[marineman]

What is the difference between lead bullets, cast bullets, jacketed bullets, and plated bullets? Thanks.

[ReloaderFred]

First of all, lead bullets can be either cast or swaged. If they're cast, then the molten alloy, usually a mixture of lead, tin and antimony, is poured into a mold, where it hardens into the final shape desired. Then they are pushed through a sizing die and lubricant is applied, either in the lube grooves, or a thin coating of lube is applied to the entire bullet.

Swaged bullets are a lead pellet that is forced into a forming die under great pressure. No heat is involved in this process. The lead is malleable and under pressure can be formed into bullets of various shapes. Once the shape is formed, they are either tumble lubed all over, or a lube groove is formed with cannellure tool, and lube is applied to the groove.

Jacketed bullets are normally what is referred to as "cup and core" bullets. This simply means that the jacket (the cup) is filled with lead (the core). This is done by swaging, forcing the core into the jacket under pressure, with no heat involved. There are variations of this process, but this is the most common.

Plated bullets are normally a pure lead core that has been swaged to the desired shape. Once the proper shape is attained, they are put in a plating machine which plates the lead core with a thin covering of copper through an electro plating process. The pellets are charged with negative electricity and the copper is charged with positive electricity. The copper flows from positive to negative and deposits itself to the lead. When the desired thickness is reached, the process is stopped.

Hope this helps.

Fred

[ArchAngelCD]

Good job with the explanation Fred, very well done Sir...

[marineman]

Thanks. Good post, but what are the pros/cons to the different types of bullets? Thanks.

[NuJudge]

Swaged Lead have great dimensional accuracy, and greatest uniformity in weight. They also can stand the least velocity. Many have bullet lubricants applied that are not smokey on firing, which is a plus.

Many Lead bullets are cast from almost pure Lead, in an effort to keep them cheap. They usually have at least a little Tin, to aid in fillout of the bullet. These should be a good bit harder than swaged, and can be pushed somewhat faster. Most bullet lubricants for these bullets smoke at least a little, and many smoke a lot.

Hard cast Lead has a few percent Tin, and a few percent Antimony, plus perhaps some Arsenic. These can be pushed up to 1100 fps, perhaps a little faster with a smooth, uniform bore. Most bullet lubricants for these bullets smoke at least a little, and many smoke a lot.


A cast bullet with the addition of a small, low cup of copper or gilding metal on the rear (a gas check) can be pushed to 1800 fps in most smooth, uniform bores, and in some bores up to 2200 fps. Most bullet lubricants for these bullets smoke at least a little, and many smoke a lot.


Some swaged Lead bullets are electroplated or by some other means clad in a thin coating of copper. These bullets may do a bit bettter than most cast. There are no lubricants on most of these bullets, so those that don't use lubes don't generate smoke from lube.

Structurally, a jacketed bullet is much harder than a swaged or cast bullet, and can withstand much rougher treatment on firing than cast can. Whacked in the rear by thousands of psi, spun at zillions of rpm, with attendant heat. They are much more forgiving, expansion is not hard to achieve, and velocities achieved can be much higher. A jacketed bullet that is a thousandth or so small will still probably shoot very well, but a swaged or cast bullet that is undersized will cause unending grief. Over extended distances, trajectory is much flatter with jacketed.

With my cast bullets, I like them much harder than most people, and I like gas checks, both of which structurally enhance the bullet, making much higher velocities possible. The hardness of my bullets means they will not expand. If I want to put a big hole in a deer with one of my bullets, it has to start out being big, which is why I like the .44 mag and the .45-70. I don't care if I generate lots of smoke, because most of my shooting is outside, where it causes far less of a problem.

There are alternative schools of thought. Some people like really soft bullets, and they use really fast burning powders, believing that the impact of the powder's pressure will upset the bullet such that a good seal is achieved. Other than with Black Powder, it has never worked for me.

Please take a shower after casting, and if handling Lead wash your hands before eating or smoking. Most Lead poisoning cases are caused by ingesting it.