Teflon shells have superior firepower

A new type of shell that heats up on impact to burn through steel is being developed by the US Office of Naval Research (ONR).

The projectile, which has shown potential for use against aircraft and light armour, contains a mixture of aluminium polytetrafluoroethylene (PTFE) and perchlorate oxidiser, moulded together into an aerodynamic shape.

Soft Teflon tape is wound around this substance at high tension then heated and covered with an epoxy glue, forming a covering that stops the projectile from disintegrating as it travels through the air at high speed.

The impact of the shell starts a reaction in which the chemicals produce a burst of heat strong enough to burn through armour plating. Pure Teflon shells have been available for some time, but a structural reactive material shell with Teflon as the binding material has not previously been developed beyond initial concept level.

The Teflon and perchlorate used in the shell are both oxidizers. Any metals in contact with them will react at their respective thermal decomposition temperatures; for example, aluminium would heat to around 3,500ºC.