Vickers Hardness Measurements of the M855 

Cartridge Case Base 

by Joseph South, Franklin Kellogg, and Dennis Henry 

ARL-TR-4781 April 2009 

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

Aberdeen Proving Ground, MD 21005-5069 

ARL-TR-4781 April 2009 

Vickers Hardness Measurements of the M855 

Cartridge Case Base 

Joseph South, Franklin Kellogg, and Dennis Henry 

Weapons and Materials Research Directorate, ARL 

Approved for public release; distribution is unlimited. 
ii

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1. REPORT DATE (DD-MM-YYYY)

April 2009 

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Final 

3. DATES COVERED (From - To) 

April 2008–September 2008 

4. TITLE AND SUBTITLE 

Vickers Hardness Measurements of the M855 Cartridge Case Base 

5a. CONTRACT NUMBER 

5b. GRANT NUMBER 

5c. PROGRAM ELEMENT NUMBER 

6. AUTHOR(S) 

Joseph South, Franklin Kellogg, and Dennis Henry 

5d. PROJECT NUMBER 

622618AH80 

5e. TASK NUMBER 

5f. WORK UNIT NUMBER 

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

U.S. Army Research Laboratory 

ATTN: AMSRD-ARL-WM-MB 

Aberdeen Proving Ground, MD 21005-5069 

8. PERFORMING ORGANIZATION 

 REPORT NUMBER 

ARL-TR-4781 

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 

Program Manager - Maneuver Ammunition Systems 

SFAE AMO MAS MC 

Bldg. 354 

Picatinny Arsenal, NJ 07806-5000 

10. SPONSOR/MONITOR’S ACRONYM(S) 

PM-MAS 

11. SPONSOR/MONITOR'S REPORT 

 NUMBER(S) 

12. DISTRIBUTION/AVAILABILITY STATEMENT 

Approved for public release; distribution is unlimited. 

13. SUPPLEMENTARY NOTES 

14. ABSTRACT 

Vickers hardness measurements were taken in order to create an axial and radial map of the base of the M855 cartridge case 

base. The goal of this investigation was to evaluate the difference in the material properties between cartridge cases that 

exhibited a dropped primer and those that did not. Dropped primers are instances when during the ignition and combustion of 

the propellant, as well as the kinematic motion of the weapon, the primer becomes separated from the primary cartridge case 

body. The free primer will either be ejected from the weapon or may remain within the weapon, possibly producing a weapon 

stoppage. This research evaluates the hardness of the cartridge case brass near the primer pocket to see if material properties 

are a contributor to dropped primers. 

15. SUBJECT TERMS

M855, 5.56 mm, small caliber, dropped primer 

16. SECURITY CLASSIFICATION OF: 

17. LIMITATION 

OF ABSTRACT 

UU 

18. NUMBER 

OF PAGES 

26 

19a. NAME OF RESPONSIBLE PERSON

Joseph South 

a. REPORT 

Unclassified 

b. ABSTRACT 

Unclassified 

c. THIS PAGE 

Unclassified 

19b. TELEPHONE NUMBER (Include area code) 

410-306-0763 

Standard Form 298 (Rev. 8/98) 

Prescribed by ANSI Std. Z39.18 
iii

Contents 

List of Figures iv

List of Tables iv

Acknowledgments v

1. Introduction 1

2. Experimental 3

2.1 Aliant Techsystems Inc. Samples ....................................................................................3

2.2 ARDEC Samples .............................................................................................................3

2.3 Hardness Testing .............................................................................................................3

3. Experimental Results for Hardness Testing 4

4. Discussion 8

5. Conclusions 8

Appendix. Hardness Testing Data 11

Distribution List 15 
iv

List of Figures 

Figure 1. The M855 cartridge case and the associated hardness gradient (the primer and 

propellant are not shown)...........................................................................................................1

Figure 2. Picture of the A–D hardness locations at the head of the M855 cartridge case 

(dimensional units are in inches). ..............................................................................................2

Figure 3. Cross section of a base of a M855 cartridge showing the common origin axes. ............4

Figure 4. Picture of the 3 × 7 hardness testing array. .....................................................................5

Figure 5. Plot of the hardness results for the 0.4-mm radial location. ............................................5

Figure 6. Plot of the hardness results for the 0.8-mm radial location. ............................................6

Figure 7. Plot of the hardness results for the 1.2-mm radial location. ............................................6

Figure 8. The three-dimensional (3-D) surface plot of the LCAAP dropped primer (DP) data. ....7

Figure 9. The 3-D surface plot of the LCAAP non-DP data. .........................................................7

List of Tables 

Table A-1. Lake City Army Ammunition Plant (LCAAP) dropped primer (DP) data. ...............12

Table A-2. LCAAP non-DP data. .................................................................................................13

Table A-3. U.S. Army Armament Research, Development, and Engineering Center data. .........14
v

Acknowledgments 

The authors would like to thank the Program Manager - Maneuver Ammunition Systems for 

their support and funding of this research. Their support has been invaluable to the development 

of the technology documented in this report. In addition, the authors would like to thank Lake 

City Army Ammunition Plant and the U.S. Army Armament Research, Development, and 

Engineering Center for providing samples to evaluate. 
vi

INTENTIONALLY LEFT BLANK. 
1

1. Introduction 

Small-caliber cartridge cases, such as the M855 ball round, are some of the simplest munitions in 

U.S. Army inventory. The M855 cartridge1

 depicted in figure 1 is comprised of three 

components—a brass cartridge, primer, and propellant charge; it is similar to the ammunition 

that has been used for the last century. This ammunition is used in service and training for the 

M16A2/A3/A4, M4, and M249 weapons. For more than 100 years, brass has served adequately 

and admirably as a material for cartridge cases. Its relatively high strength and ductility provide 

it with the twofold ability to withstand large internal pressures while undergoing deformations 

that provide the means to seal combustion gases in the chamber. These properties have made 

brass the material of choice for cartridge applications. 

Figure 1. The M855 cartridge case and the associated hardness gradient (the primer 

and propellant are not shown). 

The M855 cartridge case is produced from a homogenous annealed brass cup through a series of 

progressive deep draw and anneals. During the manufacturing of the brass cartridge, a 

processing-induced inhomogeneity is created. The processing results in a hardness and 

microstructure gradient along the length of the cartridge case.2 This gradient is produced so that 

the highest hardness within the case occurs at the unsupported region of the cartridge. The 

 1

 M855 Technical Drawing Package. U.S. Army Armament Research, Development, and Engineering Center: Picatinny 

Arsenal, NJ, 1980. 2

 Gibbs, L. E. Cold Working of Brass, with Special Reference to Cartridge (70–30) Brass; The American Society for Metals, 

Cleveland, OH, 1946. 

80

100

120

140

160

180

200

220

0.0 10.0 20.0 30.0 40.0 50.0

Location on Cartridge Case [mm]

Vickers Hardness, 2.5 kg Load [HV]

Max Min
2

lowest hardness occurs in the neck region to allow for bullet crimping and detachment from the 

cartridge during firing. 

The plot in figure 1 shows the minimum and maximum allowable Vickers hardness from a 

2.5-kg load. The hardness profile on the M855 cartridge case ends ~5 mm from the base of the 

cartridge. This final 5 mm of axial distance includes the primer pocket and the extractor groove 

and is largely unsupported by the weapon during the combustion of the propellant gasses. 

During the manufacturing of the cartridge case, there is quality sampling to ensure that the final 

product meets specifications. Cartridge cases are randomly selected and then sectioned axially in 

order to evaluate the hardness profile. For the 5 mm between the base of the cartridge and the 

first point, there are four specific points labeled A, B, C, and D. 

Figure 2 shows a picture of points A–D and their location within the head region of the cartridge 

case. The minimum hardness of these points is specified on the M855 technical drawing 

package.1

 However, these four points are not necessarily representative of the actual hardness 

profile within the head of the cartridge. The purpose of this research is to evaluate the axial and 

radial hardness profile in the head of the cartridge that did and did not exhibit a dropped primer. 

The data provides insight into whether or not the material was a significant contributor to the 

dropped primer event. 

Figure 2. Picture of the A–D hardness locations 

at the head of the M855 cartridge 

case (dimensional units are in 

inches).
3

2. Experimental 

Hardness testing was conducted to create a radial and axial map of the M855 brass cartridge case 

base. The cartridge cases were separated into four distinctive groups. The groups were broken 

down by location, where the cartridge cases were fired, and whether or not the cartridge cases 

exhibited a dropped primer. 

2.1 Aliant Techsystems Inc. Samples 

M855 standard cartridges were tested using standard Lake City Army Ammunition Plant 

(LCAAP) techniques for evaluating cartridge function. Testing was conducted at ambient 

temperatures using a M16A2 rifle. Cartridges were inspected after firing, and samples of 

cartridges that did and did not exhibit a dropped primer were collected. These cartridges cases 

were taken to building 2 at LCAAP, sectioned in half by wire EDM, and then sent to the 

metallography laboratory at LCAAP for mounting and polishing. The sectioned samples were 

mounted in rectangular plastic roughly the shape of the case. The plastic mounting media was a 

clear fast-setting acrylic cold mount. Polishing was performed in a series of progressive steps: 

120-, 320-, and 600-grit sandpaper followed by 6-μm alumina and 0.3-μm alumina powder. All 

of the polishing was done by hand. There were 14 samples for each of the two LCAAP data sets. 

2.2 ARDEC Samples 

Sectioned M855 standard cartridges were received from the U.S. Army Armament Research, 

Development, and Engineering Center (ARDEC). The cartridge cases were sectioned into 

slivers ~3.175 mm in thickness. These samples were from unfired M855 cartridge cases 

produced by LCAAP and shipped to ARDEC. The M855 cartridge slivers were hot mounted in 

epoxy resin using a Struers Prestopress-3. Ten samples were taken to a 1-μm finish through 

grinding and polishing on a Struers Planopol-2 (with a speed of 300 rpm and ranging from 500 to 

4000 grit). 

2.3 Hardness Testing 

All hardness testing was performed at U.S. Army Research Laboratory. Hardness tests were 

conducted under a load of 2.5 kg using a Tukon Wilson 300 microhardness indenter with a 

Vickers indenter TP10415. The indents were arranged in a 3 × 7 array. Twenty-one points were 

taken between the primer pocket and the extractor groove in the base of the cartridge case. The 

21 points were based off of a common origin. The intersection of the extractor groove rim and 

the base of the cartridge case were chosen as the common origin. This point was chosen because 

the intersection was a fairly sharp feature and allowed measurements on either side of the 

cartridge base. Figure 3 is a picture of the base of the M855 cartridge case. The common origin 
4

Figure 3. Cross section of a base of a 

M855 cartridge showing the 

common origin axes. 

is shown by the red-dashed axes. In order to create the 3 × 7array, a radial and axial spacing of 

0.4 mm between points was applied. The first point in the array had coordinates of 0.4 and 

0.3 mm. 

3. Experimental Results for Hardness Testing 

The results of the hardness testing on all of the cartridges cases are shown in figures 4–9. In all 

of the plots, the error bars represent standard deviation. The data presented in these figures is in 

table form in the appendix. 

A picture of the 3 × 7 hardness testing array on the cartridge case base is shown in figure 4. The 

figure shows the uniform spacing of the array and the initial offset of the first point in the array 

from the common origin. The picture shows that the resulting material buildup due to the 

hardness test does not begin to encroach on the neighboring indents in the test array. 

Figures 5–7 present the plots of the Vickers hardness as a function of the axial location for the 

three radial locations on the cartridge base. The plots show hardness measurements obtained 

from the LCAAP cartridges roughly track one another. This is true for all three radial locations, 

where the hardness initially decreases and then increases with increasing axial location. The 

initial decrease in the hardness correlates with the location of the extractor groove in the 

cartridge case. The higher hardness values correlate with the thicker cartridge wall locations at 

the extractor lip and ramp cartridge wall thickness forward of the extractor groove. 

The hardness data from the ARDEC cartridge slivers does not match as well with the LCAAP 

data. Figure 5 shows a higher initial hardness valve for the 0.3 axial locations across all three 

radial locations within the array. After this value, the trend for the ARDEC data roughly 

matches the LCAAP data. The ARDEC and the LCAAP data sets all show a slight decrease in 

the Vickers hardness for the axial points near the extractor groove. 
5

Figure 4. Picture of the 3 × 7 hardness testing array. 

Figure 5. Plot of the hardness results for the 0.4-mm radial location. 

160

170

180

190

200

210

220

230

240

0.3 0.7 1.1 1.5 1.9 2.3 2.7

Axial Location (mm)

Vickers Hardness (HV)

LCAAP DP LCAAP ARDEC
6

Figure 6. Plot of the hardness results for the 0.8-mm radial location. 

Figure 7. Plot of the hardness results for the 1.2-mm radial location.

160

170

180

190

200

210

220

230

240

0.3 0.7 1.1 1.5 1.9 2.3 2.7

Axial Location (mm)

Vickers Hardness (HV)

LCAAP DP LCAAP ARDEC

160

170

180

190

200

210

220

230

240

0.3 0.7 1.1 1.5 1.9 2.3 2.7

Axial Location (mm)

Vickers Hardness (HV)

LCAAP DP LCAAP ARDEC
7

Figure 8. The three-dimensional (3-D) surface plot of the LCAAP dropped primer (DP) data. 

Figure 9. The 3-D surface plot of the LCAAP non-DP data. 

0.3

0.7

1.1

1.5

1.9

2.3

2.7

0.4

0.8

1.2

160

170

180

190

200

210

220

230

240

Vickers Hardness (HV)

Axial Location (mm)

Radial 

Location 

(mm)

230-240

220-230

210-220

200-210

190-200

180-190

170-180

160-170

0.3

0.7

1.1

1.5

1.9

2.3

2.7

0.4

0.8

1.2

160

170

180

190

200

210

220

230

240

Vickers Hardness (HV)

Axial Location (mm)

Radial 

Location 

(mm)

230-240

220-230

210-220

200-210

190-200

180-190

170-180

160-170
8

4. Discussion 

The data in figures 5–7 show that there does not appear to be a distinctive difference in hardness 

between the LCAAP fired cartridges that did and did not exhibit a DP. The large standard 

deviations for the LCAAP data sets make the DP and the non-DP data overlap. There are some 

differences between the averages of the two data sets, particularly for the 0.4-m radial location of 

figure 5. However, as the radial location increases (e.g., the hardness locations toward the 

primer pocket of the cartridge case), the LCAAP dropped and non-DP data sets nearly 

overlapped one another. This is important to note as the metal in the cartridge case base near the 

primer pocket should have a greater influence on whether or not a primer would drop from the 

cartridge case. Figures 8 and 9 are 3-D surface plots of the LCAAP data sets. As expected, there 

is a great deal of similarity between the two figures. A noticeable feature is that the non-DP 

surface plot in figure 9 has a greater breadth of low hardness in the middle of the data set. 

Comparison of figures 5–7 showed similar trends, with axial location between ARDEC and 

LCAAP. There were minor differences between the data sets. One explanation is that the 

difference in the data sets is equivalent to the differences found within normal manufacturing. 

The cartridge cases received from the two different sites, ARDEC and LCAAP, were likely 

manufactured at different times or on different tooling. The production facility at LCAAP 

operates multiple manufacturing lines on which there are numerous tooling sets. There are over 

100 sets of tools used to manufacture cartridge cases. This introduces a great deal of variability 

within the final product. An alternate explanation is that the firing of the cartridge case resulted 

in modifications to the hardness profile. This is unlikely given the limited amount of 

deformation the cartridge case sees during firing3

 compared to the metal drawing process in 

manufacturing. In order to fully evaluate this possibility, additional testing of a larger data set 

would need to be conducted. 

5. Conclusions 

This research presented experiments and results to evaluate the axial and radial hardness profile 

in the head of the M855 cartridge case. The data showed distinct trends in the axial and radial 

hardness in the head of the cartridge case. The hardness of all three cartridges groups 

investigated showed a radial decrease in the hardness of the cartridge case head near the 

extractor groove. Hardness increased axially, moving away from the extractor groove. Testing 

conducted on cartridge cases that did and did not exhibit a DP showed little difference in the 

 3 South, J.; Burton, L. Finite Element Modeling and Analysis of an M855 Cartridge; ARL-TR-3301;U.S. Army Research 

Laboratory: Aberdeen Proving Ground, MD, September 2004.
9

radial and axial hardness. The data provided insight into whether or not the material was a 

significant contributor to the DP event. The data between the fired and the unfired cartridges 

cases showed similar trends, but small differences in the averages were noted. The difference in 

these data sets was from normal manufacturing and lot-to-lot variation.
10

INTENTIONALLY LEFT BLANK.
11

Appendix. Hardness Testing Data 
12

Table A-1. Lake City Army Ammunition Plant 

(LCAAP) dropped primer (DP) data. 

Point 

Average 

Hardness 

(HV) 

Std. Dev. 

Hardness 

(HV) 

X-Cord 

(mm) 

Y-Cord 

(mm) 

1 184.77 4.48 0.4 0.3 

2 192.36 10.98 0.4 0.7 

3 192.91 8.51 0.4 1.1 

4 190.34 6.70 0.4 1.5 

5 193.20 5.31 0.4 1.9 

6 199.93 6.86 0.4 2.3 

7 204.64 11.28 0.4 2.7 

8 188.54 9.78 0.8 0.3 

9 191.28 5.70 0.8 0.7 

10 189.91 11.44 0.8 1.1 

11 184.51 5.57 0.8 1.5 

12 186.61 6.93 0.8 1.9 

13 195.07 8.48 0.8 2.3 

14 200.39 5.34 0.8 2.7 

15 196.40 11.19 1.2 0.3 

16 190.69 7.70 1.2 0.7 

17 186.54 9.62 1.2 1.1 

18 194.07 8.49 1.2 1.5 

19 200.94 8.16 1.2 1.9 

20 207.90 10.35 1.2 2.3 

21 214.96 8.52 1.2 2.7 

Note: HV = Vickers hardness. 
13

Table A-2. LCAAP non-DP data. 

Point 

Average 

Hardness 

(HV) 

Std. Dev. 

Hardness 

(HV) 

X-Cord 

(mm) 

Y-Cord 

(mm) 

1 188.23 11.26 0.4 0.3 

2 194.67 6.69 0.4 0.7 

3 186.13 11.08 0.4 1.1 

4 183.67 7.78 0.4 1.5 

5 193.35 7.45 0.4 1.9 

6 200.98 8.59 0.4 2.3 

7 206.40 6.80 0.4 2.7 

8 188.01 10.97 0.8 0.3 

9 191.95 7.36 0.8 0.7 

10 184.07 8.39 0.8 1.1 

11 179.91 5.70 0.8 1.5 

12 187.71 7.53 0.8 1.9 

13 196.86 7.23 0.8 2.3 

14 198.58 8.14 0.8 2.7 

15 195.22 14.11 1.2 0.3 

16 190.71 6.83 1.2 0.7 

17 187.44 10.45 1.2 1.1 

18 190.77 6.99 1.2 1.5 

19 198.98 6.34 1.2 1.9 

20 204.74 6.18 1.2 2.3 

21 215.06 9.78 1.2 2.7 

Note: HV = Vickers hardness. 
14

Table A-3. U.S. Army Armament Research, Development, 

and Engineering Center data. 

Point 

Average 

Hardness 

(HV) 

Std. Dev. 

Hardness 

(HV) 

X-Cord 

(mm) 

Y-Cord 

(mm) 

1 208.19 6.57 0.4 0.3 

2 198.01 15.33 0.4 0.7 

3 191.19 11.31 0.4 1.1 

4 190.84 7.74 0.4 1.5 

5 197.78 7.305 0.4 1.9 

6 200.8 9.00 0.4 2.3 

7 205.86 14.69 0.4 2.7 

8 194.84 8.65 0.8 0.3 

9 199.86 9.63 0.8 0.7 

10 187.82 8.91 0.8 1.1 

11 184.88 9.11 0.8 1.5 

12 188.83 9.25 0.8 1.9 

13 199.4 7.94 0.8 2.3 

14 192.17 8.64 0.8 2.7 

15 200.13 17.52 1.2 0.3 

16 200.92 10.05 1.2 0.7 

17 194.63 8.65 1.2 1.1 

18 187.21 5.80 1.2 1.5 

19 193.62 12.74 1.2 1.9 

20 201.81 11.88 1.2 2.3 

21 205.08 12.42 1.2 2.7 

Note: HV = Vickers hardness. 
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