I would like to know if anyone has cast bullets in non-lead alloys. This would include Tin / Antimony formulas, Bismuth or non-lead Pewter, what some people call Britannia or Victoria metal. All of these alloys are fairly low melting point, around 500 F and within the hardness limitations of most other lead-based alloys.

The reason for asking is a familiar story we have in our area: local ranges are banning the use of lead, and I am investigating casting bullets for our club for people to use in non-lead reloading. I already know of the choices available in purchasing Barnes-X or No-tox frangible bullets, just interested in finding out what difficulties might lie in casting non-lead bullets.

Anyone?

The reason for asking is a familiar story we have in our area: local ranges are banning the use of lead, and I am investigating casting bullets for our club for people to use in non-lead reloading. I already know of the choices available in purchasing Barnes-X or No-tox frangible bullets, just interested in finding out what difficulties might lie in casting non-lead bullets.

Anyone

Are these ranges indoors or out of doors?
Jim

Are these ranges indoors or out of doors?


There is one where our club would like to use outdoors. The requirement is for "no lead". If cast, no-lead bullets can be used then we would probably be much better off economically than using some of the more expensive copper or bismuth rounds.

Are these ranges indoors or out of doors?


There is one where our club would like to use outdoors. The requirement is for "no lead". If cast, no-lead bullets can be used then we would probably be much better off economically than using some of the more expensive copper or bismuth rounds.

Are ways of casting zinc alloy...even in the 1940's-1950's there was a commercial alloy, Kirksite, that got a bit of use. The only old timer I know who has used it said that every trace of lead in the pot and mold needs to be removed...his version, I haven't tried it. Not having a good break down of Kirksite, can't swear what makes up the alloy, but it is supose to be lead free.

Do have a couple of his fired Kirksite bullets and some load data notes...the 385gr. mold he was using tossed a 195gr. Kirksite bullet that is about as hard as a rock...the recovered bullet was dug out of a dirt backstop, and looks like it could be loaded again.

Does seem to cast a bit smaller...the mold that tossed .458" tossed .456" in this alloy.

Have been compines offering cast zinc alloy bullets commecially...here one moment, gone the next. Suspect it's in the home casting possibilites to cast zinc.

Have been compines offering cast zinc alloy bullets commecially...here one moment, gone the next. Suspect it's in the home casting possibilites to cast zinc.

My first thought would be to go to the local Home Depot or lowes and purchase a couple spools of lead-free solder. It is Tin/Antimony with a fair hardness and would probably cast better than lead, although at a higher temperature. I talked to Federal Ammunition folks a couple years back when they had .22 rimfire with zinc bullets. I think they were using a zinc / bismuth alloy that was a little lighter than lead, but being a large company they were swaging the bullets. The machines they had were made to swage lead .22 bullets and the tooling kept breaking, or the bullets would become very grainy - a property of zinc apparently. Federal made quite a number of truckloads of .22 rimfire that way but gave up because of equipment problems. Needless to say, the Federal .22 ammunition is pretty much in the hands of collectors now.

I bet gold would work. LOL

Well, my original post was asking the question:

Has anyone ever cast their own bismuth bullets? Or has anyone ever cast non-lead bullets? So far the question has turned up one person who knew a little about Kirksite casting.

If anyone has the time or money they might want to try casting bismuth bullets. Bismuth is harder on the Brinell scale than lead and won't "bismuth" the barrel. It is heavier than lead, so maybe reduced powder charges are the rule. One thing I read about bismuth bullets is that they tend to be very grainy like zinc or other bullets; so grainy in fact, that if a bismuth bullet hits a hard surface like a rock, piece of concrete or a shillouette plate, the bullet will disintegrate into dust. Some of the frangible bullets are like this, although there are many frangible bullets made of compressed metal powder, not cast metal powder. Bismuth shot does NOT have this property because it is travelling at speeds of around 1300 ft / sec which is not enough speed to cause disintegration of the pellet. Speeds of around 1400 ft per second and up will cause disintegration.

This is an area that definitely needs more research.

The Zinc alloy you are looking for is Zamak #3. It melts at 710-718 degreesF. I am going to try getting a Sample myself. It costs $1.40 per #. I am told that it fills the mold poorly, and makes a slightly smaller bullet, not usually requiring sizing. You will have to go with a mould with bigger bands, and asimple design. You don't need to lube the slugs, Or so I have read. People have pushed them to 3200 FPS on a 30-06.
Check the issues of Rifle magazine from the 1970s for the article. Greg S

"Shooting Zinc in Big Bores," Handloader's Digest, 12th edition, pp. 128-132 by Karl Bosselmann.

Might find a used copy of that somewhere before you dive in.

I am currently considering the following metals for casting non-lead bullets:

1. Britannia Metal (a lead-free pewter)

2. Tin

3. Bismuth

4. Antimony/Bismuth solder (a lead-free Sb/Bi eutectic)

I have found .22 molds that will cast a 40 gr round nose bullet similar to a .22 rimfire bullets. Ultimately I may be able to work up a replacement for the now-defunct Federal Ballisticlean.