Melt cast thermoplastic elastomeric plastic bonded explosive

A method of melt casting plastic bonded explosives by: A. forming a uniform binder mixture of the following ingredients (1) from 10 to 30 weight percent of a triblock polymer of the formula A-B-A wherein A represents a polystyrene block and B represents an elastomeric midblock which is selected from the group consisting of polybutadiene, polyisoprene, and polyethylenebutylene; and (2) from 70 to 90 weight percent of a low viscosity oil selected from the group consisting of naphthenic, paraffinic, and olefinic oils by mixing the ingredients under low-shear conditions at a temperature of from 80 DEG C. to 110 DEG C.; B. mixing an energetic filler into the binder mixture under low shear conditions and at a temperature of from 80 DEG C. to 110 DEG C., provided that the viscosity of the mixture does not exceed 20 kilopoise; C. pouring the energetic filler-binder mixture formed in step B into a mold; and D. cooling energetic filler-binder mixture to form a solid explosive composite. Rubber phase associating and polystyrene phase associating hot melt resins may also be used in the binder mixture to improve the physical properties of the final plastic bonded explosive composite.