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Explosion Welding Process

Explosion welding is a solid-state process that joins dissimilar metals through high-velocity impact caused by a controlled detonation. It uses explosives to accelerate a cladding metal plate toward a base plate, joining them through mechanical bonding without melting. Key parameters include the explosive type and velocity. Common explosives used are TNT, RDX, and PETN. Advantages are large workpieces can be welded without heat effects, but the process requires simple geometries and worker safety precautions. Applications include cladding, seam/lap welds, aerospace materials, heat exchangers, and repair welding.

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Manash Dey
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57 views

Explosion Welding Process

Explosion welding is a solid-state process that joins dissimilar metals through high-velocity impact caused by a controlled detonation. It uses explosives to accelerate a cladding metal plate toward a base plate, joining them through mechanical bonding without melting. Key parameters include the explosive type and velocity. Common explosives used are TNT, RDX, and PETN. Advantages are large workpieces can be welded without heat effects, but the process requires simple geometries and worker safety precautions. Applications include cladding, seam/lap welds, aerospace materials, heat exchangers, and repair welding.

Uploaded by

Manash Dey
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Explosion Welding

Introduction
 Explosion welding is a solid-state
process that produces a high velocity
interaction of dissimilar metals by a
controlled detonation.

 This eliminates the problems of heat effects


& micro-structural changes.

 Oxides found on material surfaces must be removed


by effacement or dispersion
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.
 Waves are generated so due to mechanical
bonding joining takes place.
 A single detonation cap can be used to ignite
the explosive.
Fig. Explosive Welding
WELDING PARAMETER
Detonation velocity is a
function of
Explosivetype
Composition of explosive
Thickness of explosive
layer 𝛒 = Plate density
V = charge velocity

5
Explosive material
 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
Advantages of Explosion Welding
• Very large work pieces can be welded.

• (Al + Steel) materials can be welded.

• Can bond many dissimilar, normally unweldable


metals.

• Material melting temperatures and coefficients of


thermal expansion differences do not affect the final
product.

• Process is compact, portable, and easy to maintain.


• Welding can be achieved quickly over large areas.

• No need for surface penetration.

• Backer plate has no size limits.

• Inexpensive.

• The strength of the weld joint is equal to or greater


than the strength of the weaker of two metals joined.

• No heat-affected zone (HAZ).


Disadvantages of Explosion Welding
• 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.
Applications
• 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.
Examples
Examples

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

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