Failure analysis of the M16 rifle bolt

Recently, there have been several occurrences of failure in the bolt of the Ml6 rifle at a United States Army installation. Near the failure location, the bolt was subjected to repeated loading as the Ml6 was fired. In order to determine the stress distribution of the bolt due to the firing process, a geometric element analysis was performed using ProMechanica®. The fracture surface was examined using both an optical stereomicroscope and a scanning electron microscope in order to determine failure initiation and failure mode. It was discovered that the fracture initiated at a localized corrosion pit and propagated by fatigue. A controlled experiment was conducted where 1800 and 3600 rounds were fired using new bolts. After 1800 rounds, a region of wear was observed near the site where fracture occurred in the failed bolt. After 3600 rounds, a notch was observed in this wear region. This suggests two possibilities: firstly, exposure of the base metal may have facilitated the formation of the observed corrosion pits; and secondly, the presence of a notch may facilitate the fracture of bolts in general. In addition, Vickers microhardness profiles were taken on cross-sectional areas near the fillet region and 10 mm away from the failed locking lug. Disparities between microhardness profiles near the fillet region and 10 mm away from this region revealed that the bolt may not have been uniformly case hardened.