Explosion Welding (Without Videos)

Metallurgical and Materials Eng.
Department
Faculty of Petroleum and Mining Engineering, Suez University
Welding Metallurgy,
MTE 452 A1
‫ميتالورجيا اللحام‬
4th Year Students, 2015/2016
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Welding Metallurgy 4th Year Students 2015/2016
Metallurgical and Materials Eng. Department
Explosion Welding
By Group (20) :-
Hatem Tareq Mosaad
Muhammed Hussein Abd El-Hakeem Mansour
Mahmoud Ahmed Muhammed Abd El-Fattah
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Contents
Definition
History
Component terminology
Process procedure
Advantages
Disadvantages
Applications
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Definition
• Explosion welding (High-impulse
method of bimetal production) is a
solid-state process that produces a high-
velocity interaction of dissimilar/similar
metals tens of square meter surface areas
by a controlled detonation with explosive
charge.
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history
• Arnold 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.
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Component terminology
1- Base metal :-
Metal plate resting stationary below
cladding plate to join with and supported by
anvil.
2- Cladding metal :-
Metal plate resting above base metal plate to
join with by exposure to explosion pressure
and shielded by flyer plate.
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3- Flyer plate :-
Sacrificial plate placed above cladding metal
to protect it from explosive material.
4- Interlayer :-
Thin metal layer placed between cladding
metal and base metal to enhance their joining.
5- Anvil :-
Strong surface upon which base metal rests
during explosion process. 7
6- Standoff :-
Distance between cladding metal and base
metal filled with consumable shims ranging
thickness between 0.5-2 times thickness of
cladding metal to help the two plates fit.
7- Detonator :-
Device or spark responsible for starting the
explosion, connected with the explosive material
through combustive wires or sparked above the
weld. 8
8- Explosive Material :-
Material used for causing the explosion,

placed all over the cladding metal/flyer plate
and it is grouped into :-
- High-velocity explosives (14750-25000 ft/s)
like TNT, RDX and PETN
- Mid-low-velocity explosives (4900-47500 ft/s)
like Ammonium nitrate, Ammonium perchlorate,
Amatol.
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10
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Process procedure
1- Preparations :-
- Anvil is put to rest the base metal upon it.
- Base metal and cladding metal are surface
cleaned by effacing or dispersing oxides.
- Base metal is rested horizontally upon
anvil.
- Interlayer shims are placed horizontally
above base metal.
- Cladding metal is placed horizontally
above interlayer. 12
- Flyer plate is placed above cladding metal.

- Explosive material is homogeneously
distributed over flyer plate.
- Detonator is wire/spark connected to the
explosive material.
2- safety measurements :-
- Maintain safe distance from explosion.
- Safe placement of explosion welding process
according to the nature of the surroundings.
- Entering the welding zone after enough time
to let the volatile dust escape the place. 13
3- process of welding :-
- Initiating exploding the charge, thus,
detonation wave travels along the weld area
at uniform rate causing uniform pressure
application progressing from detonation
start point expanding transversely and
forwardly until it reaches the other end of the
plate, the high-velocity pressure causes the
cladding metal to join with the base metal
very tightly kicking out air and trapped gases
between them. 14
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4- Quality control :-
* Three types of detonation wave welds :-
1) Shock wave develops if sonic velocity is
greater than 120% of material sonic velocity.
2)Detached shock wave results when

detonation velocity is between 100% and 120%
of material sonic velocity.
3) No shock wave is produced if detonation

velocity is less than material sonic velocity.
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Type 1 :-
- Material behind shock wave is compressed to
peak pressure and density.
- Creates significant plastic deformation
locally and results in considerable shock
hardening. 17
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.
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- Effaces material and removes unwanted

oxides and other unwanted surface films.
- No bulk diffusion and only localized melting.
* Detonation velocity is a function of :-

- Explosive type
- Composition of explosive
- Thickness of explosive layer
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Sonic velocity of cladding material can

be calculated using:
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Advantages
- No heat-affected zone (HAZ).
- Only minor melting.
- Material melting temperatures and
coefficients of thermal expansion differences
do not affect the final product.
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- Can weld large areas of metal.

- Can weld inside and outside surfaces of pipes.
- The joint is formed almost instantly.
- When optimal parameters are applied,
mechanical properties of bimetal, in particular
tensile strength and shear strength, is higher
than they are for weakest component of the
composite.
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- Several studies of mechanical properties

(static strength, impact and cyclic loading,
thermal cyclic loading) as well as corrosion
resistance of clad sheets proved that explosively
clad bimetal can be allowed to use in critical
applications in the energy, chemical,
petrochemical, and other industries of modern
engineering.
23
- Any metal with sufficient strength and

ductility can be joined
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- Optimal welding process does not

change the structure and properties of
the original sheet metal except for
narrow contact zone.
25
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Disadvantages
- Requires deep study in the field of
explosive science and materials.
- safety issues and control.
- Requires enough strength and

ductility for metals to be joined.
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Applications
- Chemical Processing.
- Petroleum Refining.
- Hydrometallurgy.
- Aluminum Smelting.
- Shipbuilding.
- Electrochemical.
- Oil & Gas.
- Power Generation.
- Cryogenic Processing.
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- Pulp & Paper.

- Air conditioning & Chillers.
- Metal Production.
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Thanks for Attention
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Explosion Welding (Without Videos)

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Metallurgical and Materials Eng.

Muhammed Hussein Abd El-Hakeem Mansour

Mahmoud Ahmed Muhammed Abd El-Fattah

• Detaclad licensed the process and was bought by

Material used for causing the explosion,

- Flyer plate is placed above cladding metal.

2)Detached shock wave results when

3) No shock wave is produced if detonation

- Effaces material and removes unwanted

* Detonation velocity is a function of :-

Sonic velocity of cladding material can

- Can weld large areas of metal.

- Several studies of mechanical properties

- Any metal with sufficient strength and

- Optimal welding process does not

- safety issues and control.

- Requires enough strength and

- Pulp & Paper.

Thanks for Attention

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