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Explosion welding

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Aaqib Sufi

Explosion welding is a solid state welding process that joins materials through a controlled detonation without melting. It can bond dissimilar materials like aluminum to stainless steel. The process involves a base plate fixed to an anvil, a flyer plate placed above at an angle or parallel, and explosives on top. Upon detonation, the flyer plate is driven into the base plate at high velocity, forming a metallurgical bond through plastic deformation. It is commonly used in industries like shipbuilding, oil and gas, and power generation to weld large or hard to weld materials.

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NAME-AAQIB HUSSAIN ROLL NO-RA1612003010003 CLASS-M.Tech(CAD)
Contents: Introduction Component Terminology Principle Types Working Explosive material Advantages & Disadvantages Applications Common industries that use Examples references
Introduction: Explosion welding is also a solid state welding process. Welding occurs without application of external heat. No addition of filler material. It is mainly used to join large surface area of dissimilar materials.
Component Terminology: Base plate. Remains stationary Supported by anvil Flyer plate. This is another welding plate which is going to be weld on base plate.
Anvil: Surface of which the base plate rests during explosion Standoff Distance: Stand-off distance plays a vital role in explosion welding.
Buffer plate:Buffer plate is situated on the flyer plate. Explosive: is placed over the flyer plate. This explosive is situated in a box structure. Velocity of detonation: It is the rate at which the explosive detonate. This velocity should be kept less than 120% of sonic velocity. It is directly proportional to explosive type and its density.
Principle of Explosion This welding process works on basic principle of metallurgical bonding. In this process, a controlled detonation of explosive is used on the welding surface. flyer 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
OBLIQUE EXPLOSION WELDING In this type of welding process base plate is fixed on an anvil. Flyer plate makes an angle with the base plate. This welding configuration is used to join thin and small plates.
PARALLEL EXPLOSION WELDING In this welding configuration Flyer plate is parallel to the base plate. There is some standoff distance between base plate and flyer plate. This configuration is used to weld thick and large plates.
CONTD. Where: Vc = collision velocity VD = detonation velocity Vp = plate Collision velocity 留 = preset angle 硫 = dynamic bend
WORKING: Both the base and the flyer plate is cleaned. The base plate fixed on the anvil The flyer plate may be inclined or parallel according to the welding configuration. Now the detonator ignited the explosive which create a high pressure wave. These waves deforms the interface surface plastically and form a metallurgical bond between base plate and flyer plate. This bond is stronger than parent material.
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 Detonation velocity is a function of Explosive type Composition of explosive Thickness of explosive layer
Assuring a good weld: Sonic velocity of cladding material can calculated using: Where:- K = adiabatic bulk modulus = cladding material density E = Youngs Modulus of cladding material 廣 = Poissons ratio of cladding material
ADVANTAGES: It can join both similar and dissimilar material. Simple in operation and handling. Large surface can be weld in single pass. High metal joining rate. Mostly time is used in preparation of the welding. It does not effect on properties of welding material. It is solid state process so does not involve any filler material, flux etc.
DISADVANTAGES: It can weld only ductile metal with high toughness. It creates a large noise which produces noise Pollution. Welding is highly depends on process parameters. Higher safety precautions involved due to explosive. Designs of joints are limited.
Applications: Used to weld large structure sheets of aluminium to stainless steel. It is used to weld cylindrical component like pipe, concentric cylinder, tube etc. Join dissimilar metals which cannot be weld by other welding process. For joining cooling fan etc.
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
Examples
References: http://www.awssection.org/uploads/longbeach/files/wj0706 -38.pdf. J.Verstraete,W.De Waele and K.faes :lesson to be learned from explosive welding 2011. Wikipedia.
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Explosion welding

  • 2. Contents: Introduction Component Terminology Principle Types Working Explosive material Advantages & Disadvantages Applications Common industries that use Examples references
  • 3. Introduction: Explosion welding is also a solid state welding process. Welding occurs without application of external heat. No addition of filler material. It is mainly used to join large surface area of dissimilar materials.
  • 4. Component Terminology: Base plate. Remains stationary Supported by anvil Flyer plate. This is another welding plate which is going to be weld on base plate.
  • 5. Anvil: Surface of which the base plate rests during explosion Standoff Distance: Stand-off distance plays a vital role in explosion welding.
  • 6. Buffer plate:Buffer plate is situated on the flyer plate. Explosive: is placed over the flyer plate. This explosive is situated in a box structure. Velocity of detonation: It is the rate at which the explosive detonate. This velocity should be kept less than 120% of sonic velocity. It is directly proportional to explosive type and its density.
  • 7. Principle of Explosion This welding process works on basic principle of metallurgical bonding. In this process, a controlled detonation of explosive is used on the welding surface. flyer 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
  • 8. OBLIQUE EXPLOSION WELDING In this type of welding process base plate is fixed on an anvil. Flyer plate makes an angle with the base plate. This welding configuration is used to join thin and small plates.
  • 9. PARALLEL EXPLOSION WELDING In this welding configuration Flyer plate is parallel to the base plate. There is some standoff distance between base plate and flyer plate. This configuration is used to weld thick and large plates.
  • 10. CONTD. Where: Vc = collision velocity VD = detonation velocity Vp = plate Collision velocity 留 = preset angle 硫 = dynamic bend
  • 11. WORKING: Both the base and the flyer plate is cleaned. The base plate fixed on the anvil The flyer plate may be inclined or parallel according to the welding configuration. Now the detonator ignited the explosive which create a high pressure wave. These waves deforms the interface surface plastically and form a metallurgical bond between base plate and flyer plate. This bond is stronger than parent material.
  • 12. 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
  • 13. Assuring a good weld Detonation velocity is a function of Explosive type Composition of explosive Thickness of explosive layer
  • 14. Assuring a good weld: Sonic velocity of cladding material can calculated using: Where:- K = adiabatic bulk modulus = cladding material density E = Youngs Modulus of cladding material 廣 = Poissons ratio of cladding material
  • 15. ADVANTAGES: It can join both similar and dissimilar material. Simple in operation and handling. Large surface can be weld in single pass. High metal joining rate. Mostly time is used in preparation of the welding. It does not effect on properties of welding material. It is solid state process so does not involve any filler material, flux etc.
  • 16. DISADVANTAGES: It can weld only ductile metal with high toughness. It creates a large noise which produces noise Pollution. Welding is highly depends on process parameters. Higher safety precautions involved due to explosive. Designs of joints are limited.
  • 17. Applications: Used to weld large structure sheets of aluminium to stainless steel. It is used to weld cylindrical component like pipe, concentric cylinder, tube etc. Join dissimilar metals which cannot be weld by other welding process. For joining cooling fan etc.
  • 18. 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
  • 20. References: http://www.awssection.org/uploads/longbeach/files/wj0706 -38.pdf. J.Verstraete,W.De Waele and K.faes :lesson to be learned from explosive welding 2011. Wikipedia.