In the aftermath of the 1986 FBI Miami shootout, the FBI started the process of testing 9mm and .45 ACP ammunition in preparation to replace its standard issue revolver with a semi-automatic pistol. The semi-automatic pistol offered two distinct advantages over the revolver: 1) the automatic offered increased ammunition capacity, and 2) it was easier to reload during a gunfight. The FBI was satisfied with performance of its .38 Special +P 158gr LSWCHP cartridge ("FBI load") based on decades of dependable performance. Ammunition for the new automatic pistol had to deliver terminal performance equal or superior to the .38 Special FBI Load. The FBI developed a series of practically oriented tests involving eight test events that reasonably represented the kinds of situations that FBI agents commonly encounter in shooting incidents.
During tests of 9mm and .45 ACP ammunition, FBI Firearms Training Unit Special Agent in Charge John Hall decided to include tests of the 10mm cartridge, supplying his personally owned Colt Delta Elite 10mm semi-automatic, and personally handloading 10mm ammunition. The FBI's tests revealed that a 170-180gr JHP 10mm bullet, propelled between 900-1000 fps, achieved desired terminal performance without the heavy recoil associated with conventional 10mm ammunition (1300-1400 fps). The FBI contacted Smith & Wesson and requested it to design a handgun to FBI specifications, based on the existing large-frame S&W 4506 .45 ACP handgun, that would reliably function with the FBI's reduced velocity 10mm ammunition. During this collaboration with the FBI, S&W realized that downloading the 10mm full power to meet the FBI medium velocity specification meant less powder and more airspace in the case. They found that by removing the airspace they could shorten the 10mm case enough to fit within their medium-frame 9mm handguns and load it with a 180gr JHP bullet to produce ballistic performance identical to the FBI's reduced velocity 10mm cartridge. S&W then teamed with Winchester to produce a new cartridge, the .40 S&W. It uses a small pistol primer whereas the 10mm cartridge uses a large pistol primer.
The .40 S&W cartridge debuted January 17, 1990 along with the new Smith & Wesson Model 4006 pistol, although it was several months before the pistols were available for purchase. Austrian manufacturer Glock Ges.m.b.H. beat Smith & Wesson to the dealer shelves in 1990, with pistols chambered in .40 S&W (the Glock 22 and 23) which were announced a week before the 4006.[6] Glock's rapid introduction was aided by its engineering of a pistol chambered in 10 mm Auto, the Glock 20, only a short time earlier. Since the .40 S&W uses the same bore diameter and case head as the 10 mm Auto, it was merely a matter of adapting the 10 mm design to the shorter 9x19mm frames. The new guns and ammunition were an immediate success.[7][8]
The 40 S&W case length and overall cartridge length are shortened, but other dimensions except case web and wall thickness remain identical to the 10mm Auto. Both cartridges headspace on the mouth of the case. Thus in a semi-auto they are not interchangeable. Fired from a 10mm pistol the .40 Smith & Wesson cartridge will headspace on the extractor and the bullet will jump a .142 inch freebore just like a .38 Special fired from a .357 Magnum pistol. If the cartridge is not held by the extractor, the chances for a ruptured primer are great.[9] Smith and Wesson does make a double action revolver that can fire either at will using moon clips. A single-action revolver in the 38-40 chambering can also be modified to fire the .40 or the 10 mm if it has an extra cylinder. Most .40 caliber handguns can be easily converted to 9mm for cheaper target shooting with a simple barrel and magazine swap.[10][11]
IMI attempted a similar cartridge in the 1980s, called the .41 Action Express (or .41 AE) for the Jericho 941 pistol.[7] This cartridge was based on a new proprietary case with a 9mm base and 41 caliber suitable main case body. The .41 AE is ballistically similar to the .40 S&W, to the point that some reloading manuals suggest using .40 S&W load data in the .41 AE. The .41 AE was a poor design because the small rim and larger and higher energy .41 case beats the 9mm rim/base up badly. Case life for reloading is relatively short. The .41 AE is for all intents and purposes, now an obsolete and difficult to obtain caliber. The .41 AE uses 0.410-inch (10.4 mm) bullets, whereas the .40 S&W uses 0.400-inch (10.2 mm) bullets. However, as it lacks the backing of ammunition manufacturers in making .410 caliber bullets suited to semi-automatic pistols, the .41 AE has not achieved widespread popularity.[12
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