One of the most significant inventions in the history if firearms is the self-contained, metallic cartridge. It includes four parts: bullet, primer, brass, and powder. Since illustrations of the parts of cartridges are a standard part of hunter-ed programs have been around for decades, any recent graduate should be able rattle off this information. Our bright-eyed hunter might not realize that these four components have a profound impact on cartridge performance. It doesn’t matter if we’re talking accuracy, reliability or lethality. Not to judge the kid, but primers are not something he or she knows. Our young hunter isn’t the only one who doesn’t understand this concept. The primer is the most poorly understood of all the building blocks of a cartridge. Plus, the primer technology has made it possible to produce better ammunition.
Even the most knowledgeable reloaders can be a bit overwhelming for laymen. They will often go into detail about how to make their bullets or prepare brass to strict standards.
When asked by shooters to explain what a primer is, they often refer to it as being similar to a match that ignites powder at the cartridge’s tail end, initiating the process that propels the bullet along its path.
Each analogy is incorrect. The primer serves a more complex function than either a matchlighting or spark plug firing.
Understanding the role of primers requires that we look at the chemistry behind the volatile slurry created between the primer cup and anvil. Primer compound, also known as gunpowder, is one of the most dangerous substances in ammunition and firearm manufacturing. Although gunpowder can be flammable and the chemicals used in blue steel barrels aren’t something you would want to ingest, a primer compound that is poorly handled will result in a smoking crater. Every primer comes with its own protective cutout inside the box in which it is shipped.
Barium nitrate, which adds oxygen to the explosive, is the oxidizer. Lead styphnate serves as the primary explosive in modern primers. Tetrazene is a sensor that makes it easier for the primer to explode. The rest of the elements are fuels.
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There are many different ingredients used in primer compounds. However, the general formulas have remained relatively stable over the decades due to ammo makers (and more importantly their customers) being stubbornly hesitant to alter any recipe from the tried-and-true.
Primer must be consistent. Primer should not pop off when struck by a firingpin, regardless of how cold it is or how dirty or greasy the ignition system. This can cause shooters to be extremely cranky and unforgiving. Prime directive is to ignite the powder charge at all costs, even if it means losing accuracy.
Primer technology is currently undergoing a revolution, despite its conservative nature. The fourth member in the cartridge quartet, however, has seen some interesting developments.
Federal Ammunition engineers created the most recent generation of primers. Catalyst is the name of the new primer. It offers several improvements over previous primer compounds.
But before we get to the benefits of Catalyst primers let’s answer the question above. What are primers?
The Primer Event
A primer can be viewed as a mini volcano, rocket engine or mini volcano that produces a powerful mix of hot, burning sulfur and gunpowder. This mix was created by mixing lead-styphnate, which is the main explosive, and barium nitrate, an oxidizer (which adds oxygen into the flame). These two elements comprise about 80 percent the primer compound. A few fuels (16%) and a little bit of tetrazene (4%), are added. These substances help the compound ignite when it hits the primer cup.
The firing pin can damage the base which is a small metal cup. The friction causes the anvil’s jaws to pinch the primer compound. This creates friction which ignites the compound and ignites the powder charge.
This short eruption can last between 200 and 1,500 milliseconds (one millionths of a second is one microsecond). Three things occur: The primer compound creates flame, hot particulate matter, such as slag, and it creates an atmosphere of pressure.
To ensure that our ammunition is consistent from shot to shot, every grain of powder would be ignited simultaneously by the primer in a perfect world. The primer would not create more pressure than needed, in order to avoid causing powder to be compressed too much, which can lead to less uniform ignition.
Unfortunately, our world is not perfect. To fulfill the primary directive of primers, which ensures that cartridges fire, we use more primer than needed, which means more pressure. Ideal is that the primer explodes and the flames and hot metals penetrate the column of gunpowder. This helps us get as close to the chimeric goal of simultaneously igniting every kernel of powder. If the slag can be spread through the powder, it can transfer more heat to the propellant.
Many shooters prefer to use powder charges compressed in their reloads. This is because there is less air for powder to settle in and they get consistent results. However this can cause problems for the primer as the pressure wave that comes off it can compress the powder column making it difficult for the slag or flame to penetrate.
A New Catalyst
Like many innovations in ammunition design, the Catalyst prime was developed as a result of a large customer request. The U.S. government (military and law enforcement) wanted a primer suitable for duty that did not contain lead or any other potentially toxic metals. Federal gave the project to Joel Sandstrom who was later to invent Catalyst.
Two main functions are performed by aluminum. It makes explosive nitrocellulose less sensitive and heats up the bismuth. The “oxide”, which is bismuth oxide, adds oxygen and the remaining 10% is a mix of fuels. Binders, sensitizers, and fuels.
While there were other lead-free primers that were available over the years, they weren’t considered reliable enough for use as duty ammunition. So, they have been used for training ammo.
Federal came up with a primer to replace the existing lead styphnate blends. This was in spite of the fact that it had to be eliminated.
Drew Goodlin (senior director of technology at Vista Outdoor), the company that owns Federal Ammunition, stated, “It’s safer to make, and it is affordable and reliable.”
Catalyst has a number of advantages over current primer technology. It is compatible with modern propellants so it won’t damage the powder it comes into contact with like some other primers. Catalyst’s formula can propel more heavy metals (hot and heavy) into the propellent beds than any other Federal primer system. It also produces less pressure by gases than any other Federal primer system–even the acclaimed Gold Metal primers.
Although it is forbidden to mess with ammunition with a proven track record of quality and reliability, especially when it is primers which fall under the “if you don’t believe it’s broken, don’t dare make it worse”, Federal is planning to switch all its centerfire ammunition, including pistols, shotguns and rifles, to Catalyst primes within the next five-years.
Federal is confident in the product, and this speaks volumes. Will the public be as open to Catalyst? The new primer has a lot of credibility due to the fact that different elements of the U.S. Government are using Catalyst ammunition.
Catalyst is a primer that relies on three elements to work. A fuel source, an oxygenizer and sensitizers are the main ingredients. Catalyst primers exhibit chemical reactions that are significantly different from those made with lead styphnate.
The aluminum in Catalyst is the best part of the Catalyst pie. Although it makes up about 10% of the overall mix, it serves two complementary functions.
Aluminum can react with any explosive to increase its sensitivity. Catalyst’s primer compound is nitrocellulose. It makes up around 20 percent.
The aluminum reacts with bismuth dioxide (60 percent)–yes, that’s the exact same bismuth in nontoxic shots with a density comparable to lead. This creates what Federal engineer Sandstrom refers to as a “thermite response,” which is a fancy way to say that the aluminum gets the bismuth really hot.
It is both extremely hot and heavy so the bismuth has a superior ability to penetrate the propellant bed and transfer heat to ignite the powder. The Catalyst formula’s final 10% is a mixture of fuels, sensitizers, and binding agents.
Federal can adjust the new base formula to allow it to work in different ammunition types, from pistol calibers like.380 which require minimal primer compound to magnum rifle cartridges to shotshells that require heavier primer payloads to ignite their powder. Federal’s gamble on this technology’s success hinges on a few simple rules. Federal ammunition needs to bang and place the projectile in the area the shooter is targeting.
Catalyst is capable of doing this and we can be confident that we are entering the next major phase in ammunition technology. Even if this new hunter-ed graduate doesn’t fully understand primers, there is a good chance that they will participate in the new primer revolution as they tag their first deer.