BY

S. PRANNOY
(06881A0329)
  
Explosive welding is a solid state welding
process, which uses a controlled explosive
detonation to force two metals together at high
pressure. The resultant composite system is
joined with a durable, metallurgical bond.
WHAT IS IT?
The fearsome destructive power of explosives
can be harnessed to provide a unique joining
method, known as Explosive Welding.
 PROCESS
This is a solid state joining process.

When an explosive is detonated on the surface of a

metal, a high pressure pulse is generated.
This pulse propels the metal at a very high rate of
speed. If this piece of metal collides at an angle with
another piece of metal, welding may occur.
 For welding to occur, a jetting action is required at the
collision interface. This jet is the product of the surfaces
of the two pieces of metals colliding.
 This cleans the metals and allows to pure metallic surfaces
to join under extremely high pressure. The metals do not
commingle, they are atomically bonded.
 Due to this fact, any metal may be welded to any metal
(i.e. - copper to steel; titanium to stainless).
COMMONLY USED EXPLOSIVE
Explosive Detonation velocity , m/s
RDX (Cyclotrimethylene 8100
trinitramine) C6H6N6O6
TNT (Trinitroluene, 6600
C7H5N3O6)
Lead azide (N6Pb) 5010
Deta sheet 7020
Ammonium Nitrate (NH4NO3) 2655
 HEAT EXCHANGER SERVICE
 Explosive welding provides tube plugging, tube
expansion, tube to tube sheet welding for heat
exchanger users and manufacturers and debris
removal from industrial plant by the use controlled
explosive charges.
 PROBLEM
 Over last 30 years heat exchangers have been subject to
increasingly stressful conditions operating under high
temperature and pressures and consequently requiring
tighter leak security such conditions have highlighted
problems with fusion welding of tube to tube plate joints.
 In high pressure applications tube joint leaks can be lead
to the scrapping of the unit long before it estimated life
span. Fusion welding determines the materials that can be
used, materials, which are often not the most suitable for
the operating conditions.
 THE SOLUTION
 Explosive welding produces a high velocity movement
from a controlled axial detonation. This ensures leak proof
method of jointing which is able to with stand the high
temperatures and greater working pressures of modern
heat exchangers.
COMMONLY USED CLAD
METALS
 ADVANTAGES
   Joining of pipes and tubes.

   Major areas of the use of this method are heat exchanger tube
sheets and pressure vessels.
   Remote joining in hazardous environments.

   Joining of dissimilar metals - Aluminum to steel, Titanium

alloys to Cr – Ni steel, Cu to stainless steel, Tungsten to Steel.
     Attaching cooling fins.
 LIMITATIONS
 The metals must have high enough impact resistance,
and ductility.
 Noise and blast can require operator protection,
vacuum chambers, buried in sand/water.
 The geometries welded must be simple – flat,
cylindrical, conical.
 CONCLUSION
 Three-staging of formation of strong bonds between the
atoms of welded metals is established: activation of
contact surfaces; formation of physical contact; volume
impact and plastic deformation behind the contact point.
Thank Q