A capsule assembly for an ultra-high pressure furnace, comprising a containment tube defining a central longitudinal axis, a chamber suitable for accommodating a reaction assembly, a proximate and a distal end heater assembly, and a side heater assembly. When assembled, the chamber and the side heater assembly are contained within the containment tube and arranged longitudinally between the proximate and distal end heater assemblies. Each end heater assembly comprises a respective conduction volume forming a respective electrical path through the end heat assembly. The side heater assembly electrically connects the respective conducting volumes to each other, and heat is produced in the chamber in response to an electric current flowing through the side heater assembly and the conducting volumes. At least the proximate end heater assembly comprises a first insulation component including an outer insulation volume. The conducting volume of at least the proximate end heater assembly includes an inner conducting volume, and the inner conducting volume is laterally spaced apart from the containment tube by the outer insulation volume.

A method for the manufacture of a composite fragmenting material having exothermic properties includes the steps of packing a mold with preformed metal fragments; filling interstitial spaces surrounding the metal fragments with a reactive metal powder to form a mixture; and then sintering the mixture at a temperature effective to both coat the metal fragments with the reactive metal powder and to bond the metal fragments together. In one embodiment the composite fragmenting material is formed into a nosecone for a warhead.

A method for the manufacture of a composite fragmenting material having exothermic properties includes the steps of packing a mold with preformed metal fragments; filling interstitial spaces surrounding the metal fragments with a reactive metal powder to form a mixture; and then sintering the mixture at a temperature effective to both coat the metal fragments with the reactive metal powder and to bond the metal fragments together. In one embodiment the composite fragmenting material is formed into a nosecone for a warhead.

A method of forming tooling for fabricating a part made from a metal powder is described herein. The method includes forming a first sheet and second sheet. The first sheet includes a first protrusion defining a first cavity and a first flange extending about the first protrusion. The second sheet includes a second flange. Additionally, the method includes arranging the first sheet and the second sheet to abut together the first flange of the first sheet and the second flange of the second sheet and to define an enclosure. The enclosure includes a void defined between the first cavity of the first sheet and the second sheet. The void has a shape of the part. The method further includes welding together the first flange of the first sheet and the second flange of the second sheet along a portion of the first flange spaced away from the first protrusion.