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Explosion Welding Seminar

The document discusses explosion welding, which bonds materials through high-speed collision rather than melting. It begins with an introduction and history, then covers principles, features, materials, advantages, disadvantages, and applications. Explosion welding works by detonating explosives above plates set at an angle, driving them together at velocities over 4000 m/s. The impact forms a wavy bond through mechanical interlocking without melting. It can join normally unweldable combinations like aluminum and steel. Common applications include cladding, heat exchangers, and repairs.

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vaibhavsawal
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691 views22 pages

Explosion Welding Seminar

The document discusses explosion welding, which bonds materials through high-speed collision rather than melting. It begins with an introduction and history, then covers principles, features, materials, advantages, disadvantages, and applications. Explosion welding works by detonating explosives above plates set at an angle, driving them together at velocities over 4000 m/s. The impact forms a wavy bond through mechanical interlocking without melting. It can join normally unweldable combinations like aluminum and steel. Common applications include cladding, heat exchangers, and repairs.

Uploaded by

vaibhavsawal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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PRESENTED BY :- VAIBHAV B.

SAWAL
GUIDED BY : D.S. BHAMARE
Department of Mechanical Engineering
NDMVP NASHIK
 INTRODUCTION

 HISTORY

 PRINCIPLES OF EXPLOSION WELDING

 SAILENT FEATURES OFEXPLOSION WELDING

 EXPLOSIVE MATERIALS

 ADVANTAGES & DISADVANTAGE

 APPLICATIONS

 REFERENCES
 What is Explosion welding ?

 No filler metal used

 No external heat supplied

 No diffusion occur

 Bonding is metallurgical, combined with mechanical


interlocking that results from a wavy interface between metals
 Arnold Holtzman

 Holtzman filed for a US patent in 1962 and received patent in 1964

 Detaclad licensed the process and was bought by Dynamic Materials


Corporation (DMC).
 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.

 Waves are generated so due to mechanical bonding joining takes

place.

 A single detonation cap can be used to ignite the explosive.


Where:
Vc = collision velocity
sin  sin  VD = detonation velocity
Vc  VD  VD
sin(   ) sin  Vp = plate Collision velocity
α = preset angle
β = dynamic bend angle
γ = collision angle
 The high velocities are promoted by carefully detonated explosives.

 The process can be done in vacuum to reduce sound & blast.

 Typical impact pressure are millions of psi.

 Well suited to metals that are prone to brittle joints when heat welded such as,

• Al on steel
• Ti on steel
 This process doesn’t work well for,

• Brittle metals with < 5% tensile elongation


• Charpy V-notch value < 10 ft.lb.
Contd..
 TYPICAL EXPLOSIVE FORMS

• Plastic flexible sheer


• Cord
• Pressed shapes
• Cast shapes
• Powder/granular
 DETONATION VELOCITY IS A FUNCTION OF
• Composition of explosive
• Thickness of explosive layer
Contd..

K E
Vs  K
 3(1  2 )
Where:
K = Adiabatic bulk modulus
ρ = Cladding material density
E = Young’s Modulus of cladding material
‫ = ע‬Poisson’s ratio of cladding material
Contd..

 STRAIGHT, DIRECT METAL-TO-METAL

 WAVY

 STRAIGHT, BUT WITH A CONTINUOUS LAYER


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)
Contd..
 Type 1
• compressed to peakpressure and density
• significant plastic deformation
considerable ‘shock hardening

 Type 2 & 3
• Pressure is generated ahead of collision point
• Effaces material and removes unwanted oxides •
No bulk diffusion and only localized melting
 High velocity (4572-7620 m/s)
• Trinitrotoluene (TNT)
• Cyclotrimethylenetrinitramine (RDX)
• Pentaerythritol Tetranitrate (PETN)
• Datasheet
• Primacord
 Mid-low velocity (1524-4572 m/s)
• Ammonium nitrate
• Ammonium perchlorate
• Amatol
• Nitroguonidine
• Dynamites
• Diluted PETN
• Very large work pieces can be welded.
• (Al + Steel) materials can be welded.
• Can bond many dissimilar, normally unweldable metals..
• Process is compact, portable, and easy to maintain.

• No ned for surface penetration.


• No heat-affected zone (HAZ).
• The strength of the weld joint is equal to or greater than the
strength of the weaker of two metals joined.
• Metals must have high enough impact resistance and ductility
• The geometries welded must be simple-flat, cylindrical, conical
• The cladding plate can’t be too large
• Noise & blast can require worker protection, vacuum chambers, buried in sand/water.
• Cladding of base metals with thinner alloys e.g. cladding of Ti with mild steel.
• Seam and lap welds.
• Reinforcing aerospace materials with dissimilar metal ribs.
• Heat exchangers.
• Tubular transition joints.
• Used as a repair tool for repairing leaking tube-to-tube sheet joints.
• Spot welding.
• Flat plates.
• Joining of pipes in socket joints.
• Any metal with sufficient strength and ductility can be joined
Contd..
Common industries that use Explosion Welding

• Petroleum Refining • Chemical Processing

• Hydrometallurgy • Aluminum Smelting

• Shipbuilding • Electrochemical

• Oil & Gas • Power Generation

• Cryogenic Processing • Pulp & Paper

• Air conditioning & Chillers • Metal Production


3” Diameter AI/SS Ring Copper/Stainless 12” UHV Assembly
 Zhanga, Ke Xin Jiaoa,⁎, Jian Liang Zhanga,b, Jianping LiucMicrostructure and mechanical
properties investigations of copper-steel composite fabricated by explosive welding
Parmar, R.S. "Explosion Welding."Welding Processes and Technology. Third ed. New Delhi: Khanna,
2012. 389-403. Print.
Kalpakjian Seope, Schmid Steven R.: “Manufacturing Engineering & Technology” Pearson
Education India, 2009, pp 832.
Sharma, P.C. A textbook of production Technology. 7. New Delhi: S.Chand & Company Ltd, 2011,
373-374. Print.
Moeed, K.M., Manufacturing Science, Umesh Publications, New Delhi, New Delhi, 2006.

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