Abstract: An improved process provides high-density pre-form billets that meet dimensional limitations required for case-load tooling. Previous isostatic fill procedures were improved in two ways to accommodate varying bulk densities or powder compositions. First, during the isostatic fill procedure, the powder fill is subject to both a high frequency vibration and a high amplitude, low frequency impulse. The combination of these two inputs is critical to ensure polymer bonded explosives pack to consistent densities. Second, unlike in conventional practices, the fill rate is kept constant throughout the entire fill process and the mold is completely filled by the time the required powder mass has been dispensed.

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.