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Explosion Welding

Explosion welding is a solid-state process that joins dissimilar metals through a controlled detonation. It produces a high-strength metallurgical bond without melting the metals. Key advantages include no heat-affected zone, only minor melting, and insensitivity to differences in material properties. The process involves detonating explosives between the metals to be joined, using a shock wave to achieve intimate atomic contact at very high velocity. Common applications include pipe welding and cladding metals like copper and nickel alloys.

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97 views22 pages

Explosion Welding

Explosion welding is a solid-state process that joins dissimilar metals through a controlled detonation. It produces a high-strength metallurgical bond without melting the metals. Key advantages include no heat-affected zone, only minor melting, and insensitivity to differences in material properties. The process involves detonating explosives between the metals to be joined, using a shock wave to achieve intimate atomic contact at very high velocity. Common applications include pipe welding and cladding metals like copper and nickel alloys.

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Explosion Welding

Keith Powell
Michael Fernandez
Staton Burrell
Basics
• Explosion welding is a solid-state process
that produces a high velocity interaction of
dissimilar metals by a controlled
detonation
• Oxides found on material surfaces must
be removed by effacement or dispersion
• Surface atoms of two joining metals must
come into intimate contact to achieve
metallic bond
Advantages
• No heat-affected zone (HAZ)
• Only minor melting
• Material melting temperatures and
coefficients of thermal expansion
differences do not affect the final product
• The shock front compresses and heats the
explosive material which exceeds the
sonic velocity of undetonated explosives
Component Terminology
• Base component
– Joined to cladder
– Remains stationary
– Supported by anvil
• Cladding metal
– Thin plate in direct contact with explosives
– Can be shielded by flyer plate
• Flyer plate
– Sacrificial plate placed between explosive
material and cladder plate
– Used to protect cladder metal
• Interlayer
– Thin metal layer
– Enhances joining of cladder to base plate
• Anvil
– Surface of which the backer rests during
explosion
• Standoff
– Distance between cladder and base plate
before explosion
• Bond Window
– A range of variable in process such as
velocity, dynamic bend, and standoff distance
that result in successful weld
• Bonding Operation
– Detonation of explosives that result in a weld
Principle of Explosion
• Cladder metal can be placed parallel or
inclined to the base plate
• Explosive material is distributed over top
of cladder metal
• Upon detonation, cladder plate collides
with base plate to form weld
Placement of Cladder metal-parallel
• Standoff distance predetermined
and unique to material combination
– Achieved by placing shims
between plates
– Shims designed to be
consumed by explosion wave
and do not affect weld
• Usually ranges between 0.5-2 times
the thickness of cladder plate
• Cladder must reach critical velocity
before impact
Cladder placement-Angled

VD

Where:
Vc = collision velocity
Vc
VD = detonation velocity
Vp Vp = plate Collision velocity
α = preset angle
β = dynamic bend angle
γ = collision angle
Explosive material
• High velocity (14750-25000 ft/s)
– Trinitrotoluene (TNT)
– Cyclotrimethylenetrinitramine (RDX)
– Pentaerythritol Tetranitrate (PETN)
• Mid-low velocity (4900-47500 ft/s)
– Ammonium nitrate
– Ammonium perchlorate
– Amatol
Assuring a good weld
• Three types of detonation wave welds
– Shock wave develops if sonic velocity is
greater than 120% of material sonic velocity
(type 1)
– Detached shock wave results when
detonation velocity is between 100% and
120% of material sonic velocity (type 2)
– No shock wave is produced if detonation
velocity is less than material sonic velocity
(type 3)
Assuring a good weld
• Type 1
– Material behind shock wave is compressed to
peak pressure and density
– Creates significant plastic deformation locally
and results in considerable ‘shock hardening’
• Type 2 & 3
– Pressure is generated ahead of collision point
of metals
– When subject to large pressures, metal
ahead of collision point flows into spaces
between plates and takes form of high-
velocity jet
– Effaces material and removes unwanted
oxides and other unwanted surface films
– No bulk diffusion and only localized melting
Assuring a good weld
• Detonation velocity is a function of
– Explosive type
– Composition of explosive
– Thickness of explosive layer
– Can be found in tables
Assuring a good weld
• Sonic velocity of cladding material can
calculated using:

Where:
K = adiabatic bulk modulus
ρ = cladding material density
E = Young’s Modulus of cladding material
‫ = ע‬Poisson’s ratio of cladding material
Applications
• Any metal with sufficient strength and
ductility can be joined
Applications
• Can weld large areas of metal
• Can weld inside and outside surfaces of
pipes
• Transition joints can be made
History
• Arnold Holtzman and a team at DuPont in Delaware put
a lot of research into developing the process.
• Holtzman filed for a US patent in 1962 for explosion
welding, received the patent in 1964 and began
commercial production of bi-metallic explosion welded
clad in 1965.
• Detaclad licensed the process and was bought by
Dynamic Materials Corporation (DMC).
• Other companies have merged with DMC and acquired
the current name DMC Groupe SNPE making them a
worldwide company.
Common industries that use explosion welding

• Chemical Processing
• Petroleum Refining
• Hydrometallurgy
• Aluminum Smelting
• Shipbuilding
• Electrochemical
• Oil & Gas
• Power Generation
• Cryogenic Processing
• Pulp & Paper
• Air conditioning & Chillers
• Metal Production
Examples
Examples

3” Diameter AI/SS Ring Copper/Stainless 12” UHV Assembly


Examples
• United States dimes and quarters are
presently a clad “sandwich” of copper
inner-core and a silver-colored nickel-
copper alloy
Works Cited
• http://www.annualreviews.org/doi/pdf/10.1146/annurev.ms.05.08017
5.001141
• http://www.authorstream.com/Presentation/rock354-421051-
explosive-welding-final-unconventional-machining-mp-iii-education-
ppt-powerpoint/
• Young, G (2004). "Explosion Welding, Technical Growth and
Commercial History" (PDF). Dynamic Materials Corporation.
http://www.dynamicmaterials.com/data/brochures/1-
%20Young%20Paper%20on%20EXW%20History.pdf. Retrieved
2010-11-29

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