For velocity, bigger isn't better. There is a theoretical limit around 5,000 fps for a conventional rifle/powder combination. (It is based on the speed of the flame front, not pressure).
The limit is related to the speed of sound in the gun gas (the products of the powder's combustion), not the speed at which the powder burns. The outright theoretical limit is what's known as a "free expansion", that's the case where you have a bullet with a weight of zero, and your gun gas expands at a very high (but finite) speed.
Higher muzzle velocities than 5000fps are possible, but this is seriously in the realm of diminishing returns. I think I recall reading something semi-credible (in Handloaders Guide to Cartridge Conversions, perhaps?) that reported achieving 5,280fps (i.e. one mile per second was his goal). This is within the realm of believability, if not practicality(!).
There are various ways to get higher velocities
- different powder formulations, aimed at increasing the sound speed in the gas produced by the powder. The two main routes to this are to decrease the average molecular weight of the gas molecules produced (e.g. change the powder chemistry so you get more H2 and CO, less CO2), the other is to increase the temperature of the products of combustion
- "travelling charge effect"
- "light gas gun"
- "driver" or "2-stage" gun
If you want to truly get over 5,000 fps, you will need a sabot, and multi staged propellant charges.
http://www.canadiangunnutz.com/forum/showthread.php?t=418967 see page 3
Anywhere you read that so-and-so got over 5,000 fps with his hunting rifle, lets just say that is an INTERNET record....... (or a malfunctioning chronograph). Gerald Bull got one of the HARP guns up to about 5,400 fps. It was a 7" smoothbore with a 3" diameter saboted round, 55' long barrel, loaded with 110 lbs of powder.
Interesting stuff you wrote over that at post #30. I had never heard of "firebrakes" in an artillery charge before, though it sounds like a plausible concept (this would be an effort to achieve the "travelling charge effect"). And it's always nice to read about HARP stuff.
Something to keep in mind with these really high performance guns. There is a parameter called "C/W", which is the ratio of the weight of the powder charge (C) to the weight of the bullet (W).
An ordinary centerfire rifle cartridge will see a C/W in the 0.3 ballpark, e.g. in my .308 target rifle, 45 grains of powder pushing a 155 grain bullet makes for C/W = 0.29. A pretty high performance cartridge would have C/W=0.5 (say a 7mm Rem Mag using 70 grains of powder to fire a 140 grain bullet). If you consider a crazy-overbore cartridge say a .30-378 using 120 grains of powder to push a 125 grain bullet, you get C/W = 0.96.
In the real high velocity guns, C/W ratios of 5 or even more are used to achieve the 5500+fps velocities you read about.
Using 5 - 10 times as much powder as your bullet weighs, truly is in the land of "diminishing returns"!!