Abstract: A composite material, comprising a carrier strip the carrier strip comprising a first side the first side comprising a substantially uniform roughness, an electrolytically deposited copper foil layer having opposing first and second sides and a thickness of from 0.1 micron to 15 microns and the entire metal foil layer thickness having been deposited from a copper containing alkaline electrolyte, and a release layer effective to facilitate separation of the metal foil layer from the carrier strip disposed between and contacting both the first side of the carrier strip and the second side of the metal foil layer.

Abstract: A jacket precursor, a pellet first core precursor, and a second core precursor are provided. The pellet and second core precursor are inserted into the jacket precursor. The second core precursor is pressed against the pellet so as to deform the pellet to fill a frontal volume of the jacket precursor as a first core with relatively less (if any) deformation of the second core precursor. An aft portion of the jacket precursor is deformed to contain the second core precursor as a second core. Preferred embodiments are formed substantially as drop-in replacements for existing bullets. A match embodiment features a lead rear core and a very light front core (e.g., a carbonate powder). A non-toxic embodiment comprises a tin front core and a harder rear core.