M4 Carbine Fares Poorly in Dust Test
Military.com | By Christian Lowe | December 18, 2007

The primary weapon carried by most soldiers into battle in Iraq and Afghanistan performed the worst in a recent series of tests designed to see how it stacked up against three other top carbines in sandy environments.

After firing 6,000 rounds through ten M4s in a dust chamber at the Army's Aberdeen test center in Maryland this fall, the weapons experienced a total of 863 minor stoppages and 19 that would have required the armorer to fix the problem. Stacked up against the M4 during the side-by-side tests were two other weapons popular with special operations forces, including the Heckler and Koch 416 and the FN USA Special Operations Combat Assault Rifle, or Mk16.

Another carbine involved in the tests that had been rejected by the Army two years ago, the H&K XM8, came out the winner, with a total of 116 minor stoppages and 11 major ones. The Mk16 experienced a total of 226 stoppages, the 416 had 233.

The Army was quick to point out that even with 863 minor stoppages -- termed "class one" stoppages which require 10 seconds or less to clear and "class two" stoppages which require more than ten seconds to clear -- the M4 functioned well, with over 98 percent of the 60,000 total rounds firing without a problem.

"The M4 carbine is a world-class weapon," said Brig. Gen. Mark Brown, the Army's top equipment buyer, in a Dec. 17 briefing at the Pentagon. Soldiers "have high confidence in that weapon, and that high confidence level is justified, in our view, as a result of all test data and all investigations we have made."

Though Army testers and engineers are still evaluating the data, officials with the Army's Infantry Center based in Fort Benning, Ga., said they planned to issue new requirements for the standard-issue carbine in about 18 months that could include a wholesale replacement of the M4. But the Army has been resistant to replace the M4, which has been in the Army inventory for over 18 years, until there's enough of a performance leap to justify buying a new carbine.

"We know there are some pretty exciting things on the horizon with technology ... so maybe what we do is stick with the M4 for now and let technologies mature enough that we can spin them into a new carbine," said Col. Robert Radcliffe, director of combat development at the Army's Infantry Center. "It's just not ready yet. But it can be ready relatively rapidly."

That's not good enough for some on Capitol Hill who've pushed hard for the so-called "extreme dust test" [see Pt 2] since last spring. Oklahoma Republican Senator Tom Coburn placed a hold on the nomination of Army Secretary Pete Geren earlier this year to force the Army to take another look at the M4 and its reliability.

In an April 12 letter to the still unconfirmed Geren, Coburn wrote that "considering the long standing reliability and lethality problems with the M16 design, of which the M4 is based, I am afraid that our troops in combat might not have the best weapon." He insisted the Army conduct a side-by-side test to verify his contention that more reliable designs existed and could be fielded soon.

Despite the 98 percent reliability argument now being pushed by the Army, one congressional staffer familiar with the extreme dust tests is skeptical of the service's conclusions.

"This isn't brain surgery -- a rifle needs to do three things: shoot when you pull the trigger, put bullets where you aim them and deliver enough energy to stop what's attacking you," the staffer told Military.com in an email. "If the M4 can't be depended on to shoot then everything else is irrelevant."

The staffer offered a different perspective of how to view the Army's result. If you look at the numbers, he reasoned, the M4's 882 total stoppages averages out to a jam every 68 rounds. There are about 30 rounds per magazine in the M4.

By comparison, the XM8 jammed once every 472 rounds, the Mk16 every 265 rounds and the 416 every 257 rounds. Army officials contend soldiers rarely fire more than 140 rounds in an engagement.

"These results are stunning, and frankly they are significantly more dramatic than most weapons experts expected," the staffer said.

Army officials say the staffer's comparison is "misleading" since the extreme dust test did not represent a typical combat environment and did not include the regular weapons cleaning soldiers typically perform in the field.

So the Army is sticking by the M4 and has recently signed another contract with manufacturer Colt Defense to outfit several more brigade combat teams with the compact weapon. Service officials say feedback from the field on the M4 has been universally positive -- except for some grumbling about the stopping power of its 5.56mm round. And as long as soldiers take the time to clean their weapons properly, even the "extreme" dust testing showed the weapon performed as advertised.

"The force will tell you the weapon system is reliable, they're confident in it, they understand that the key to making that weapon system effective on the battlefield and killing the enemy is a solid maintenance program and, just as important, is a marksmanship program," said Sgt. Maj. Tom Coleman, sergeant major for PEO Soldier and the Natick Soldier Systems Center. "So, you can't start talking about a weapon system without bringing in all the other pieces that come into play."

That's not enough for some who say the technology is out there to field a better, more reliable rifle to troops in contact now.

"It's time to stop making excuses and just conduct a competition for a new weapon," the congressional staffer said.

Senator Tells Army to Reconsider M4
Military.com | By Christian Lowe | April 30, 2007
The debate over the Army's choice to purchase hundreds of thousands of M4 carbines for its new brigade combat teams is facing stiff opposition from a small group of senators who say the rifle may be inferior to others already in the field.

In an April 12 letter to acting Army Secretary Pete Geren, Oklahoma Republican Sen. Tom Coburn said purchase of the M4 - a shortened version of the Vietnam-era M16 - was based on requirements from the early 1990s and that better, more reliable weapons exist that could give Army troops a more effective weapon.

Coburn asked the Army to hold a "free and open competition" before inking sole-source contracts worth about $375 million to M4 manufacturer, West Hartford, Conn.-based Colt Defense - which just received a $50 million Army contract for M4s on April 20.

"I am concerned with the Army's plans to procure nearly half a million new rifles outside of any competitive process," Coburn wrote in the mid-April letter obtained by Military.com.

A Geren spokesman said the secretary's office is putting together a reply to Coburn's letter, but provided no further details.

Take Action: Tell your public officials how you feel about this issue.

Coburn has banded together with a small group of like-minded senators to push the Army into a competition to determine whether the M4 is the best choice to equip newly-forming brigade combat teams, a top Coburn aide said.

The senator's concerns grew out of media coverage that showed the M4's design fails in critical situations and that special operations forces prefer other designs.

"Considering the long standing reliability and lethality problems with the M16 design, of which the M4 is based, I am afraid that our troops in combat might not have the best weapon," Coburn wrote. "A number of manufacturers have researched, tested and fielded weapons which, by all accounts, appear to provide significantly improved reliability."

Related Article: Army Won't Field Rifle Deemed Superior to M4

Special operations forces, including "tier one" units such as the Army's Delta Force and the Navy's SEAL Development Group - or SEAL Team Six - have used their own funds to purchase the Heckler & Koch-built 416, which uses a gas-piston operating system less susceptible to failure than Colt's gas-operated design.

"That's significant, because these guys don't screw around," the aide said.

In fact, Colt included four different weapons in the competition to build the Special Operations Forces Combat Assault Rifle, or SCAR, none of which used the M4s gas system, the aide said.

In a routine acquisition notice March 23, a U.S. Special Forces battalion based in Okinawa announced that it is buying 84 upper receiver assemblies for the HK416 to modify their M4 carbines. The M4 fires using a system that redirects gas from the expended round to eject it and reload another. The 416 and SCAR use a gas-operated piston that physically pushes the bolt back to eject the round and load another.

Carbon buildup from the M4's gas system has plagued the rifle for years, resulting in some close calls with Soldiers in combat whose rifles jammed at critical moments.

According to the solicitation for the new upper receiver assemblies, the 416 "allows Soldiers to replace the existing M4 upper receiver with an HK proprietary gas system that does not introduce propellant gases and the associated carbon fouling back into the weapon's interior. This reduces operator cleaning time, and increases the reliability of the M4 Carbine, particularly in an environment in which sand and dust are prevalent."

Yet the Army has still declined to buy anything other than the M4 for its regular troops, requesting about $100 million in the 2007 wartime supplemental to buy M4s for its Soldiers.

The office in charge of equipping Soldiers said in a March 30 statement the service has no plans to purchase the HK416.

"I am certain we can all agree that America's Soldiers should have the best technology in their hands," Coburn wrote. "And there is simply no excuse for not providing our soldiers the best weapon - not just a weapon that is 'good enough.' "

The Army has not yet responded to Coburn's letter, but his aide said if the senator doesn't receive a response to the letter by Monday, Coburn plans to call Geren personally to address the issue.

"Our feeling is once people see the facts on the face of it they're going to say that this is ridiculous and demand that the Army does it right and competes the contract," the aide said.

By Matthew Cox - Staff writer
Posted : Monday Dec 17, 2007 9:25:16 EST

The M4 carbine, the weapon soldiers depend on in combat, finished last in a recent “extreme dust test” to demonstrate the M4’s reliability compared to three newer carbines.

Weapons officials at the Army Test and Evaluation Center at Aberdeen Proving Ground, Md., exposed Colt Defense LLC’s M4, along with the Heckler & Koch XM8, FNH USA’s Special Operations Forces Combat Assault Rifle and the H&K 416 to sandstorm conditions from late September to late November, firing 6,000 rounds through each test weapon.

When the test was completed, ATEC officials found that the M4 performed “significantly worse” than the other three weapons, sources told Army Times.

Officials tested 10 each of the four carbine models, firing a total of 60,000 rounds per model. Here’s how they ranked, according to the total number of times each model stopped firing:

• XM8: 127 stoppages.

• MK16 SCAR Light: 226 stoppages.

• 416: 233 stoppages.

• M4: 882 stoppages.

the results of the test were “a wake-up call,” but Army officials continue to stand by the current carbine, said Brig. Gen. Mark Brown, commander of Program Executive Office Soldier, the command that is responsible for equipping soldiers.

“We take the results of this test with a great deal of interest and seriousness,” Brown said, expressing his determination to outfit soldiers with the best equipment possible.

The test results did not sway the Army’s faith in the M4, he said.

“Everybody in the Army has high confidence in this weapon,” Brown said.

Lighter and more compact than the M16 rifle, the M4 is more effective for the close confines of urban combat. The Army began fielding the M4 in the mid-1990s.

Army weapons officials agreed to perform the test at the request of Sen. Tom Coburn, R-Okla., in July. Coburn took up the issue following a Feb. 26 Army Times report on moves by elite Army combat forces to ditch the M4 in favor of carbines they consider more reliable. Coburn is questioning the Army’s plans to spend $375 million to purchase M4s through fiscal 2009.

Coburn raised concerns over the M4’s “long-standing reliability” problems in an April 12 letter and asked if the Army had considered newer, possibly better weapons available on the commercial market.

John Hart, a spokesman for Coburn, who was traveling, said the senator was reviewing the test results and had yet to discuss it with the Army.

The M4, like its predecessor, the M16, uses a gas tube system, which relies on the gas created when a bullet is fired to cycle the weapon. Some weapons experts maintain the M4’s system of blowing gas directly into the firing mechanism of the weapon spews carbon residue that can lead to fouling and heat that dries up lubrication, causing excessive wear on parts.

The other contenders in the dust test — the XM8, SCAR and 416 — use a piston-style operating system, which relies on a gas-driven piston rod to cycle the weapon during firing. The gas is vented without funneling through the firing mechanism.

The Army’s Delta Force replaced its M4s with the H&K 416 in 2004 after tests revealed that the piston operating system significantly reduces malfunctions while increasing the life of parts. The elite unit collaborated with the German arms maker to develop the new carbine.

U.S. Special Operations Command has also revised its small-arms requirements. In November 2004, SOCom awarded a developmental contract to FN Herstal to develop its new SCAR to replace its weapons from the M16 family.

And from 2002 to 2005, the Army developed the XM8 as a replacement for the Army’s M16 family. The program led to infighting within the service’s weapons community and eventually died after failing to win approval at the Defense Department level.

How they were tested

The recent Aberdeen dust test used 10 sample models of each weapon. Before going into the dust chamber, testers applied a heavy coat of lubrication to each weapon. Each weapon’s muzzle was capped and ejection port cover closed.

Testers exposed the weapons to a heavy dust environment for 30 minutes before firing 120 rounds from each.

The weapons were then put back in the dust chamber for another 30 minutes and fired another 120 rounds. This sequence was repeated until each weapon had fired 600 rounds.

Testers then wiped down each weapon and applied another heavy application of lubrication.

The weapons were put back through the same sequence of 30 minutes in the dust chamber followed by firing 120 rounds from each weapon until another 600 rounds were fired.

Testers then thoroughly cleaned each weapon, re-lubricated each, and began the dusting and fire sequencing again.

This process was repeated until testers fired 6,000 rounds through each weapon.

The dust test exposed the weapons to the same extreme dust and sand conditions that Army weapons officials subjected the M4 and M16 to during a “systems assessment” at Aberdeen last year and again this summer. The results of the second round of ATEC tests showed that the performance of the M4s dramatically improved when testers increased the amount of lubrication used.

Out of the 60,000 rounds fired in the tests earlier in the summer, the 10 M4s tested had 307 stoppages, test results show, far fewer than the 882 in the most recent test.

in the recent tests, the M4 suffered 643 weapon-related stoppages, such as failure to eject or failure to extract fired casings, and 239 magazine-related stoppages.

Colt officials had not seen the test report and would not comment for this story, said James Battaglini, executive vice president for Colt Defense LLC, on Dec. 14.

Army officials are concerned about the gap between the two tests becaus the “test conditions for test two and three were ostensibly the same,” Brown said.

There were, however, minor differences in the two tests because they were conducted at different times of the year with different test officials, Brown said. Test community officials are analyzing the data to try to explain why the M4 performed worse during this test.

Weapons officials pointed out that these tests were conducted in extreme conditions that did not address “reliability in typical operational conditions,” the test report states.

Despite the last-place showing, Army officials say there is no movement toward replacing the M4.

The Army wants its next soldier weapon to be a true leap ahead, rather than a series of small improvements, Brown said.

“That is what the intent is,” he said, “to give our soldiers the very best and we are not going to rest until we do that.”

Col. Robert Radcliffe, head of the Directorate of Combat Developments for the Infantry Center at Fort Benning, Ga., said the test results will be considered as the Army continues to search for ways to improve soldier weapons.

For now, he said the Army will stick with the M4, because soldier surveys from Iraq and Afghanistan continue to highlight the weapon’s popularity among troops in the combat zone.

“The M4 is performing for them in combat, and it does what they needed to do in combat,” Radcliffe said.

I carry an M4 and its really no problem if you keep it relatively clean, the one i have now has never had a stoppage and i've put it through countless missions and some training exercises in the desert and the north in real shitty wheather.