Why do welders have explosions?
Explosion welding is used primarily for preparing blanks or billets, although it can also be used for such applications as joining pipes or securing tubes in tubeplates. The method is often used for a combination of materials that are difficult to join using other methods.
What are the explosive material used in explosive welding?
For explosive welding we used plates of technically pure copper (99.98% Cu) and tantalum (99.95% Ta). The materials used are significantly different in structure, density, melting point, and thermal conductivity in (Table 1).
What is the main application of explosive welding?
The explosive welding technique has found major use for cladding low cost plate (usually carbon steel) with more expensive corrosion resistant materials. This clad plate is typically used in the chemical and petrochemical industries as tube sheet for heat exchangers.
What is explosion welding process?
Explosion welding is basically a solid-phase welding process, in which explosives are used to accelerate the parts to be joined into a high velocity oblique collision. The process was first discovered quite by accident by ordinance specialists, although they did not recognize it as a welding process.
How much do explosion welders make?
The salaries of Explosion Welders in the US range from $23,950 to $60,000 , with a median salary of $36,150 . The middle 50% of Explosion Welders makes between $36,150 and $38,150, with the top 83% making $60,000.
What are the three essential variables of an explosion weld?
Explosion welding 1 Flyer (cladding). 2 Resolidified zone (needs to be minimised for welding of dissimilar materials). 3 Target (substrate).
What industries use explosion welding?
Flat plates and cylinders for the aerospace, rail, automotive and construction industries, which trust the flexibility of explosion-bonded clad, welded steel and aluminum, to achieve lightweight designs without forgoing strength and reliability.
What are the limitations of explosive welding?
The weld itself is very clean because the surface material of the metals is violently expelled during the reaction. One disadvantage of explosion welding is that before carrying out this welding method you must have extensive knowledge of explosives before the procedure can be carried out safely.
What is cladding in explosive welding?
The Cladding Metal (also called the cladder) is the plate, which is in contact with the explosive. It is typically the thinner component. The Base Metal is the plate onto which the cladding metal is being bonded.
What do you need to know about explosion welding?
Explosion welding ( EXW) is a solid state (solid-phase) process where welding is accomplished by accelerating one of the components at extremely high velocity through the use of chemical explosives. This process is most commonly utilized to clad carbon steel plate with a thin layer of corrosion resistant material (e.g.,…
Why is explosive welding used in space applications?
In many of the critical components used in space and nuclear applications, explosive welding is used to fabricate them as they cannot be made by another process, and quite often this proves to be the least costly process in some of the commercial applications.
How is an explosive charge used in welding?
In the most common application of the process, two flat plates are joined to form a bimetallic structure. An explosive charge is used to force the upper or ‘flier’ plate on to the baseplate in such a way that a wave of plastic material at the interface is extruded forward as the plates join (Fig. 1.5 ).
What is the bond zone of an explosion Weld?
The bond zone of an explosion weld has a characteristic wavy appearance, reflecting the severe, highly localised plastic deformation occurring in the process. Explosion welding is limited to lap joints and to cladding of parts with a second metal. The process is used for cladding carbon steel, stainless steel, copper or titanium with aluminium.