Exactly what is Explosive Welding Plates?
Copper Clad Steel, that is, the metal composite plate produced by the explosive welding method (explosion welding method), explosive welding plate generally refers to the explosion of the metal composite plate. An explosive welding composite plate is a type of composite material plate manufactured by utilizing explosive forming technology, along with its manufacturing process involves multiple steps like explosive forming, metal composite, and surface treatment.
Metal explosive welding technology is a composite material processing technology that utilizes the large energy generated by the instantaneous generation of explosives to instantly composite 2 or more kinds of similar or dissimilar materials together, which technology can weld alloys with various properties, especially those that are not dissolved, into one piece.
In comparison with the direct rolling composite method:
(1) loading speed, that is, the loading process is instantaneous ;
(2) Placed on the workpiece high-pressure pulse load, loading stress is a lot higher than the yield strength of the metal material;
(3) The bonding area shows wave-like metallurgical bonding characteristics;
Explosive welding composite plate history
Explosive composite discovery is the earliest in 1944, the American L.R. Karl (Carl) inside a dynamite explosion test, accidentally found two bits of 1-inch diameter, thickness of .035 inches of thin brass discs, due to the sudden impact of the explosion and was welded together. In fact, in World War II, individuals the repair of wounded tanks, but additionally often found that tilted impact to the tank on the shrapnel will be firmly welded to the tank armor phenomenon, just during the war individuals have no time to analyze it.
In 1947, the Siberian branch of the Soviet Academy of Sciences, the famous scientists M.A. Lavrentsev in the study of polymer bombs to penetrate the armor also found this phenomenon, within his dissertation formally known as “explosive welding”.
In the field of welding, the welding of various materials, like steel and aluminum, steel and copper, is technically very difficult. And huge welding depth of welding can also be very difficult, if you wish to use conventional welding, shielding welding and other welding methods will be two 40mm thick wide plate welded into a 80mm thick wide plate, it is estimated that no one can do. However, the explosive welding is ideal to resolve the two problems at the same time.
Explosive welding composite plate principle production method
Explosive welding is a composite plate manufacturing method that combines one or even more materials into a single piece using explosives as the energy source. Following the explosion of explosives, the blast products form a high-pressure pulse load, directly working on the compound plate, promoting the high-speed movement of the compound plate, in the collision point of the compound plate as well as the substrate tilt collision, accompanied by violent plastic deformation as well as the formation of the jet, the jet takes away the top of the contamination layer, so the welded metal flat plate with a clean surface in contact with one another at high temperatures and high pressures, the two kinds of plate will realize the strong metallurgical bonding.
Explosive welding composite plate-specific production methods:
1. Explosion molding
Explosion molding is the initial step in the manufacture of explosive welding composite plates. Within the explosion forming process, explosives in some conditions instantly detonated, the resulting high-pressure gas will be pushed to the opposite side of the metal plate mold, so the metal plate in an instant to achieve the desired size and shape. This forming technique is described as high precision and high efficiency.
2. Metal composite
Within the explosion molding, the necessity for metal composite. This step is usually utilized in explosion welding or explosion crimping and other methods, 2 or more metal plates with the explosion energy combined together to form a composite material. Throughout the metal composite process, a metallurgical reaction occurs between different metals, forming a strong metallurgical bond.
3.Surface treatment
Surface treatment is usually needed to enhance the surface quality and corrosion resistance of the explosive welding plate. Commonly used surface treatment methods include spraying, plating, chemical plating and so on. These techniques can increase the wear resistance, corrosion resistance and aesthetics of the composite plate.
Explosive welding composite plate production process, although simple, flexible production, however the technical requirements are high, hard to accurately control, the parent material properties (toughness, impact properties, etc.), explosives properties (bursting speed stability, safety, etc.), the initial parameters (the amount of explosives per unit area, the base compound plate spacing, etc.) as well as the dynamic parameters (collision angle, the compound plate collision speed, etc.) of the choice and system coordination of the composite plate of the finished product yield and quality has a direct impact.
The composite interface includes direct bonding area, melting layer and vortex. Atomic diffusion exists in the bonding interface, and severe plastic deformation with work hardening happens in the bonding zone. The bonding surface has a wavy structure, that is beneficial to the improvement of bonding strength and tensile strength.
Explosive welding plate performance
Explosive welding explosive welding plate is not going to alter the chemical composition and physical state of the original material, according to the actual needs of the composite material to be individually processed into the required optimal state.
Explosive welding plate application performance is superb, can withstand cold, hot processing without changing the thickness of the combination of materials compared to the combination of composite materials is extremely high strength, usually higher than the lower side of the combination of materials, that is unattainable by other technologies. The composite material is not going to delaminate or crack during subsequent heat treatment, leveling, cutting, rolling, spinning and other production.
For room temperature and 550 ? heat management of carbon steel surface layer (near the interface layer) has serious deformation caused by fibrous tissue and several fine particles, the center of the organization of ferrite plus pearlite; stainless steel interface for the second phase of point-like organization, the center of the needle-like organization. But by 650 ? management of carbon steel samples near the interface area of small particles of the organization disappeared (that may occur decarburization), the grain becomes coarse, the center of the organization is still ferrite plus pearlite, but can not be seen in the business of the slip line produced by deformation; as well as in the stainless steel interface there are a large number of small black particles, titanium steel composite plate could be the decarburization of chromium carbide particles formed after the advantages of the fabric into a whole, giving full play to the usage of different metal materials, and greatly save rare and rare materials, and the usage of different metal materials. The use of performance greatly saves rare metal materials, thus lowering the production cost of equipment.
Weak demand and oversupply in Asia have pushed steelmakers in the area to develop supplies of low-carbon steel and iron, especially as the Jan. 31 reporting deadline for the European Union’s Carbon Boundary Adjustment Mechanism (CBAM) draws nearer, market participants said.
The problem is further complicated by the fact that other Western countries, namely the U.S., are looking to introduce similar policies.
A Singaporean trader said, “Asian steel producers have not slowed down production and are looking to increase output, so we expect capacity additions to outpace demand growth, particularly in the post-epidemic recovery period.” . “…… Products have to go somewhere. Producers can export to Europe, but that means they need to offer low-carbon products at competitive prices.”
Asia’s way to decarbonization has already seen a number of breakthroughs, particularly as policymakers have committed to various climate targets and dealt with public and private stakeholders to develop low-carbon technologies.
These investments have enabled steelmakers to explore commercially viable technologies and reliable sources of clean energy, namely direct decrease in iron from scrap or gas, or shifting to electric arc furnace steelmaking, which has a lower carbon intensity compared to blast furnaces.
Paolo Frediani, senior analyst at Fastmarkets, said the marketplace is reacting to the steadily growing demand for green steel, given the amount of pipeline investment.
“CBAM will certainly give a major boost [in creating a green steel supply chain], but regardless of the advanced regulation of steel emissions in Europe, the green steel premium is essentially supported by the fact that increasingly more end-users are attempting to reduce their overall carbon footprint,” says Frediani. “While this drive is stronger in certain regions than the others, it is being a global phenomenon.”
Explosive composite explosion welding advantages
Explosive composite this new process, new technology inside a short period of time to acquire rapid development and wide application, the main reason is it has got the following four advantages:
(1) A number of composite materials could be combined it will make the melting point, strength, coefficient of thermal expansion and other performance differences are extremely disparate metal combinations to achieve composite. Such as aluminum – steel, titanium – steel. At present has realized the composite material combination of over 300 kinds, that is incomparable with other methods.
(2) Excellent material properties
Composite plate of the general design principle would be to meet the mechanical properties of the structure of the base material, compound plate to meet the corrosion or wear resistance and other properties. Therefore, compared with just one metal plate, the composite plate makes full utilisation of the best performance of the substrate, as well as the compound plate not only has got the required high strength but additionally has excellent corrosion resistance, wear resistance, and other properties of high production efficiency.
(3) High production efficiency/high bond strength.
Explosive composite in a very short period of time, and can be welded spanning a large area, a place of up to 20 square meters or even more, in the composite interface, dissimilar metals with the metal bond to achieve inter-atomic bonding is generally not less than the minimum of the strength of the composite material constituting the respective parent body.
(4) Good economy
The use of explosion welding technology to create composite plate products have both the corrosion resistance of the compound layer and other functional characteristics and both the strength of the grass-roots level and plastic toughness indicators, you can save precious metal resources, reduce costs.
Use of explosive welding plate
Composite materials produced by the explosive welding method continues to be commonly used in petroleum, chemical, shipbuilding, electronics, electric power, metallurgy, machinery, aerospace, atomic energy and other industrial fields. The composite plate is carbon steel as a substrate, single-sided or multi-faceted with precious metals as a double layer of high-efficiency energy-saving new composite materials, composite by explosion welding of special processing technology, both with the corrosion resistance of precious metals, wear resistance, but additionally with carbon steel, good weldability, molding, extensibility, thermal conductivity; explosive welding plate is now commonly used in the petrochemical industry, metallurgy, salt production and alkali production, the water industry, Nuclear industry.
Shipbuilding
In shipbuilding, explosive welding plates may be used to manufacture hull structures, decks, bulkheads, etc. Due to its high strength and good corrosion resistance, the explosive welding plate can effectively enhance the durability and repair life of the ship.
Aerospace
Within the aerospace field, explosive welding composite plates may be used to manufacture airplane fuselage, wings, engine parts, etc. Due to its good thermal stability and high strength, explosive welding composite plate can enhance the performance and safety of aircraft.
Construction Industry
Within the construction industry, explosive welding composite plates may be used to manufacture structural parts for bridges, high-rise buildings, highways, and so on. Due to its high strength and good corrosion resistance, explosive welding composite plate can enhance the safety and repair life of buildings.
Automobile manufacturing
In automobile manufacturing, explosive welding composite plates may be used to manufacture body structural parts, engine parts, and so on. Due to its lightweight, high strength, and good thermal stability, the explosive welding plate can enhance the performance and safety of automobiles.
Explosive welding plate cladding of metals supplier
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