NOBELCLAD TECHNICAL BULLETIN NT 200

EXPLOSION BONDING PROCESS

A. NOBILI
NOBELCLAD
Rivesaltes plant - France
INTRODUCTION
The explosion bonding process, also known as "cladding by the explosion welding process", is a
technically based industrial welding process. As any other welding process, it complies with well
understood, reliable principles. The process uses an explosive detonation as the energy source to
produce a metallurgical bond between metal components. It can be used to join virtually any
metals combination, both those that are metallurgically compatible and those that are known as
non-weldable by conventional processes. Furthermore, this process can clad one or more layers
onto one or both faces of a base metal, with the potential for each to be a different metal type or
alloy.
Due to its use of explosive energy, the process occurs extremely fast; unlike conventional welding
processes, parameters cannot be fine-tuned during the bonding operation. The bonded product
quality is assured through selection of proper process parameters, which can be well controlled.
These include material surface preparation, plate separation distance prior to bonding, and
explosive load, velocity, and detonation energy. Selection of parameters is based upon the
mechanical properties, mass, and acoustic velocity of each component metal being bonded.
Optimum bonding parameters, which result in consistent product quality, have been established
for most metals combinations. Parameters for other systems can be determined by calculation
using established formulas.
The explosion cladding process was discovered in the late 1950s. By the end of the 1960s the
process had been industrialized worldwide. During the near forty years of industrial application,
the process has been continuously refined. Nobelclad and other experienced manufacturers have
codified the technology and the method of determining bonding parameters. In comparison to the
1960s, today manufacturers can produced much larger plates, up to 30 square meters, and have
mastered the more difficult metals combinations including cladding zirconium onto stainless steel.
TERMINOLOGY
As with other welding processes, the explosion cladding process applies special terminology to
many of the process variables.
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.
The Standoff Distance is the separation distance between the cladding metal and the base metal
when fixtured parallel to each other prior to the bonding operation.
The Assembly Operation is the process in which the metals are fixtured into the proper positions
for bonding, including setting standoff distance and explosive load.
The Bonding Operation is the period in which the explosive detonation occurs and in which the
actual bonding occurs.
PRINCIPLE
Preparation: The first step of the cladding
operation is the preparation of the two surfaces
that are to be bonded together. These surfaces are
ground or polished to achieve a uniform surface
finish with a roughness Ra of 3 m (140 RMS) or
below, dependent upon the metals combination
and thicknesses.
Assembly: The cladding plate is positioned
parallel to and above the base plate, at a standoff
distance which has been predetermined for the
specific metals combination being bonded. This
distance is selected to assure that the cladding
plate collides with the base plate after accelerating
to a specific collision velocity. The standoff
distance typically varies from 0.5 to 4 times the
cladder sheet thickness dependent upon the
choice of impact parameters as described below.
The limited tolerance in collision velocity results
in a similar tolerance control of the standoff
distance.
The standoff distance is controlled by support spacers at the plate edges and internally as needed.
Internal standoff devices are designed to be consumed by the jet, which is discussed below.
An explosive containment frame is placed around the edges of the cladding metal plate. The height
of the frame is set to contain a specific amount of explosive providing a specific energy release per
unit area.
Bonding Operation : The explosive composition and type is selected to yield a specific energy
release and a specific detonation rate (the speed at which the detonation front travels across the
explosive layer). The detonation rate must be subsonic to the acoustic velocities of the metals.
The explosive, which is generally granular, is uniformly distributed on the cladding plate surface
filling the containment frame. It is ignited at a predetermined point on the plate surface using a
high velocity explosive booster. The detonation travels away from the initiation point and across
the plate surface at the specified detonation rate. The gas expansion of the explosive detonation
accelerates the cladding plate across the standoff gap resulting in an angular collision at the
specified collision velocity. The resultant impact creates very high-localized pressures at the
collision point.
These pressures travel away from the collision point at the acoustic velocity of the metals. Since the
collision is moving forward at a subsonic rate, pressures are created at the immediately
approaching adjacent surfaces, which are sufficient to spall a thin layer of metal from each surface
and eject it away in a jet. The surface contaminants, oxides and impurities are stripped away in the
jet. At the collision point, the newly created clean metal surfaces impact at high pressures of
several GPa (Figure 2). Although there is much heat generated in the explosive detonation,
there is no time for heat transfer to the metals. The result is an ideal metal-metal bond without
melting or diffusion.
Impact parameters: The proper impact parameters for a specific metal combination are dependent
upon the metal types, thicknesses, and mechanical properties. Selection of the proper parameters is
critical to assure a strong, high quality, ductile bond. The impact conditions are associated by the
equation:
Vp =2 Vc sin ( / 2)
Since the plates are parallel, the impact point
velocity, Vc, is equal to the detonation velocity
Vd.
Explosive detonation velocity, Vd, (2000 to 3500
m/ s) is an independent variable selected to
achieve required impact conditions.
Standoff Distance is an independent variable
selected to achieve required impact conditions.
The impact angle is a dependent variable, controlled
by Vd and the standoff distance. It is typically 5 to
25.
JET
EXPLOSIVE
BASE METAL
CLADDING PLATE
Figure 2 : Explosion bonding process
STANDOFF DISTANCE
The plate collision velocity at the impact point,
Vp, is typically in the 250 to 500 m/ s range, with
the specific value being dependent upon metal
types, their physical and mechanical properties
and chemical compatibility.
The shooting parameters: The independent
variables in the above equation, explosive
detonation rate and standoff distance, are two
major shooting parameters. These are selected to
achieve the desired impact parameters. The
explosive type and amount per sq-m is selected to
achieve the necessary detonation energy and
detonation velocity.
EXPLOSIF
METAL DE BASE
REVETEMENT
Figure 3 : Impact parameters
STANDOFF DISTANCE

Vp
Vd
Vc
In combination with this, the plate separation distance is selected to achieve the collision velocity.
These values are calculated for each metal combination using established formulas. Cladding metal
thickness and mechanical properties of both metals are critical factors in these calculations. Most
manufacturers have these calculations computerized.
- The amount of explosive per sq-meter C, is a
function of the explosive energy E, the R ratio
(unit area weight of explosive divided by unit
are weight of cladding metal), the physical and
mechanical properties of the metals.
Vp = (E,R)
- The standoff distance, as well as the above
parameters controls the specific plate velocity
at the collision point.
- C and e typically vary with cladding metal
thickness as shown in Figure 4.
25 3
e (mm)
d : standoff distance (mm)
C : amount of explosive
(kg/m)
Figure 4 : Example of diagram used for the calculation
of amount of explosive and standoff distance
Process Variables: Table 1 lists the process variables and indicates those that are essential and non-
essential parameters of the cladding process.
Field Variable Essential Non Essential
Type and grade X
Thickness X
Base metal
Heat Treat Condition X
Type and grade X
Thickness X
Cladder metal
Heat Treat Condition X
Plate surface area X
Thickness ratio (Clad:Base) X
Global
dimensions
Length and Width X
Stand-off distance X
Explosive, weight/ sq-m X
Explosive type and composition X
Surfaces preparation X
Ignition kind and point X
Spacers device types X
Total weight of explosive X
Explosive Detonation rate X
Cladding
Operation
Variables
Explosive Confinement X
Table I: Explosion Cladding process Variables
Practical Manufacturing Considerations: The tolerances for explosive detonation rate and
explosive energy are highly controlled for two reasons: 1) for many metals combinations the
detonation rate window for bonding is small, 2) Non-uniformity in the explosion front can result
in the jet front converging which causes nonbonding and damage. The explosives must comply
with very strict standards for uniformity of detonation energy and detonation velocity. Proper
understanding of the explosive manufacturing parameters and quality control processes is
mandatory for consistent, reliable cladding.
Since out-of-flatness of the cladding and base plates results in standoff variations, flatness
requirements of component metals for cladding are typically much tighter than standard
commercial tolerances.
Interface: The interface generally exhibits wavy
bond morphology (Figure 5). The wavelength
and the height h of the waves depend on the
impact parameters. The angle and the thickness
e of the cladding plate directly determine the
wavelength .
=k e sin (/ 2) k is a constant which varies
with metals types and properties.
Thus, the wavelength can be controlled through
impact parameters to achieve specific bond
features as needed.
Figure 5 : Explosion Bonding Interface Zirconium / CSteel
The wave shape is perfectly symmetric for metals with the same density and becomes increasingly
asymmetric as the density differences increase. At excessive detonation rates, the vortex of the wave
can exhibit localized melting due to adiabatic heating.
From the metallurgical perspective, the bond of
an explosive clad plate is a direct interface
between grains of the two different metal types.
There is no diffusion as a result of the low
temperatures of bonding. Metallurgically, the
bond is very similar to a high-energy grain
boundary, Figure 6. Due to the cold deformation
of bond wave formation there is a slight increase
in hardness in the bond area.
Limitations: Explosive cladding deforms the
metals at very high rates (10
4
up to 10
5
sec
-1
). The
metals must be ductile enough to undergo this
deformation without cracking. Limits usually
accepted are a minimum elongation of 15 % and a
notch toughness value above 30 J at bonding
temperature. Most common engineering metals
meet these criteria and are readily bondable.
Figure 6 : Titanium / Steel interface
(AFM from ENI Tarbes)
Titane
CSteel
Performance: The strength of the interface is
usually greater than the strength of the weaker
component metal. Shear testing or bend testing
typically measures Bond strength. Bond integrity
is normally measured using an ultrasonic test.
Tests are performed to international standards.
Typical shear strengths and minimum
guaranteed values are shown in Table II.
Extensive tests over the past 40 years have shown
that the process has slight effect on the
mechanical properties of the base metal. These
results have led to establishing additional
specification requirements for the purchasing the metal that is to be bonded. Thus at the final step of
production operations, including heat treatments if needed, the base metal complies with the
customers required specifications.
INDUSTRIALISATION
The explosion cladding process is
commonly used for flat plates. The process
can also be used for the manufacture of
concentrically bonded tubes and pipes. In
tube cladding, the explosive can be place
inside the bore, or on the outside of the
outer tube, dependent upon diameters,
wall thicknesses and other factors. The
process is not suitable for cladding of
complex contoured surfaces. When shaped
products are required, such as heads, the
clad is produced as flat plate and formed
into the required product configuration after bonding.
Table III shows the wide range of combinations that can be done with explosion bonding
Cladding metal Shear Strength
(MPa) *
Shear Strength
(MPa) **
Stainless steel 210 520
Nickel alloys 210 470
Cu-Ni alloys 140 285
Cu-Al alloys 140 400
Titanium Gr. 1 140 290
Zirconium 702 140 240
* Mini. Guaranteed by NOBELCLAD NC 501specification.
** According to NOBELCLAD tests.
Table II : Shear Strength of explosion bonding plates
Cladding metal Base Metal (ASTM)
DUPLEX
SSteel 300
SSteel 400
Copper and alloys
Aluminum and alloys
Nickel and alloys
Titanium gr.1,7,12, etc.
Zirconium gr. 702
Tantalum
Rolling CSteel
A 516
A 387
Forged CSteel
A 266, A 350
A 182
Forged or Rolled SSteel 300
Table III : Main combinations done by explosive bonding
The cladding global dimensions are typically limited only by the availability of flat component metal
sheet or plate and transport constraints. Maximum plate size may also be limited by explosive
detonation limits, such a noise and environmental constraints. Rarely is size limited by cladding
know-how.
The following maximum plate sizes can typically be produced:
Length 12,000 mm
Width 5,000 mm
Base thickness 500 mm
Cladding thickness 25 mm
Surface 35 m
Annex I shows an example of a manufacture control chart. As shown, Nobelclad uses bar codes to
track process operations and to optimize scheduling and work flow.
FABRICATION
Clad metal can be readily formed and welded as needed to construct process equipment. However, it
is not the aim of this paper address clad metal fabrication process. Many equipment fabricators
worldwide have extensive expertise and know how in this area. Head and shell forming and welding
of clad plates is well known by fabricators specializing in clad. For additional information, have a look
at Nobelclad technical bulletins or Nobelclad web site http:/ / www.nobelclad.snpe.com.