While analyzing the radar data on the new bullet, Hornady engineers noticed something right away that was puzzling. In Drag Coefficient versus Mach (Cd vs Mach) graphs, they saw that the new projectile was gaining drag shortly after leaving the barrel, which affected the performance of that bullet for the rest of its flight path. Simply put, the bullet acted like it had one particular BC for the first 100 to 150 yards, then transitioned to a lower BC for the rest of its flight path. Further testing was done with other bullets including BTHP match and A-Max bullets. While the BTHP bullets Cd vs Mach charts looked as expected, the A-Max bullets were showing the same increase in drag that the prototype hunting bullet did. It was as if the bullet was changing shape in flight.
Further testing was done to confirm suspicions that the polymer tip was the culprit. Aerodynamically efficient, high BC bullets at high velocity were suffering from polymer tips softening and deforming in flight. Further testing proved that it happens to all conventional polymer tipped bullets, regardless of manufacturer. Tipped varmint bullets and conventional low to medium BC (sub .550 G1) bullets are not significantly affected. They simply do not hold a high velocity long enough for the aerodynamic heating to significantly affect their tip.
The Hornady 6.5mm 140gr A-Max is a very popular match bullet. Its long-time published G1 BC of .585 has been measured with chronographs at the muzzle, 100 and 200 yards. The radar verifies that exact BC out to 200 yards. When fired at 800 yards; however, the radar verified average BC it is actually .545. This is because of the polymer tip melting and deforming during flight. When the traditional tip is replaced with a Heat Shield tip, the Radar verified 800 yard average BC becomes .610 – a huge improvement! Why a .610 when we already established a 200 yard BC of .585? The .610 BC shows that the traditional tip was already exhibiting degradation at 200 yards.