Method of making a metal injection molded ammunition cartridge

1. A method of making a metal injection molded ammunition cartridge comprising the steps of:

providing an ammunition cartridge mold;

injecting a metal composition into the ammunition cartridge mold to form a metal injection molded ammunition cartridge comprising a bottom surface, an extraction flange positioned around the bottom surface; a side wall extending from the extraction flange toward a nose end to form a nose end aperture; a propellant chamber extending from the nose end aperture to the bottom surface; a primer recess extending partially through the bottom surface; a flash hole extending from the primer recess to the propellant chamber to allow passage between the propellant chamber and the primer recess;

wherein the metal composition comprises stainless steel, ceramic alloys, copper/cobalt/nickel/custom alloys, tungsten, tungsten carbide, carballoy, ferro-tungsten, titanium, copper, cobalt, nickel, alumina oxide, zirconia and aluminum; and

removing the metal injection molded ammunition cartridge from the ammunition cartridge mold.

2. The method of claim 1 , further comprising the step of forming a shoulder in the metal injection molded ammunition cartridge.

3. The method of claim 2 , further comprising the step of forming a neck between the shoulder and the nose end aperture to form a projectile aperture.

4. The method of claim 1 , wherein the metal injection molded ammunition cartridge is a 5.56 mm, 7.62 mm, 308, 338, 3030, 3006, 50 caliber, 45 caliber, 380 caliber, 38 caliber, 9 mm, 10 mm, 12.7 mm, 14.5 mm, or 14.7 mm ammunition cartridge.

5. The method of claim 1 , wherein the metal injection molded ammunition cartridge is 20 mm, 25 mm, 30 mm, 40 mm, 57 mm, 60 mm, 75 mm, 76 mm, 81 mm, 90 mm, 100 mm, 105 mm, 106 mm, 115 mm, 120 mm, 122 mm, 125 mm, 130 mm, 152 mm, 155 mm, 165 mm, 175 mm, 203 mm, 460 mm, 8 inch, or 4.2 inch.

6. The method of claim 1 , wherein the metal composition comprises 102, 174, 201, 202, 300, 302, 303, 304, 308, 309, 316, 316L, 316Ti, 321, 405, 408, 409, 410, 415, 416, 416R, 420, 430, 439, 440, 446 or 601-665 grade stainless steel.

7. The method of claim 1 , wherein the metal composition comprises (a) 2-16% Ni; 10-20% Cr; 0-5% Mo; 0-0.6% C; 0-6.0% Cu; 0-0.5% Nb+Ta; 0-4.0% Mn; 0-2.0% Si and the balance Fe; (b) 2-6% Ni; 13.5-19.5% Cr; 0-0.10% C; 1-7.0% Cu; 0.05-0.65% Nb+Ta; 0-3.0% Mn; 0-3.0% Si and the balance Fe; (c) 3-5% Ni; 15.5-17.5% Cr; 0-0.07% C; 3-5.0% Cu; 0.15-0.45% Nb+Ta; 0-1.0% Mn; 0-1.0% Si and the balance Fe; or (d) 10-14% Ni; 16-18% Cr; 2-3% Mo; 0-0.03% C; 0-2% Mn; 0-1% Si and the balance Fe.

8. A method of making a metal injection molded ammunition cartridge comprises the steps of:

providing an ammunition cartridge mold;

injecting a metal composition into the ammunition cartridge mold to form a metal injection molded ammunition cartridge comprising a bottom surface, an extraction flange positioned around the bottom surface; a side wall extending from the extraction flange toward a nose end to form a nose end aperture; a propellant chamber extending from the nose end aperture to the bottom surface; a primer recess extending partially through the bottom surface; a flash hole extending from the primer recess to the propellant chamber to allow passage between the propellant chamber and the primer recess;

wherein the metal composition comprises

a) 2-16% Ni; 10-20% Cr; 0-5% Mo; 0-0.6% C; 0-6.0% Cu; 0-0.5% Nb+Ta; 0-4.0% Mn; 0-2.0% Si and the balance Fe;

b) 2-6% Ni; 13.5-19.5% Cr; 0-0.10% C; 1-7.0% Cu; 0.05-0.65% Nb+Ta; 0-3.0% Mn; 0-3.0% Si and the balance Fe;

c) 3-5% Ni; 15.5-17.5% Cr; 0-0.07% C; 3-5.0% Cu; 0.15-0.45% Nb+Ta; 0-1.0% Mn; 0-1.0% Si and the balance Fe;

d) 10-14% Ni; 16-18% Cr; 2-3% Mo; 0-0.03% C; 0-2% Mn; 0-1% Si and the balance Fe;

e) 12-14% Cr; 0.15-0.4% C; 0-1% Mn; 0-1% Si and the balance Fe;

f) 16-18% Cr; 0-0.05% C; 0-1% Mn; 0-1% Si and the balance Fe;

g) 3-12% aluminum, 2-8% vanadium, 0.1-0.75% iron, 0.1-0.5% oxygen, and the remainder titanium; or

h) about 6% aluminum, about 4% vanadium, about 0.25% iron, about 0.2% oxygen, and the remainder titanium; and

removing the metal injection molded ammunition cartridge from the ammunition cartridge mold.

9. A method of making a metal injection molded ammunition cartridge comprising the steps of:

injecting molding a metal injection molded ammunition cartridge comprising a bottom surface, an extraction flange positioned around the bottom surface; a side wall extending from the extraction flange toward a nose end to form a nose end aperture; a propellant chamber extending from the nose end aperture to the bottom surface; a primer recess extending partially through the bottom surface; a flash hole extending from the primer recess to the propellant chamber to allow passage between the propellant chamber and the primer recess; wherein the metal injection molded ammunition cartridge comprises 2-16% Ni; 10-20% Cr; 0-5% Mo; 0-0.6% C; 0-6.0% Cu; 0-0.5% Nb+Ta; 0-4.0% Mn; 0-2.0% Si and the balance Fe; 2-6% Ni; 13.5-19.5% Cr; 0-0.10% C; 1-7.0% Cu; 0.05-0.65% Nb+Ta; 0-3.0% Mn; 0-3.0% Si and the balance Fe; 3-5% Ni; 15.5-17.5% Cr; 0-0.07% C; 3-5.0% Cu; 0.15-0.45% Nb+Ta; 0-1.0% Mn; 0-1.0% Si and the balance Fe; 10-14% Ni; 16-18% Cr; 2-3% Mo; 0-0.03% C; 0-2% Mn; 0-1% Si and the balance Fe; 12-14% Cr; 0.15-0.4% C; 0-1% Mn; 0-1% Si and the balance Fe; 16-18% Cr; 0-0.05% C; 0-1% Mn; 0-1% Si and the balance Fe; 3-12% aluminum, 2-8% vanadium, 0.1-0.75% iron, 0.1-0.5% oxygen, and the remainder titanium; or 6% aluminum, about 4% vanadium, about 0.25% iron, about 0.2% oxygen, and the remainder titanium.