Design, analysis, manufacturing, and testing of a composite gun barrel.

User expects his weapon to be light and reliable and to perform multiple times firing per unit time at the same time. In today's technology, the maximum number of firings can be made per unit time with steel barreled weapons, but in composite barrels; many problems occur due to overheating, strength and reliability. Meeting these opposite demands is an engineering problem. In this study, the design of a composite‐steel combination light gun barrel is studied. Firstly, pressure distribution through the barrel has been calculated using Vallier‐Heydenreich method. According to the calculations, analysis has been conducted using both steel barrel and composite barrel. After the analysis, a composite barrel has been manufactured and testing has been conducted on an all‐steel barrel and the manufactured composite barrel. Composite is carbon fiber and resin is epoxy resin. In composite material, carbon fiber is preferred at the rates of 50% and 60%, the material of the steel barrel is AISI 416R stainless steel. The manufactured steel barrels have the same outer diameter but different wall thickness ratios, firing tests were conducted in such a way that the number of shots per unit time was the same. Highlights: Stress distribution within a gun barrel was calculated using Vallier‐Heydenreich method.Design and finite element analysis analysis for an all‐steel gun barrel and a composite gun barrel was conducted.A composite gun barrel was manufactured; by using composite materials, the barrel was lightened by 24.8%.The manufactured composite gun barrel and an all‐steel gun barrel were tested by firing over 2500 shots. [ABSTRACT FROM AUTHOR]