Disproving the myth of "Air Gap is dangerous" for Black Powder Cartridges

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When you try to push a granular substance through a bottle neck case, the granules cannot slide past one another in the shoulder but transfer pressure to the case wall at the bottle neck and form a dam at that spot so that the pressure has no easy place to go. My rifle bolt has a flame cut ring around the firing pin hole when the primer came out. The case head expanded so that primers will rattle in the primer pocket. I have no idea what the pressure level was, but thankfully the action was well made. I switched from cream of wheat to kapok and all worked fine.

NRA Benefactor Golden Eagle

All the more reason to fill it up with bp.
 
Good thread. I think air gap is more relevant when you have an obstructed bore and a fresh newly fired oncoming object. The compression is between the obstruction and the fresh oncoming object. But I'm no scientist and certainly not a physicist.

The air gap between the power and the bullet is of less consequence. The idea behind a filler in more modern reloads is to get more consistent ignition. The gallery loads discussed is almost like a squib load. Is there sufficent power to genetrate the gases that will dislodge the bullet from the case and drive it out through the bore?
 
Most of the discussions about gunpowders, be they black powder and smokeless, treat the combustion as if it was linear, like a candle. I have read enough on smokeless to know, combustion is not nice and linear, and what actually happens during combustion is beyond what my little mind can understand. I would assume that black powder needs to be compacted and dense to have a clean, smooth pressure curve.

A smokeless rocket motor class, the teacher talked about the interaction between acoustic and propellant pressure waves, and when they conflicted, the rocket went kaboom. I have read papers describing how unburnt propellants carried along at the front of a pressure wave, reflect pressure waves back at some ignition point, causing over pressure conditions. These papers were all based on computer modeling, and I am sure the models have been updated.

I did find this:


Cookoff of Black Powder and Smokeless Powder

https://www.osti.gov/servlets/purl/1784620

note at the end, while they were not looking for violence of explosion, the authors found some funnies during cook off. Maybe the powder partially combusted, and then, the rest went adding to the violence of the initial burn.

Conventional knowledge can be wrong, but I don't see any harm in compacting the charge of blackpowder, either in a muzzle loader, or cartridge case, as we have been taught. I always seated my Minies, round balls to the charge if I kept the barrel clean.
 
I tried Cream O Wheat filler in .44 WCF. It works ok in a revolver, but ended up with a cooked mess the last 6", in the 23' barrel after the SASS match (50 rounds)
Would never even think of the trouble of using it a cap and ball gun.
 
I would assume that black powder needs to be compacted and dense to have a clean, smooth pressure curve.

I find much less smoke and fouling when well compacted/compressed. Of course it still goes boom, and spits the bullet out the barrel un-compressed.

I've tried for years to tell people pressure curves are not linear, and why just because a specific charge of smokeless, that produces the same overall pressure as a black powder load is not always safe, or the "same difference". (usually in discussions about shooting smokeless in the Trapdoor Springfield)
 
Slamfire said: I would assume that black powder needs to be compacted and dense to have a clean, smooth pressure curve.

That is the reason I was told for not having an air gap between between powder and ball/bullet in a black powder cartridge.
Consistent rate of burn. Consistent burn. Consistent velocity. .
I was not told an air gap between black powder and ball or bullet in a BP cartridge was dangerous.

I have been told that a smokeless powder charge in a BP rifle cartridge should be pressed against the primer with some sort of filler to avoid the powder charge being partially ignited, driven against the bullet base, exploding and sending a secondary pressure wave back to collide with the initial pressure wave. Sounded to me like the explanation of how RDX/Cyclonite "blows down" whereas blasting powder "blows up" when set off on a surface.
 
Dan Rowan and Dick Martin… “I didn’t know that!!”

Those were interesting times. I remember most of them, ....... sort of.

To keep it on topic, I think I'll continue to compress my black powder. I did learn something about fillers in bottleneck cartridges though.
 
OK

Then why was the Frankford Arsenal filling up the extra space in 45 Colt cartridges with only 30 grains of powder with wadding?

Why did 45-70 carbine loads with only 55 grains of powder have wadding to take up the extra space?

I agree, 5 or so grains ain't gonna bulge anything.

But 30 grains in a 45 Colt or 55 grains in a 45-70 without anything taking up the extra space might have a different result.

And no, I am not going to load 55 grains in 45-70 and shoot them off in my Trapdoor, thank you very much.
So what’s the explanation of why it’s ok in smokeless rounds but not with black powder. Just what happens to that air trapped in a cartridge case that differs between the two types of gun powder.
 
So what’s the explanation of why it’s ok in smokeless rounds but not with black powder. Just what happens to that air trapped in a cartridge case that differs between the two types of gun powder.

Black powder burns at a consistent linear rate when its confined. When there's an airgap the flame can get ahead of the charge and make it explode all at once. Loaded in a cartridge it probably won't make any difference. Take some smokeless powder and make a trail out of it and light it. The flame just crawls down the length of it. Do the same with bp and it burns up right now. Smokeless burns the same whether it's confined or not. Compressed bp burns like the smokeless.
 
When there's an airgap the flame can get ahead of the charge and make it explode all at once
While I do want a controlled-burn/compressed column of BP as my 1st choice,
`splain why the original Sharps -- which cuts the tail off the paper cartridge to
spill back into the chamber and leave a considerable air space -- is not a problem?
 
While I do want a controlled-burn/compressed column of BP as my 1st choice,
`splain why the original Sharps -- which cuts the tail off the paper cartridge to
spill back into the chamber and leave a considerable air space -- is not a problem?

You got me. I wondered the same thing when I had my Sharps. My Sharps had a bigger chamber than most. It held 110 grains of loose Swiss 2F with a 490 grain ringtail. The factory recommended charge was 80 grains. That's a lot of airgap. The pamphlet that came with it just said to make sure the powder was touching the bullet but any airgap would turn it from a propellant into an explosive. I'm guessing with relatively small powder charges it wouldn't make any difference but get two or three inches between bullet and powder it would be a whole new ballgame.
 
Roger that.
I now assemble flat-ended cartridges that take a few seconds
longer to form, but solve any number of WhatCouldBe problems.

(Loaded back in `88. You've seen this before... I think) :thumbup:
63-Sharps-Cartridge.jpg
 
I didn't go to all that trouble. I just figured out how deep to seat the bullet in the cartridge so that 80 grains of powder came right to the edge of the breech. 80 grains worked best for me. With 90 grains it lost all semblance of accuracy. 100 grains was actually a bit more accurate than 80 but it had more flash from the breech block than I liked. When the cartridge was cut it lost very little powder. Once the cartridge was made I dipped the bullet in lube and slightly onto the paper. It looks like the air space is taken up by the cartridge but the cartridge is only the thickness of a couple of wraps of wrapping paper bigger than the bullet and the bullet was a sloppy fit in the chamber.

uWE8zTIl.jpg

Cartridge seated in chamber,

Miocs3cl.jpg
 
Shooting was a lot more fun before I got involved in the science of it.

Yep. The more I learn the more I wish I'd stayed dumb. I can't shoot the same guns I used to shoot the way I shot them back in the day. Now a lot of my guns I have to make special ammo for instead of just buying stuff off the shelf and shooting them without a care in the world.
 
I was always taught that air gap in black powder cartridges was dangerous. The logic was from muzzleoading, where if you short-started but forgot to ram down a ball, you ended up with a bore obstruction some 2 feet away from the powder charge, leading to a risk of ringing the barrel.

While that may happen with black powder muzzleloaders, this phenomenon was never considered a risk by individuals loading black powder cartridges in the 1880's (prior to the invention of smokeless powder).

In the 1880's, US government issued black powder gallery cartridges using full-sized 45-70 cases, a 5 grains of black powder, a large air gap, and then a ~.455" (140 gr) round ball seated at the mouth of the case. NO FILLER WAS USED.

View attachment 1097982

Yes, these were .455", which matches the weight of 140gr (though tolerance from .454" to .459" was allowed). See the picture of the winchester "45.5 Armory Practice Round Balls" as further evidence. And no, these were not "collar button" bullets, these were clearly round balls, as marked on the winchester box.

Captain Stanhope Blunt's 1889 Small Arms Firing Regulations further specifies that the powder charge can range from 4gr-7gr, depending on the powder type available (Fg, FFg, FFFg). These balls were coated with a wax lubricant.

View attachment 1097986

And before you cry "well that's only 5 grs of powder, that's nothing", the Frankfort Arsenal made a heavier gallery load in 1902. They used a normal 45-70 case, a charge of 20 grains of black powder (probably FFg), a large air gap, and old leftover 230 gr 45 colt bullets seated at the mouth of the case. (remember, the military had swapped to the 38 long colt 1892 revolver at that point, and didn't officially swap back to 45 colt until 1909, so they had leftover 45 cal revolver bullets)

In essence, a light 45 colt load, loaded into a 45-70 case, and a large air gap in between.

View attachment 1097983

Other companies like UMC (prior to the merger with remington) also manufactured these gallery rounds from the 1880s to at least the 1900's. Note the crimp showing that the 140gr 45 cal round ball is seated far away from the 5 grs of powder.
View attachment 1097984

Not only that, but these air-gapped black powder cartridges were expected to be used hundreds of times over. Regarding the roundball gallery load, Blunt's manual reads "The endurance of the service shells when used only for gallery practice is between 200 and 300 rounds; they should be occasionally washed in warm water, and if they become expanded so as to fit tightly the chamber of the gun they should be resized; this, however, will not often be required. The lead recovered from firing can be re-melted and cast three or four times.


Therefore, we know that leaving an air gap in a black powder rifle cartridge is dangerous is 100% myth. The US army and the Frankfort Arsenal regularly loaded 45-70 with large air gaps for practice rounds.

Filler is not necessary. Seating the bullet to the powder is not necessary. Sure, accuracy may (or may not) be as good as a properly loaded cartridge with compressed powder or fillers, but according to the US government, it is not dangerous to load black powder cartridges with an air gap! In fact, casings from these gallery loads was encouragted to be re-used hundreds of times!

Further, these gallery loads were encouraged over fully charged 45-70 for practice purposes. Many trapdoor service rifles that were stuck in barracks and not used in the Indian wars (e.g., on the east coast) would have seen more light-loaded 45-5-140 gallery loads than fully charged 45-70-405 loads in their lifetimes!

https://americansocietyofarmscollec...s/2019/06/2017-B116-Military-Marksmanship.pdf

The article above tells you more about how frequently gallery loads were used and encouraged for practice. Evidently the US government was a lot more frugal about their training budgets back in the day
Thank you for the excellent information that you provided in post. I happened to own a Frankford arsenal .45 caliber 4 cavity Roundball mould, like what you mentioned, and now I am going to have to try this! Good info sleepysquirrel2.
 
Black powder burns at a consistent linear rate when its confined. When there's an airgap the flame can get ahead of the charge and make it explode all at once. Loaded in a cartridge it probably won't make any difference. Take some smokeless powder and make a trail out of it and light it. The flame just crawls down the length of it. Do the same with bp and it burns up right now. Smokeless burns the same whether it's confined or not. Compressed bp burns like the smokeless.
I ask for a reason, that’s one explanation, although I fully don’t follow it.
A full load of black generates X amount of pressure. An air gap ahead of the burn increases that pressure enough to create a problem ??? The air gap adds energy. ??
 
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