Abstract: A method of filling a projectile case with energetic material includes isostatically pressing a column of the powder to create a pre-formed billet (PFB). The single PFB is placed in and then pressed into the projectile case to create the finished warhead. The single PFB effectively fills a projectile case having a large l/d ratio. The single PFB eliminates the problems and poor quality associated with pressing multiple increments in a projectile case.

Abstract: A press punch for pressing a powder includes a generally cylindrical metallic body and a polyurethane layer disposed around the metallic body. The metallic body has a nominal outside diameter and a generally flat bottom face. The polyurethane layer is disposed around the metallic body such that a bottom of the polyurethane layer is flush with the generally flat bottom face of the metallic body and an outside diameter of the polyurethane layer is substantially the same as the nominal outside diameter of the metallic body. In another embodiment, the outside diameter of the polyurethane layer is greater than the nominal outside diameter of the metallic body.