Lightweight Rifle Barrels from Elite Warrior Armament

Elite Warrior Armament has developed a hybrid rifle barrel which marries a steel barrel core with an aircraft-grade aluminum jacket. The core is welded to the jacket, greatly reducing weight, improving rifle balance by reducing the weight up front, and vastly improving heat dissipation.

The aluminum exterior of the barrel quickly absorbs heat from the steel core and radiates it into the air much faster than steel. Not only does this reduce the heat of the barrel for handling, it can increase the lifespan of the barrel by up to 100%.

A 20-inch medium contour barrel for a Remington 700 in .308 reduces weight by 1.5 pounds. This is evident when carrying the rifle and even more obvious when shouldering it and aiming. Another potential gain from the Lightweight Rifle Barrel is that, thanks to the reduced weight and improved handling, longer barrels may be used, improving range and accuracy.

The next item on the Elite Warrior Armament’s list is a Lightweight Rifle Barrel for 5.56/.223 ARs. An initial prototype was on display but no testing has been performed yet.

elite warrior armament barrel

Shelby Murdoc

Murdoc is a freelancer who writes at various publications and web sites including Shooting Sports Retailer and


  • Joshua

    well we know how this turned out with the original AR-10….
    but we’ve gotten smarter since then right?

    • Dave

      This appears to have both a thicker steel core and a thicker jacket than the AR-10 did. The AR-10 had only a very thin steel barrel liner.
      Did they mention how the steel and aluminum parts were welded together?

      • dickburger

        Very carefully

        • Dave

          Lol, probably true. I was going for something more along the lines of what welding process is used though.

          • Joshua

            I would also be very curious to know this, as so far as I know there is no way to weld dissimilar metals, you end up brazing them together

          • Steve

            Theoretically, you can sweat aluminum rod onto the steel and it becomes weldable via GTAW, but I can’t see a manufacturer going through all the trouble (or the cost to train the employees, for that matter). If I could see the area that they say they had welded, then it would be easier to say.

          • GSC

            Some type of friction welding, maybe?

          • Steve

            More than likely it would be ultrasound or friction welded.

          • jared

            Yeah that’s what I am thinking. You would have to or you wouldn’t be able to bond the two within the middle of the barrel

      • Explosive bonding

    • Esh325

      I think there’s been a lot more R&D and advancements in manufacturing since then that might make this idea viable, but I could be wrong.

      • Joshua

        I hope there has been, hence the comment about how we’re supposed to be smarter now than when the Hollywood AR-10s were made

    • Tom

      I don’t think this is meant for high rates of fire, note they show it on a bolt action. The problem you run into with aluminum and steel is the difference in thermal expansion. The aluminum jacket is going to expand around 30% more than the steel core as it gets hot.

      • Wetcoaster

        I have to wonder what happens if these barrels are used in temperature extremes, say in a Midwest winter or the arctic. Actually, I wonder about this with all barrels that involve wrapping some other, lighter material around a steel liner.

  • Will P.

    Would the just rifle barrels be available or are the only going to offer the entire firearm? Because I have a Mauser action that is just begging for a good barrel.

  • Blake

    Any idea how much, say, a Rem 700 bbl costs?

    I hope they offer a threaded option, because recrowning one of these would probably be really hard & might even mess it up.

  • Mr.T

    This is most likely OEM barel from Lothar Walther that have been offering this tech for a decade or so .LW barrels are sold under many brands many aimed at .10/22market

  • No, Chuck Warner is using explosive bonding to join the dissimilar materials.

  • George

    I have been working on composite Al/Steel along these lines for a couple of years. I found that it did not make the barrel much lighter … The stiffness per weight was about a wash… But it does wonders for heat dissipation.

    I am a little confused by why it makes sense for bolt action, but I suspect looking bigger is the main draw here. Which is perfectly reasonable.

  • Giolli Joker

    Longer barrels do not improve accuracy.

  • petru sova

    Such barrels are usually an accuracy failure when compared to all steel heavy barrels. The heavier a gun the less it moves when you pull the trigger or even put your check on the stock. Many rim fire match competitors do not even touch the stock with their hand or face that’s how much even light pressure will cause even a heavy barrel gun to move. The sleeved aluminum barrels and the barrels that were wrapped in nylon on other weapons did not shoot as well as full heavy barrels. They are nothing more than a gimmick of the “Latest and Greatest”.