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A shell, in a modern military context, is a projectile whose payload contains an explosive, incendiary, or other chemical filling. Originally it was called a bombshell, but "shell" has come to be unambiguous in a military context. A shell can hold a tracer.
All explosive- and incendiary-filled projectiles, particularly for mortars, were originally called grenades, derived from the French language word for pomegranate, so called because of the similarity of shape and that the multi-seeded fruit resembles the powder-filled, fragmentizing bomb. Words cognate with grenade are still used for an artillery or mortar projectile in some European languages.
Shells are usually large-caliber projectiles fired by artillery, armoured fighting vehicles (e.g. , , and ), , and . The shape is usually a cylinder topped by an ogive-tipped nose cone for good aerodynamic performance, and possibly with a tapered boat tail; but some specialized types differ widely.
In a gunpowder-based shell, the casing was intrinsic to generating the explosion, and thus had to be strong and thick. Its fragments could do considerable damage, but each shell broke into only a few large pieces. Further developments led to shells which would fragment into smaller pieces. The advent of high explosives such as TNT removed the need for a pressure-holding casing, so the casing of later shells only needed to contain the munition, and, if desired, to produce shrapnel. The term "shell," however, was sufficiently established that it remained as the term for such munitions.
Hollow shells filled with gunpowder needed a fuse that was either impact triggered (percussion) or time delayed. Percussion fuses with a spherical projectile presented a challenge because there was no way of ensuring that the impact mechanism contacted the target. Therefore, ball shells needed a time fuse that was ignited before or during firing and burned until the shell reached its target.
Shells were used in combat by the Republic of Venice at Jadra in 1376. Shells with fuses were used at the 1421 siege of St Boniface in Corsica. These were two hollowed hemispheres of stone or bronze held together by an iron hoop.Hogg, p. 164. At least since the 16th century grenades made of ceramics or glass were in use in Central Europe. A hoard of several hundred ceramic grenades dated to the 17th century was discovered during building works in front of a bastion of the Bavarian city of Ingolstadt, Germany. Many of the grenades contained their original black-powder loads and igniters. Most probably the grenades were intentionally dumped in the moat of the bastion before the year 1723. An early problem was that there was no means of precisely measuring the time to detonation reliable fuses did not yet exist, and the burning time of the powder fuse was subject to considerable trial and error. Early powder-burning fuses had to be loaded fuse down to be ignited by firing or a portfire or slow match put down the barrel to light the fuse. Other shells were wrapped in bitumen cloth, which would ignite during the firing and in turn ignite a powder fuse. Nevertheless, shells came into regular use in the 16th century. A 1543 English mortar shell was filled with "wildfire."
By the 18th century, it was known that if loaded toward the muzzle instead, the fuse could be lit by the flash through the windage between the shell and the barrel. At about this time, shells began to be employed for direct fire from with a small propellant charge and, in 1779, experiments demonstrated that they could be used from guns with heavier charges.
The use of exploding shells from field artillery became relatively commonplace from early in the 19th century. Until the mid 19th century, shells remained as simple exploding spheres that used gunpowder, set off by a slow burning fuse. They were usually made of cast iron, but bronze, lead, brass and even glass shell casings were experimented with.Hogg, pp. 164–165. The word bomb encompassed them at the time, as heard in the lyrics of The Star-Spangled Banner ("the bombs bursting in air"), although today that sense of bomb is obsolete. Typically, the thickness of the metal body was about a sixth of their diameter, and they were about two-thirds the weight of solid shot of the same caliber.
To ensure that shells were loaded with their fuses toward the muzzle, they were attached to wooden bottoms called sabots. In 1819, a committee of British artillery officers recognized that they were essential stores and in 1830 Britain standardized sabot thickness as a half-inch.Hogg, p. 165. The sabot was also intended to reduce jamming during loading. Despite the use of exploding shells, the use of smoothbore cannons firing spherical projectiles of shot remained the dominant artillery method until the 1850s.
During the 20th century, shells became increasingly streamlined. In World War I, ogives were typically two circular radius head (crh) – the curve was a segment of a circle having a radius of twice the shell caliber. After that war, ogive shapes became more complex and elongated. From the 1960s, higher quality steels were introduced by some countries for their HE shells, this enabled thinner shell walls with less weight of metal and hence a greater weight of explosive. Ogives were further elongated to improve their ballistic performance.
The piece was rifling, which allowed for a much more accurate and powerful action. Although rifling had been tried on small arms since the 15th century, the necessary machinery to accurately rifle artillery only became available in the mid-19th century. Martin von Wahrendorff and Joseph Whitworth independently produced rifled cannons in the 1840s, but it was Armstrong's gun that was first to see widespread use during the Crimean War. The cast iron shell of the Armstrong gun was similar in shape to a Minié ball and had a thin lead coating which made it fractionally larger than the gun's bore and which engaged with the gun's rifling grooves to impart spin to the shell. This spin, together with the elimination of windage as a result of the tight fit, enabled the gun to achieve greater range and accuracy than existing smooth-bore muzzle-loaders with a smaller powder charge.
The gun was also a breech-loader. Although attempts at breech-loading mechanisms had been made since medieval times, the essential engineering problem was that the mechanism could not withstand the explosive charge. It was only with the advances in metallurgy and precision engineering capabilities during the Industrial Revolution that Armstrong was able to construct a viable solution. Another innovative feature was what Armstrong called its "grip", which was essentially a squeeze bore; the 6 inches of the bore at the muzzle end was of slightly smaller diameter, which centered the shell before it left the barrel and at the same time slightly down its lead coating, reducing its diameter and slightly improving its ballistic qualities.
Rifled guns were also developed elsewhere – by Major Giovanni Cavalli and Baron Martin von Wahrendorff in Sweden, Krupp in Germany and the Wiard rifle in the United States.Hogg, pp. 80–83. However, rifled barrels required some means of engaging the shell with the rifling. Lead coated shells were used with the Armstrong gun, but were not satisfactory so studded projectiles were adopted. However, these did not seal the gap between shell and barrel. Wads at the shell base were also tried without success.
In 1878, the British adopted a copper "Gas check" at the base of their studded projectiles and in 1879 tried a rotating gas check to replace the studs, leading to the 1881 automatic gas-check. This was soon followed by the Vavaseur copper driving band as part of the projectile. The driving band rotated the projectile, centered it in the bore and prevented gas escaping forwards. A driving band has to be soft but tough enough to prevent stripping by rotational and engraving stresses. Copper is generally most suitable but cupronickel or gilding metal were also used.Hogg, pp. 165–166.
The percussion fuze was adopted by Britain in 1842. Many designs were jointly examined by the army and navy, but were unsatisfactory, probably because of the safety and arming features. However, in 1846 the design by Quartermaster Freeburn of the Royal Artillery was adopted by the army. It was a wooden fuze about 6 inches long and used shear wire to hold blocks between the fuze magazine and a burning match. The match was ignited by propellant flash and the shear wire broke on impact. A British naval percussion fuze made of metal did not appear until 1861.Hogg, pp. 203–203.
Small arms could not withstand the pressures generated by guncotton. After one of the Austrian factories blew up in 1862, Thomas Prentice & Company began manufacturing guncotton in Stowmarket in 1863; and British War Office chemist Sir Frederick Abel began thorough research at Waltham Abbey Royal Gunpowder Mills leading to a manufacturing process that eliminated the impurities in nitrocellulose making it safer to produce and a stable product safer to handle. Abel patented this process in 1865, when the second Austrian guncotton factory exploded. After the Stowmarket factory exploded in 1871, Waltham Abbey began production of guncotton for torpedo and mine warheads.Sharpe, Philip B. Complete Guide to Handloading. 3rd edition (1953). Funk & Wagnalls. pp. 141–144.
In 1884, Paul Vieille invented a smokeless powder called Poudre B (short for poudre blanche—white powder, as distinguished from gunpowder)Davis, Tenney L. The Chemistry of Powder & Explosives (1943), pages 289–292. made from 68.2% insoluble nitrocellulose, 29.8% soluble nitrocellulose gelatinized with diethyl ether and 2% paraffin. This was adopted for the Lebel rifle.Hogg, Oliver F. G. Artillery: Its Origin, Heyday and Decline (1969), p. 139. Vieille's powder revolutionized the effectiveness of small guns, because it gave off almost no smoke and was three times more powerful than black powder. Higher muzzle velocity meant a flatter trajectory and less wind drift and bullet drop, making 1000 meter shots practicable. Other European countries swiftly followed and started using their own versions of Poudre B, the first being Germany and Austria which introduced new weapons in 1888. Subsequently, Poudre B was modified several times with various compounds being added and removed. Krupp began adding diphenylamine as a stabilizer in 1888.
Britain conducted trials on all the various types of propellant brought to their attention, but were dissatisfied with them all and sought something superior to all existing types. In 1889, Sir Frederick Abel, James Dewar and W. Kellner patented (No. 5614 and No. 11,664 in the names of Abel and Dewar) a new formulation that was manufactured at the Royal Gunpowder Factory at Waltham Abbey. It entered British service in 1891 as Cordite Mark 1. Its main composition was 58% nitro-glycerine, 37% guncotton and 3% mineral jelly. A modified version, Cordite MD, entered service in 1901, this increased guncotton to 65% and reduced nitro-glycerine to 30%, this change reduced the combustion temperature and hence erosion and barrel wear. Cordite could be made to burn more slowly which reduced maximum pressure in the chamber (hence lighter breeches, etc.), but longer high pressure – significant improvements over gunpowder. Cordite could be made in any desired shape or size.Hogg, Oliver F. G. Artillery: Its Origin, Heyday and Decline (1969), p. 141. The creation of cordite led to a lengthy court battle between Nobel, Maxim, and another inventor over alleged British patent infringement.
A modern version of the incendiary shell was developed in 1857 by the British and was known as Martin's shell after its inventor. The shell was filled with molten iron and was intended to break up on impact with an enemy ship, splashing molten iron on the target. It was used by the Royal Navy between 1860 and 1869, replacing heated shot as an anti-ship, incendiary projectile.
Two patterns of incendiary shell were used by the British in World War I, one designed for use against Zeppelins.Hogg, pp. 171–174.
Similar to incendiary shells were star shells, designed for illumination rather than arson. Sometimes called lightballs they were in use from the 17th century onwards. The British adopted parachute lightballs in 1866 for 10-, 8- and 5-inch calibers. The 10-inch was not officially declared obsolete until 1920.Hogg, pp. 174–176.
Smoke balls also date back to the 17th century, British ones contained a mix of saltpetre, coal, pitch, tar, resin, sawdust, crude antimony and sulphur. They produced a "noisome smoke in abundance that is impossible to bear". In 19th-century British service, they were made of concentric paper with a thickness about 1/15th of the total diameter and filled with powder, saltpeter, pitch, coal and tallow. They were used to 'suffocate or expel the enemy in casemates, mines or between decks; for concealing operations; and as signals.
During the First World War, and explosive shells inflicted terrible casualties on infantry, accounting for nearly 70% of all war casualties and leading to the adoption of steel on both sides. Frequent problems with shells led to many military disasters with dud shells, most notably during the 1916 Battle of the Somme. Shells filled with poison gas were used from 1917 onwards.
Explosive rounds as small as 12.7 x 82 mm and 13 x 64 mm have been used on aircraft and armoured vehicles, but their small explosive yields have led some nations to limit their explosive rounds to 20mm (.78 in) or larger. International Law precludes the use of explosive ammunition for use against individual persons, but not against vehicles and aircraft. The largest shells ever fired during war were those from the German super-, Schwerer Gustav, which were 800 mm (31.5 in) in caliber. Very large shells have been replaced by , missiles, and . Today shells exceeding 155 mm (6.1 in) are much less commonly used, with the exception of certain dated legacy systems. The 203mm Soviet-era 2S7 Pion is a noteworthy example, seeing regular usage throughout the Russo-Ukrainian War by the armed forces of both countries. Ukraine was able to continue fielding these heavy howitzers thanks to 203mm shells donated by the US, formerly used by the now-retired M110 howitzer.
Gun calibers have standardized around a few common sizes, especially in the larger range, mainly due to the uniformity required for efficient military logistics. Shells of 105 and 155 mm for artillery with 105 and 120 mm for tank guns are common in NATO allied countries. Shells of 122, 130, and 152 mm for artillery with 100, 115, and 125 mm for tank guns, remain in common usage among the regions of Eastern Europe, Western Asia, Northern Africa, and Eastern Asia. Most common calibers have been in use for many decades, since it is logistics complex to change the caliber of all guns and ammunition stores.
The weight of shells increases by and large with caliber. A typical 155 mm (6.1 in) shell weighs about 50 kg (110 lbs), a common 203 mm (8 in) shell about 100 kg (220 lbs), a concrete demolition 203 mm (8 in) shell 146 kg (322 lbs), a 280 mm (11 in) battleship shell about 300 kg (661 lbs), and a 460 mm (18 in) battleship shell over 1,500 kg (3,307 lbs). The Schwerer Gustav large-calibre gun fired shells that weighed between 4,800 kg (10,582 lbs) and 7,100 kg (15,653 lbs).
During the 19th century, the British adopted a particular form of designating artillery. Field guns were designated by nominal standard projectile weight, while howitzers were designated by barrel caliber. British guns and their ammunition were designated in pounds, e.g., as "two-pounder" shortened to "2-pr" or "2-pdr". Usually, this referred to the actual weight of the standard projectile (shot, shrapnel, or high explosive), but, confusingly, this was not always the case.
Some were named after the weights of obsolete projectile types of the same caliber, or even obsolete types that were considered to have been functionally equivalent. Also, projectiles fired from the same gun, but of non-standard weight, took their name from the gun. Thus, conversion from "pounds" to an actual barrel diameter requires consulting a historical reference. A mixture of designations were in use for land artillery from the First World War (such as the BL 60-pounder gun, RML 2.5 inch Mountain Gun, 4 inch gun, 4.5 inch howitzer) through to the end of World War II (5.5 inch medium gun, 25-pounder gun-howitzer, 17-pounder tank gun), but the majority of naval guns were by caliber. After the end of World War II, field guns were designated by caliber.
Britain also deployed Palliser shells in the 1870s–1880s. In the shell, the cavity was slightly larger than in the shot and was filled with 1.5% gunpowder instead of being empty, to provide a small explosive effect after penetrating armour plating. The shell was correspondingly slightly longer than the shot to compensate for the lighter cavity. The powder filling was ignited by the shock of impact and hence did not require a fuze."Treatise on Ammunition", 4th Edition 1887, pp. 203–205. However, ship armour rapidly improved during the 1880s and 1890s, and it was realised that explosive shells with steel had advantages including better fragmentation and resistance to the stresses of firing. These were cast and forged steel.
AP shells containing an explosive filling were initially distinguished from their non-HE counterparts by being called a "shell" as opposed to "shot". By the time of the Second World War, AP shells with a bursting charge were sometimes distinguished by appending the suffix "HE". At the beginning of the war, APHE was common in anti-tank shells of 75 mm caliber and larger due to the similarity with the much larger naval armour piercing shells already in common use. As the war progressed, ordnance design evolved so that the bursting charges in APHE became ever smaller to non-existent, especially in smaller caliber shells, e.g. Panzergranate 39 with only 0.2% HE filling.
Japan followed with an "improved" formula known as shimose powder. In 1889, a similar material, a mixture of ammonium cresylate with trinitrocresol, or an ammonium salt of trinitrocresol, started to be manufactured under the name ecrasite in Austria-Hungary. By 1894, Russia was manufacturing artillery shells filled with picric acid. Ammonium picrate (known as Dunnite or explosive D) was used by the United States beginning in 1906.Brown, G. I. (1998) The Big Bang: a History of Explosives. Sutton Publishing. . pp. 151–163.Marc Ferro. The Great War. London and New York: Routeladge Classics, p. 98. Germany began filling artillery shells with Trinitrotoluene in 1902. Toluene was less readily available than phenol, and TNT is less powerful than picric acid, but the improved safety of munitions manufacturing and storage caused the replacement of picric acid by TNT for most military purposes between the World Wars. However, pure TNT was expensive to produce and most nations made some use of mixtures using cruder TNT and ammonium nitrate, some with other compounds included. These fills included Ammonal, Schneiderite and Amatol. The latter was still in wide use in World War II.
The percentage of shell weight taken up by its explosive fill increased steadily throughout the 20th Century. Less than 10% was usual in the first few decades; by World War II, leading designs were around 15%. However, British researchers in that war identified 25% as being the optimal design for anti-personnel purposes, based on the recognition that far smaller fragments than hitherto would give a better effect. This guideline was achieved by the 1960s with the 155 mm L15 shell, developed as part of the German-British FH-70 program. The key requirement for increasing the HE content without increasing shell weight was to reduce the thickness of shell walls, which required improvements in high tensile steel.
The most common shell type is high explosive, commonly referred to simply as HE. They have a strong steel case, a bursting charge, and a Artillery fuse. The fuse detonates the bursting charge which shatters the case and scatters hot, sharp case pieces ( fragments, splinters) at high velocity. Most of the damage to soft targets, such as unprotected personnel, is caused by shell pieces rather than by the blast. The term "shrapnel" is sometimes used to describe the shell pieces, but functioned very differently and are long obsolete. The speed of fragments is limited by Gurney equations. Depending on the type of Artillery fuse used the HE shell can be set to burst on the ground (percussion), in the air above the ground, which is called air burst (time or Proximity fuze), or after penetrating a short distance into the ground (percussion with delay, either to transmit more ground shock to covered positions, or to reduce the spread of fragments). Projectiles with enhanced fragmentation are called high-explosive fragmentation (HE-FRAG).
RDX and TNT mixtures are the standard chemicals used, notably Composition B and Cyclotol. The introduction of "insensitive munition" requirements, agreements and regulations in the 1990s caused modern western designs to use various types of plastic bonded explosives (PBX) based on RDX.
In the late 19th century "double common shells" were developed, lengthened so as to approach twice the standard shell weight, to carry more powder and hence increase explosive effect. They suffered from instability in flight and low velocity and were not widely used.
In 1914, common shells with a diameter of 6-inches and larger were of cast steel, while smaller diameter shells were of forged steel for service and cast iron for practice. They were replaced by "common lyddite" shells in the late 1890s but some stocks remained as late as 1914. In British service common shells were typically painted black with a red band behind the nose to indicate the shell was filled.
In British service common pointed shells were typically painted black, except 12-pounder shells specific for QF guns which were painted lead colour to distinguish them from 12-pounder shells usable with both BL and QF guns. A red ring behind the nose indicated the shell was filled.
By World War II they were superseded in Royal Navy service by common pointed capped (CPC) and semi-armour piercing (SAP), filled with TNT.
Early shells had walls of the same thickness for the whole length, later shells had walls thicker at the base and thinning towards the nose. This was found to give greater strength and provide more space for explosive. Later shells had 4 c.r. heads, more pointed and hence streamlined than earlier 2 c.r.h. designs.
Proper detonation of a lyddite shell would show black to grey smoke, or white from the steam of a water detonation. Yellow smoke indicated simple explosion rather than detonation, and failure to reliably detonate was a problem with lyddite, especially in its earlier usage. To improve the detonation "exploders" with a small quantity of picric powder or even of TNT (in smaller shells, 3 pdr, 12 pdr – 4.7 inch) was loaded between the fuze and the main lyddite filling or in a thin tube running through most of the shell's length.
Lyddite presented a major safety problem because it reacted dangerously with metal bases. This required that the interior of shells had to be varnished, the exterior had to be painted with leadless paint and the fuze-hole had to be made of a leadless alloy. Fuzes containing any lead could not be used with it.
When World War I began Britain was replacing lyddite with modern "high explosive" (HE) such as TNT. After World War I the term "common lyddite" was dropped, and remaining stocks of lyddite-filled shells were referred to as HE (high explosive) shell filled lyddite. Hence "common" faded from use, replaced by "HE" as the explosive shell designation.
Common lyddite shells in British service were painted yellow, with a red ring behind the nose to indicate the shell had been filled.
The mine shell concept was invented by the Germans in the Second World War primarily for use in aircraft guns intended to be fired at opposing aircraft. Mine shells produced relatively little damage due to fragments, but a much more powerful blast. The aluminium structures and skins of Second World War aircraft were readily damaged by this greater level of blast.
The gunner set the shell's time fuze so that it was timed to burst as it was angling down towards the ground just before it reached its target (ideally about 150 yards before, and 60–100 feet above the groundI.V. Hogg & L.F. Thurston, British Artillery Weapons & Ammunition. London: Ian Allan, 1972. Page 215.). The fuze then ignited a small "bursting charge" in the base of the shell which fired the balls forward out of the front of the shell case, adding 200–250 ft/second to the existing velocity of 750–1200 ft/second. The shell body dropped to the ground mostly intact and the bullets continued in an expanding cone shape before striking the ground over an area approximately 250 yards × 30 yards in the case of the US 3-inch shell.Hamilton 1915, p. 13. The effect was of a large shotgun blast just in front of and above the target, and was deadly against troops in the open. A trained gun team could fire 20 such shells per minute, with a total of 6,000 balls, which compared very favorably with rifles and machine-guns.
However, shrapnel's relatively flat trajectory (it depended mainly on the shell's velocity for its lethality, and was lethal only in the forward direction) meant that it could not strike trained troops who avoided open spaces and instead used dead ground (dips), shelters, trenches, buildings, and trees for cover. It was of no use in destroying buildings or shelters. Hence, it was replaced during World War I by the high-explosive shell, which exploded its fragments in all directions (and thus more difficult to avoid) and could be fired by high-angle weapons, such as howitzers.
Artillery-scattered mines allow for the quick deployment of into the path of the enemy without placing engineering units at risk, but artillery delivery may lead to an irregular and unpredictable minefield with more unexploded ordnance than if mines were individually placed.
Signatories of the Convention on Cluster Munitions have accepted restrictions on the use of cluster munitions, including artillery shells: the treaty requires that a weapon so defined must contain nine or fewer submunitions, which must each weigh more than 4 kilograms, be capable of detecting and engaging a single target, and contain electronic self-destruct and self-deactivation systems. Submunitions which weigh 20 kg or more are not restricted.
Chemical shells were most commonly employed during the First World War. Use of chemical agents of all kinds has been forbidden by numerous international treaties starting with the 1925 Geneva Protocol (not to be confused with the Geneva Convention), with the 1993 Chemical Weapons Convention being the most modern treaty which also outlaws production, stockpiling and transfer of such weapons. All signatories have renounced the use of both lethal chemical agents and incapacitating agents in warfare.
Base ejection smoke is usually white, however, colored smoke has been used for marking purposes. The original canisters typically used hexachloroethane-zinc (HC), modern ones use red phosphorus because of its multi-spectral properties. However, other compounds have been used; in World War II, Germany used oleum (fuming sulfuric acid) and pumice.
Due to the nature of their payload, powder smoke shells using white phosphorus in particular have a secondary effect as incendiary weapons, though they are not as effective in this role as dedicated weapons using thermite.
A modern illumination shell has a time fuze that ejects a flare "package" through the base of the carrier shell at a standard height above ground (typically about 600 metres), from where it slowly falls beneath a non-flammable parachute, illuminating the area below. The ejection process also initiates a pyrotechnics flare emitting white or "black" infrared light.
Typically illumination flares burn for about 60 seconds. These are also known as star shells. Infrared illumination is a more recent development used to enhance the performance of night-vision devices. Both white- and black-light illuminating shells may be used to provide continuous illumination over an area for a period of time and may use several dispersed aimpoints to illuminate a large area. Alternatively, firing single illuminating shells may be coordinated with the adjustment of HE shell fire onto a target.
Colored flare shells have also been used for target marking and other signaling purposes.
The gun, operated remotely for safety in case it fails, fires the proof shot, and is then inspected for damage. If the barrel passes the examination, "" are added to the barrel. The gun can be expected to handle normal ammunition, which subjects it to less stress than the proof shot, without being damaged.
Sometimes, one or more of these arming mechanisms fail, resulting in a projectile that is unable to detonate. More worrying (and potentially far more hazardous) are fully armed shells on which the fuze fails to initiate the HE firing. This may be due to a shallow trajectory of fire, low-velocity firing or soft impact conditions. Whatever the reason for failure, such a shell is called a blind or unexploded ordnance (UXO) (the older term, "dud", is discouraged because it implies that the shell cannot detonate.) Blind shells often litter old battlefields; depending on the impact velocity, they may be buried some distance into the earth, all the while remaining potentially hazardous. For example, antitank ammunition with a piezoelectric fuze can be detonated by relatively light impact to the piezoelectric element, and others, depending on the type of fuze used, can be detonated by even a small movement. The battlefields of the First World War still claim casualties today from leftover munitions. Modern electrical and mechanical fuzes are highly reliable: if they do not arm correctly, they keep the initiation train out of line or (if electrical in nature) discharge any stored electrical energy.
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