Methods of manufacturing metal, metal-matrix, metal-metal-matrix composite weapon barrels offer barrels with improved thermal performance and rigidity with no, minimal or negative weight increase. A barrel may include a barrel core surrounded by a lightweight, thermally conductive sleeve made from metal, metal-matrix composite (MMC) materials, also referred to as metal-matrix material. The barrel core and barrel sleeve may include aligning features to prevent separation and movement of the sleeve along the core. The disclosed methods provide for material combinations and part designs that prevent separation of their parts over the life of the weapon barrel and allow the barrel to perform at high cadence over the whole temperature range the barrel is used.