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"The M4 has served us well but it's not as good as it needs to be," Coburn said.

Battlefield surveys show that nearly 90 percent of soldiers are satisfied with their M4s, according to Brig. Gen. Peter Fuller, head of the Army office that buys soldier gear. Still, the rifle is continually being improved to make it even more reliable and lethal.

Fuller said he's received no official reports of flawed weapons performance at Wanat. "Until it showed up in the news, I was surprised to hear about all this," he said.

The study by Douglas Cubbison of the Army Combat Studies Institute at Fort Leavenworth, Kan., hasn't been publicly released. Copies of the study have been leaked to news organizations and are circulating on the Internet.

Cubbison's study is based on an earlier Army investigation and interviews with soldiers who survived the attack at Wanat. He describes a well-coordinated attack by a potent enemy that unleashed a withering barrage with AK-47 automatic rifles and rocket-propelled grenades.

The soldiers said their weapons were meticulously cared for and routinely inspected by commanders. But still the weapons had breakdowns, especially when the rifles were on full automatic, which allows hundreds of bullets to be fired a minute.

Cubbison acknowledges the high rates of fire during the two-hour battle may have led to the failures. But he says numerous problems occurred relatively early in the engagement.

He also said the enemy forces were "experienced, numerically powerful, highly skilled, adequately equipped (and) tactically accomplished."

The platoon-sized unit of U.S. soldiers and about two dozen Afghan troops was shooting back with such intensity the barrels on their weapons turned white hot. The high rate of fire appears to have put a number of weapons out of commission, even though the guns are tested and built to operate in extreme conditions.

Cpl. Jonathan Ayers and Spc. Chris McKaig were firing their M4s from a position the soldiers called the "Crow's Nest." The pair would pop up together from cover, fire half a dozen rounds and then drop back down.