials along 

with other fiber reinforcements (2). 

1
Compression molding is an established composite-processing technique which was originally 

developed for the stamping of thermoset matrix composite pre-impregnated sheets to complex 

geometries. In this process, a pre-impregnated sheet molding compound (SMC) is heated to its 

softening point, and then transferred to a compression-molding press, where the sheet is formed 

using double-sided tooling (aluminum, steel, or epoxy). The important feature of this process is 

that during forming, the material is not subjected to high levels of stress as in injection molding, 

and therefore the reinforcement is not damaged (5). In the case of LFT-compression molding, 

the process begins by hot-melt impregnating reinforcing fibers with a thermoplastic matrix and 

subsequently chopping the continuous tow into pellets of a set length (between 8 and 50 mm) 

(figure 2). Hot-melt impregnation is performed by wire coating, crosshead extrusion, and/or 

thermoplastic pultrusion (3). The long fiber pellets are fed into the hopper of a single-screw, 

low-shear extruder. A molten charge of a predetermined size and shape (usually cylindrical) is 

extruded, which is then transferred by an operator (or a robot) to the compression-molding press 

for the forming operation (figure 3). 

 

Take Up [7]

Pelletizer[6] 

Puller[5] 

Extruder [3] 

Chiller[8] 

Cooled Rollers[4] 

Let-Off [1] 

Impregnation Chamber [2]

Figure 2. Hot-melt impregnation line for production of thermoplastic composite pellets and tape (courtesy: 

National Composite Center). 

Cycle times for this process can be as short as one part per minute, and the production rate can be 

accelerated by utilizing multiple cavity tools. The extrusion-compression molding is ideal for 

small-to-medium sized semi-structural components for the automotive industry and has already 

been implemented in applications such as automotive side panels, bumper beams, dash boards, 

underbody panels, and hoods. The potential for using thermoplastic LFT technology in other 

applications such as military components, infrastructure and aerospace is expanding due to the 

cost-effective nature of the resins and processing methods. 

2
150 mm C.A. Lawton Plasticator 

400 Ton Down-Acting Compression Molding Press

Chopped 

impregnated 

fibers is fed 

here 

Plasticated 

Output collected 

here 

Plasticated Output is 

transferred here for 

compression molding 

Figure 3. Extrusion compression molding line for LFT (courtesy: National Composite Center). 

2. Kinetic-Energy Penetrator 

A kinetic-energy (KE) penetrator is one of the ammunition types used by the military as the main 

ammunition on tanks. A KE projectile is comprised of three parts: (1) the nosecone, tailored for 

aerodynamics and penetration; (2) the projectile mass rod, where most of the projectile’s mass is 

concentrated to achieve a high KE during impact; and (3) the tailcone, which is aerodynamically 

designed to induce drag and stabilize the projectile by inducing rotation. In the field, the 

stabilizer used in the KE projectile includes a finned assembly, but, in the case of training 

rounds, the use of fin-stabilized rounds is not required. Instead, a grooved stabilizer made of 

machined aluminum is used. The projectile is encapsulated in a shell and it is fired by the 

combustion of a propellant inside the chamber (6). 

The use of a plastic tailcone for a KE penetrator training round was investigated by Garner et al. 

(7). From this study, it was evident that by manufacturing the tailcone using a conventional 

plastic processing route such as injection molding, significant cost savings could be achieved 

when compared to an aluminum-machined tailcone that is currently used. Studies by Garner 

3
et al. (7) also demonstrated that select commercial polymers could withstand the extreme 

conditions witnessed during firing inside the barrel, and the pressure drop during the muzzle exit 

of the projectile. However, the cost of the proposed polymer resins (poly ether ether ketone 

[PEEK]) in their study is relatively high and currently runs about $96/kg ($44/lb) (8). In this 

study, the manufacturing of a thermoplastic composite tailcone made of nylon66/glass LFT is 

discussed. The focus of this work is to demonstrate the feasibility of producing a thermoplastic 

tailcone that is both cost-effective and easy to process in a medium-volume production 

environment. 

3. Material Selection 

Several high-performance materials have been investigated for use in a training projectile for 

military ammunition. Both thermoset and thermoplastic polymers, fiber-reinforced, and 

unreinforced polymers have been field tested under high pressures and accelerations experienced 

during firing of the projectile with mixed results (9). The extreme loading conditions witnessed 

by the sub-components inside the bore and in the transition loads at the muzzle end must be 

taken into account during the material selection process. A detailed finite-element analysis 

(FEA) based study was conducted (10) based upon which long-fiber-reinforced polyamide 

(nylon (wF = 10%, and wF = 40%) was chosen for this application. 

4. Manufacturing 

Presently, the all-aluminum tailcone is manufactured from aluminum bar stock which is 

manually fed to a computer numeric controlled (CNC) mill and machined down to closetolerance (figure 4). The estimated machining time for these parts is about 5 hr followed by 

surface-finishing operations. Extrusion-compression molding of LFTs was chosen as the 

manufacturing process in this study, since it met the requirements of low cycle time and retention 

of fiber integrity during processing. 

A single-cavity steel tool was developed for the compression molding of the LFT thermoplastic 

tailcone. The tool was designed to have enough flexibility that would allow some changes in the 

design without major tooling re-engineering. The conceptual schematic for molding the plastic 

tailcone is presented in figure 4. A four-component, compression-molding tool featured a top 

lid, an interchangeable block, a cap, and a solid cavity. The solid female tool includes the 

external geometry of the tailcone and the spin grooves. The interchangeable block allows for the 

manufacturing of a hollow-back tailcone or solid-back tailcone, depending on the desired shape. 

The cap allows for insert positioning previous to the molding and facilitates the demolding 

4
 

Solid Cavity 

Cap 

Interchangeable 

Block 

Top Lid 

Molded Part 

Figure 4. Molding concept for manufacturing of plastic tailcones: (a) exploded view and (b) cross section. 

operation. This cap includes the inner threads that assemble to the back of the KE projectile. 

The molten charge is placed in the solid cavity and formed by the pressure exerted during closing 

of the press to the final shape. 

An internal insert made of steel was used in order to adapt the existing threads of the aluminum 

tailcone. Several insert designs were considered, and two final concepts were chosen for the 

molding trials. Two insert configurations were used; a fully threaded insert and a partially 

threaded beaded insert. The cross-sectional view of the LFT tailcone with the two types of 

inserts (for the case of the hollow-back tailcone) is shown in figure 5. 

 

a) b) 

Figure 5. Cross section of LFT composite tailcone showing detail on inserts used during molding trials of hollowback thermoplastic composite tailcones: (a) threaded insert and (b) beaded insert. 

5
6

Straight-threaded aluminum inserts, 95 and 100 mm long, were used when molding the backfilled LFT composite tailcone. The cross section of the back-filled tailcone solid model is shown 

in figure 6. 

Figure 6. Back-filled LFT composite tailcone cross section. 

5. Molding 

A 400,000 kg (400 metric ton) press was used to mold the LFT composite tailcone. The initial 

set of tail cones was molded using nylon 66/E-glass LFT with 40% Wf (table 1). The second set 

of tail cones was molded using nylon 66/E-glass LFT with 10% Wf. The two fiber loadings 

represent a high- and low-fiber-loading case respectively, and demonstrate the flexibility of the 

extrusion-compression molding process. The aluminum insert was screwed to the cap and 

placed inside the solid cavity of the tool prior to LFT charge placement. The temperature of the 

bottom cavity of the mold was raised to 121 °C (250 °F). The plasticator was set at 287 °C 

(550 °F). Once the extruded charge was transferred from the plasticator to the mold, the press 

was lowered and a 300,000-kg (300-metric-ton) force was applied to consolidate the LFT charge 

around the insert. The mold was cooled in air and demolded. The manufacturing cycle time was 

approximately 60 s. The molded nylon LFT 40% Wf thermoplastic composite hollow-back 

tailcones are shown in figure 7, alongside the all-aluminum tailcone and some of the inserts used 

in the first molding trials. 
Table 1. Physical, mechanical, and thermal properties of nylon 66 (PA) long glass fiber. 

Physical Properties English Metric ASTM 

Primary additive 50% 50% — 

Specific gravity 1.57 1.57 D 792 

Molding shrinkage 

1/8-in (3.2-mm) section 0.0010–0.0030 in/in 0.10%–0.30% D 955 

Mechanical Properties 

Impact strength, Izod 

Notched 1/8-in (3.2-mm) section 5.0 ft-lb/in 267 J/m D 256 

Unnotched 1/8-in (3.2-mm) section 24.0 ft-lb/in 1281 J/m D 4812 

Tensile strength 35000 psi 241 MPa D 638 

Tensile elongation 2.0%–3.0% 2.0%–3.0% D 638 

Tensile modulus 2.50 × 106

 psi 17238 MPa D 638 

Flexural strength 50000 psi 345 MPa D 790 

Flexural modulus 2.30 × 106

 psi 15858 MPa D 790 

Thermal Properties 

Deflection temperature 

At 264 psi (1820 kPa) 460 °F 238 °C D 648 

At 66 psi (455 kPa) 475 °F 246 °C D 648 

Aluminum 

XM1002 

LFT 

GLass/Nylon 

Figure 7. Molded thermoplastic composite tailcone, 

aluminum inserts, and aluminum tailcone. 

The second molding trials were performed using 0% (neat nylon 66), 10%, and 40% Wf LFT 

pellets under the same processing conditions previously described. The second molding attempt 

concentrated on the manufacture of the back-filled tailcones. Cost analysis comparing an allaluminum vs. an LFT composite tailcone as well as microstructural studies were conducted to 

evaluate the volume fractions, fiber lengths, and fiber orientations developed in the tailcone by 

burn-off studies (11). To minimize the effect of thermal stresses developed during the cooling 

cycle of the tailcones, moldings were cooled using different cooling rates and under different 

conditions. 

7
The produced back-filled cones are shown in figure 8. Once they were visually inspected, they 

were sectioned and polished to assess the quality of the molded parts. The tailcones molded with 

pure nylon showed severe external cracks induced by the excessive shrinkage of the polymer 

during the cooling stage (figure 9) and were discarded for any further analysis. 

 

a) b) 

Figure 8. (a) Back-filled cones produced during second molding trials using neat nylon 66 (white cone), 10% (right) 

and 40% Wf glass LFT (left). (b) Detail showing as produced hollow-back tailcone (first molding) and 

back-filled version (second molding). 

 cracks 

cracks 

Figure 9. Cross-section image of neat nylon 66 tailcone and detail on thermally induced cracks. 

The tailcones molded with a glass fiber loading of 10% Wf showed small signs of warpage. The 

tailcones molded with 40% Wf did not show any significant signs of processing induced flaws. 

Once the visual inspection was finished, both the 10% and the 40% Wf loaded cones were 

sectioned to determine the porosity and the occurrence on internal flaws. The cross-section 

images for the 10% and 40% moldings are shown in figures 10 and 11. It is clear that the 

8
 

Figure 10. Cross-section image of 10% Wf nylon 66 tailcone and detail on porosity and thermal stress 

induced crack. 

 

Figure 11. Cross-section image of 40% Wf nylon 66 tailcone and detail on minor crack formation at 

the edge of the tailcone. 

increase in fiber loading on the part restricts the crack formation due to thermal stresses and 

reduces thermally induced flaws (as the glass fiber content increases, the CTE is lowered). The 

internal cracks observed on the 10% Wf moldings are highly developed and can affect the 

9
10

performance of the tailcones significantly during firing. There were some small cracks observed 

on the 40% moldings, but these are not expected to be a detriment to the structural integrity due 

to their location and size. To minimize the probability of thermal cracking inside the cones the 

upper tool temperature was increased and the resident time in the press during cooling was 

adjusted to 3 min. 

6. Summary 

Thermoplastic composites can be used effectively in replacing metal components that require 

extensive machining, such as in the case of an all-aluminum tailcone used in a KE penetrator. 

Long fiber thermoplastic-composite tailcones with hollow-back and back-filled configuration 

were manufactured successfully using extrusion-compression molding. Processing issues related 

to optimum resident time in the press and upper- and lower-tool temperatures were optimized to 

produce good quality moldings. A projected 230% cost savings is realized in adopting the long 

fiber thermoplastic tailcone in place of an all-aluminum one, for training round applications. 

Successful firing trials have been conducted with the 40% LFT filled nylon 66 tailcones; 

furthermore, the projectiles stabilized by the thermoplastic-composite tailcone hit the desired 

location in the target. 
7. References 

1. Häuptli, M.; Winski, J. Plastics Additives and Compounding 2003, 39.

2. Knights, M. Plastics Technology. Gardner Publications 2003, 04. 

3. Thomason, J.; Vlug, M. A. Composites: Part A. 1996, 27A, 477–484. 

4. Schut, J. Plastics Technology. Garner Publications 2002, 04. 

5. Advani, S.; Sozer, E. Process Modeling in Composites Manufacturing; Marcel Dekker Inc.: 

New York, 2002. 

6. Thomson, T.; Kamdar, D. The National Defense Industrial Association 36th Annual Gun 

and Ammunition Symposium and Exhibition 2001. 

7. Garner, J.; Bundy, M.; Newill, J. Development of a Plastic Stabilizer for the M865 Training 

Projectile; ARL-MR-445; U.S. Army Research Laboratory: Aberdeen Proving Ground, 

MD, 1999. 

8. http://www.plasticstechnology.com/pricing/ (accessed July 2005). 

9. Bundy, M. Plastic Fins for Kinetic Energy (KE) Penetrators; ARL-TR-1267; U.S. Army 

Research Laboratory: Aberdeen Proving Ground, MD, 1996. 

10. Vaidya, U.; Villalobos, A.; Serrano, J.; Husman, G.; Sands, J. SAMPE International 

Technical Conference, 2005; Vol. 37. 

11. Vaidya, U.; Janowski, G. Microstructure in LFT Composite Molded Tailcone. Journal 

submission draft. 

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