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Riot police are marching across the burning fields of the UN capital on Mars to quell pro alien insurrectionists. Ethics and activism dictate that no lethal weapons can be used on other humans. But since handheld railgun tech is already widespread for anti-alien use some generals in the chain of command want to save money. Here is their paraphrased conversation:

Steve: Bob, we need to get rid of these rebels, but we can’t use our big supply of lethal railguns. How can our police quell the riots without using the money we have set aside for personal use?

Bob: If only all those railguns we have could be nonlethal!

The railguns are similar to assault rifles, but they can get up to 2kps and rapid fire. Is there any way to make a railgun nonlethal without spending too much of the generals' vacation money?

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    $\begingroup$ There is no such thing as a non-lethal weapon; there are only less lethal weapons. (Because a truely non-lethal weapon is obviously a non-weapon.) To reduce the lethality of rail guns do what we do with firearms: fire less lethal projectiles. Ground salt, rubber etc. In other words, you make a less lethal rail gun in the same way that you make a less lethal sling, or less lethal bow, or less lethal shotgun, and so on. $\endgroup$
    – AlexP
    Commented Jan 7, 2021 at 18:11
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    $\begingroup$ Rubber bullets hurt a lot of people because the shooters use them improperly. Rubber bullets are usually made to be shot so they bounce off the ground before hitting the rioters. $\endgroup$
    – NomadMaker
    Commented Jan 8, 2021 at 0:19
  • $\begingroup$ R u familiar with Right Hand Rule? Basically the power of the accelerating projectile depends on how much juice(electricity) and mass of bullet, go with rubber bullet or chalk and go easy on the juice your target should be fine ;D $\endgroup$
    – user6760
    Commented Jan 8, 2021 at 6:22
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    $\begingroup$ What exactly do you want to do? I think you're missing a big part of your question. Rebels + nonlethal rail gun = what exactly? Do you want to cripple all protesters? If you can disable, you can kill. It sounds like your entire plan is to randomly shoot into a crowd and then magic happens, the thread is stopped but nobody died. If that's your level of realism, you might as well say the rail gun is just non lethal. Could you please explain the strategy of your police force? Instead of a nonlethal weapon, choose a strategy that minimizes fatalities $\endgroup$
    – Raditz_35
    Commented Jan 8, 2021 at 9:56
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    $\begingroup$ Don't forget railguns (as we have them) require the bullet be made of metal you can put a rubber tip on it, but that might melt off as the metal heats during firing! $\endgroup$ Commented Jan 8, 2021 at 15:04

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It's a railgun where the round is accelerated by the gun itself down the barrel by electronics...It's not like a gunpowder cartridge where the power level is determined by the powder charge in the round so you're trapped at whatever power level the round is.

So just dial down the acceleration in the barrel and at some point it would just be like lobbing bullets at people with your hands. Nothing says a railgun has to shoot at hypersonic speeds.

Then you would also need to to modify the bullet materials so they aren't so hard. Since there are no explosions and the acceleration is more gradual than a bullet you could conceivably use other materials designed to reduce the impact (putty or something maybe?).

The metallic part of the round would have to be minimized such that it is foil or powder and sheds so it can be slowed down by air resistance. Or impregnated through a softer medium.

That's about as nonlethal as you could manage with something like that where your impact surface is small making it difficult to distribute the force out and reduce the pressure exerted on impact. The smaller diameter your regular railgun rounds are, the more challenging this will be. Larger round diameters and round lengths let you do things like fire long sticks of putty that have much more mass but can also deform.

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    $\begingroup$ Pretty much this. You also can use coilguns with rubber-coated rods instead - even modern RL portable coilguns constructed by some guy in a garage have a considerable punch (enough to go through an unopened soda can), but probably aren't lethal, especially if the projectile will have blunt end. The only think to keep in mind tho is that the effective firing distance will suffer from the projectile speed greatly. But I think that for a riot control even 100-meter fire range would be bit excessive anyway. $\endgroup$ Commented Jan 8, 2021 at 5:27
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    $\begingroup$ This is technically correct if we just look at the title of the question, but it will not stop any protesters. As we all know from stonings, you can kill people by throwing stuff at them. The standard in this stack exchange is really low if you're collecting upvotes here. Could you include how this will still be a weapon to control, I quote, riots? Even medieval armor was able to completely deflect arrows that would fly through a normal human body like hot butter. This sounds really ineffective once the protesters figure out the concept of protecting themselves $\endgroup$
    – Raditz_35
    Commented Jan 8, 2021 at 10:01
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    $\begingroup$ @Raditz_35 I feel like this is moving goalposts a bit as you seem to expect be all end all 100% non-lethal weapon that is also automatically effective against everything from puppies to armoured knights. The stoning and plate armour and stoning examples I feel are specially misleading in real world circumstances. Protestors throw rocks during riots. Do you consider that lethal force because stonings can kill people? And plate armour also works against rubber bullets but how many rioters do you see running around with plate armour? $\endgroup$
    – DKNguyen
    Commented Jan 8, 2021 at 14:33
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    $\begingroup$ @Raditz_35 You can certainly argue a frame challenge though but that is broader than just about how to adapt a tool to be more fit for purpose. $\endgroup$
    – DKNguyen
    Commented Jan 8, 2021 at 14:36
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    $\begingroup$ @Raditz_35 I'll have to just repeat that you seem to expect the railgun to be the be-all-end all riot suppression tool. That's not the way I interpreted the question, but if that's what you believe what the OP intended then you should frame challenge. Because just like you said, police don't just use rubber bullets, or just use water cannon, or just use tear gas. There are multiple tools. $\endgroup$
    – DKNguyen
    Commented Jan 8, 2021 at 16:04
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Shock-Bayonets

A railgun needs to have a big powersource in form of a battery to work. We could use this electric energy to power a bayonet-like device, which the police could use as a shocking stick, kinda like an electric cattle prod.

enter image description here

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  • $\begingroup$ For comparison, tasers or shock prods typically run on a handful of consumer-grade batteries, so using a railgun-sized power source is major overkill and is not needed in the slightest. This solution seems rather unrelated to the railgun itself - you could bolt a taser onto virtually any weapon and call it "nonlethal". $\endgroup$ Commented Jan 8, 2021 at 14:42
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    $\begingroup$ @NuclearHoagie well there is a difference between adding an independent taser system and utilizing the already available battery pack of the railgun. It would at least save some weight. Remember that the great power supply is still used for the railgun itself. The taser is just a free bonus. $\endgroup$
    – Art Krenn
    Commented Jan 8, 2021 at 15:22
  • $\begingroup$ I wonder whether it would be possible to statically charge up a round prior to firing so that it shocks the target on impact, and then shoot such a round at lower velocities. $\endgroup$
    – DKNguyen
    Commented Jan 8, 2021 at 20:25
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Fit them as rifle grenade launchers. When the railgun projectile gets to the end of the barrel, the fast-moving but lightweight projectile hits a much heavier grenade, sending it off at a sedate pace that-a-way. Inside the grenades, you have traditional less-lethal payloads: tear gas, flashbangs, etc. Disadvantages are indifferent range and accuracy, not huge drawbacks under the circumstances.

The size and shape of the railgun itself (fairly lightweight, long durable barrel) would make it ideal for close quarters combat, which may or may not be lethal depending on how much practice your troops have had with it.

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    $\begingroup$ "hits a much heavier grenade, sending it off at a sedate pace" - at 2 km/s... I don't think so. The grenade would disintegrate right then and there. $\endgroup$
    – Alexander
    Commented Jan 7, 2021 at 18:41
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    $\begingroup$ @Alexander 2 km/s is only about twice as fast as a conventional assault rifle round. Depending on the size of your projectile, it wouldn't be that far out of the ballpark of what's been done before. $\endgroup$
    – Cadence
    Commented Jan 7, 2021 at 18:45
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    $\begingroup$ @Alexander Existing "bullet-trap" style rifle grenades, that is. The railgun projectile would be in the same ballpark of kinetic energy (perhaps a few times as much, but potentially much closer if it was lighter than an equivalent rifle round) so the engineering requirements would be similar. $\endgroup$
    – Cadence
    Commented Jan 7, 2021 at 19:12
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    $\begingroup$ The only type of "bullet-trap" style rifle grenades suitable for railguns would be "rod type" (because railguns have no muzzle blast), and this type was relatively poor performing 100 years ago. With 2 km/s speeds, there is a good chance of a grenade and the railgun itself coming apart during firing. $\endgroup$
    – Alexander
    Commented Jan 7, 2021 at 19:29
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    $\begingroup$ @Alexander and yes, with GUNPOWDER (or nitrose pulver), those were performing badly. Because you have a fucking explosion meeting too much resistance. But railguns accelerate gradually. Meaning that "rod type" grenades could work perfectly. (Of course depending on the specifics of the railgun, but there's a good chance they are designed this way). And they absolutely would be, given that they were designed against aliens, so potentially doubling as grenade launchers would concievably have been a "nice to have" in the design specs $\endgroup$
    – Hobbamok
    Commented Jan 8, 2021 at 12:12
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Much depends on how the railgun technology works.

For example, would it be possible to replace the bullets with very small metal pellets (possibly metal foam or wireballs) covered in soft rubber and ablative foam? This would enormously decrease the range, but the weapons could become nonlethal - less metal to be electromagnetically accelerated, way less kinetic energy, no penetrative power to speak of.

Or the other way round: heavier projectiles, that would not be accelerated to the same disastrous speeds, and whose nature could be further rendered less lethal. Imagine a rigid steel wire, powering a nerf bullet with a soft (or not so soft) rubber tip. This could still have a significant range - it would be a sort of arrow - while not being necessarily lethal. The energy transfer from the railgun coil would probably shorten the railgun lifetime significantly - instead of a quick electromagnetic fling you'd get a comparatively slower build-up.

Or "micro-flechette rounds" - depending on the size of the flechettes, air friction could slow them down enough to not be (immediately) lethal, or not unless some vital organ gets mulched (e.g. liver or spleen). The railgun would still be lethal at point-blank range, which could be useful in some scenarios. And of course it would depend on which bullets were fired.

This might have any negative effect on the railguns' life that we might desire (from none at all, to turning them into one-shot blunderbusses when the internal linear coupled coil overloads and cracks, or even melts down).

Also the firing could have lots of attached special effects, like the ablative foam exploding with a loud bang (2 kps is way over the speed of sound), or the wireballs igniting due to atmospheric friction (that is actually very unlikely at sea level, but who knows... maybe magnesium-steel wireballs were selling for a song and someone thought they might cheaply replace pure steel ones).

"Nonlethal" means actually "not intentionally and directly lethal". Someone hit in the face, or at point-blank range, or set on fire by an unintentionally incendiary round could still die. A hard hit in the wrong place can still kill someone with the appropriate condition. Hitting someone who is driving... etc.

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    $\begingroup$ How about some kind of chaff bullet, whose muzzle velocity breaks it up into a cloud of tiny pieces of foil? They slow down dramatically, but a cloud of them would sting like heck. $\endgroup$ Commented Jan 9, 2021 at 6:01
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Gas Parachutes.

The bullets are long and include a fluid chamber. Further they have an air duct leading from the front of the bullet to a parachute-like part of the bullet. As long as the bullet is faster than x, the parachute-like part expands outwards slowing the bullet down greatly. Below speed x it doesn't expand anymore so the bullet won't instantly fall to the ground.

The bullets have a foam tip so they don't hurt.

The foam is connected to the chamber - but only when or after the parachute expands. This way you can put in a non lethal contact poison which doesn't hurt people handling the bullets.

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A big problem with these "less lethal" guns is the projectile speed and muzzle energy are set by the explosive charge, which means they're always the same. But the large projectile slows down quickly as it flies due to air drag, so it will be "less lethal" over a short range of distance, useless at long range, and at close range it will crack skulls. If it was weak enough to be safe at close range, it would then be useless at 20 meters...

enter image description here

Sure, the military want railguns because they can shoot projectiles much faster than powder, but being electric, railguns and coilguns have another feature: adjustable projectile speed.

So you could make a "less lethal" railgun by having a scope rangefinder that automatically measures distance to target and adjusts shot power to deliver the required projectile speed at the target.

This could lead to some interesting plot twists, for example:

  • The integrated face and shape recognition software which was originally designed to avoid shooting people in the face doesn't work that well with aliens, leading to various losses of appendages, and of course accusations of "racist guns designer to murder only aliens".

  • Likewise, power should be adjusted depending on the target ; after all some aliens come with thick scales and would shrug off bullets and others are quite squishy and would explode if they receive a shot intended for the former. Great opportunity for unintended misbehavior of software "features" and class action lawsuits.

  • If you aim at someone far away, the gun will set itself to high power, then if someone steps in front of it at the shot is fired, they get obliterated.

Although... I'd recommend a coilgun instead. Railguns require a conductive sabot to propel the round, and that will fly off and split into several pieces, possibly sharp and very hot, turning the thing into a kind of shotgun. But everyone knows the real reason it was decommissioned was cost ; after all those sabots (and lawsuits) are expensive, and if you use a coilgun you can shoot the same projectile several times if you recover it...

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This answer considers the case where a railgun works under the same principle as current technology.

Step 1: Calculate the % of the default current needed to make the railgun bullets as slow as they need to be to be considered non-lethal. Eg: 10% of the original power makes bruises but doesn't penetrate people.

Step 2: Add a resistor (obviously low resistance, high power) in parallel to the rail-bullet-rail circuit in order to suck out the remaining percentage of the current. Resistors, and their accompanying metal connector modules, will probably be dirt cheap.

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    $\begingroup$ Bullets are devastating because of the kinetic energy that they deliver to a target. They tend to have low mass and high velocity. What you want for a "less-lethal" weapon though is not so much kinetic energy, but a big wallop of momentum. If you simply dial down the velocity, then the tiny bullet that was ideal for the "lethal" application will carry nowhere near enough momentum for the "less-lethal" application. You need a big, massive projectile for that. $\endgroup$ Commented Jan 8, 2021 at 17:14
  • $\begingroup$ I think you're jumping from one end of the other; surely between "lethal" and "useless" there will be some sweet point. I agree with enlarging the projectile - kind of "flying fists". $\endgroup$ Commented Jan 9, 2021 at 18:04
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Ferro-fluid adhesive gel balls. The ferro-fluid provides the ferrous material necessary to accelerate the ball electromagnetically. Then the ferro-fluid causes the ball material to wrap around the target immobilizing them. Maybe a binary composition that mixes on contact and causes the ferrous particles to simultaneous repel and attract each other causing them to spread out evenly around the target. Then quickly hardening to impede movement. Removal could be done with a ceramic knife to part the gel and peel it off of the target. Or an antagonist component that breaks down the gel.

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Bolo projectiles. When launched from the rail gun the weights separate drawing a thin cable between them. The cable hits the targets and the weights cause the cable to wrap around the target and then lock somehow when they finish wrapping. Of course, as with any seemingly non-lethal weapon, accidents will happen (wrapping around the throat, crushing the skull, etc.) but they are rare incidents.

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    $\begingroup$ Or just headshotting someone with the bola-ball. Which, in a riot situation, is gonna be pretty common. $\endgroup$
    – Erik
    Commented Jan 8, 2021 at 22:53
  • $\begingroup$ @Erik, yeah, but this is just a best attempt to utilize existing hardware without too much expense. You gotta expect a 'few' accidents. I envision this as being preferred with individuals fleeing from the authorities. Rather than shooting them dead, you shoot a bolo round at their legs, then catch up with them at a more leisurely pace. In any event, you use the tools you have been allocated. $\endgroup$
    – Arluin
    Commented Jan 8, 2021 at 22:55

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