To improve the energy property and low vulnerability of cast HMX-Al based explosives， high solid -content aluminized PBX were designed by analyzing the influences of Al and HMX contents on detonation properties. A casted PBX GOL-42 of 90% solid content with HTPB/IPDI binder was manufactured by introducing desensitizers and process agents and was optimized by three-grade grain-size distribution. The GOL-42 explosive showed good processing and safety properties. The detonation property， low vulnerability， mechanical property， thermal property and accelerated storage property were measured by their corresponding standard test methods. The results showed that its measured density， detonation velocity， detonation pressure， Gurney coefficient of Φ25 mm cylinder test was 1.782 g·cm^-3， 8251 m·s^-1， 26.9 GPa， 2.76 mm·μs^-1， respectively. And in the low vulnerability examinations， including bullet impact test， slow cook-off test and fast cook-off test， all the reaction grades were combustion. Its estimated storage life was over 20 years. GOL-42 showed perfect overall properties and was predicted as a long-life low vulnerability cast explosive.