Examination of copper/stainless steel joints formed by explosive welding

In this study, bonding ability of copper and steel with explosion welding was investigated using different ratios of explosive and different stand-off distance. Experimental studies showed out that, copper and stainless steel could be bonded with a good quality of bonding properties with explosion welding. In the bonding interface, intermetallics were not formed. It was observed that, when explosive ratio and stand-off distance were increased smooth bonding interface was transformed to a wavy bonding interface. As the ratio of explosive and stand-off distance increase, the amplitude and wavelength of wave were increased. It was found that, hardness of bonding interface and outer face of plates were increased because of deformation that was originating from impact the effect. Total interface area increased as a result of wavy interface, which was caused by increased explosive ratio and stand-off distance. In addition, wavy interfaces did not separate after tensile-shearing test. Bending tests applied on bonded samples had different diameters indicated that interfaces of the bonded samples have not any defect. EDS analyses in SEM showed that diffusion did not take place between bonding plates, however, diffusion was observed after annealing of the bonded samples for different times.     

Effect of explosive characteristics on the explosive welding of stainless steel to carbon steel in cylindrical configuration

The aim of this research is to study the influence of explosive characteristics on the weld interfaces of stainless steel AISI 304L to low alloy steel 51CrV4 in a cylindrical configuration. The effect of ammonium nitrate-based emulsion, sensitized with different quantities and types of sensitizing agents (hollow glass microballoons or expanded polystyrene spheres) and Ammonium Nitrate Fuel Oil (ANFO) explosives on the interface characteristics is analyzed. Research showed that the type of explosive and the type and proportion of explosive sensitizers affect the main welding parameters, particularly collision point velocity. The morphology of the wavy weld interfaces, chiefly the amplitude and length of the waves, is affected both by the impact velocity and the type and particle size of the explosive sensitizers, and increases with particle size. All the weld interfaces, except welds done with ANFO, displayed localized melted and solidified regions, whose chemical composition resulted from the contribution of both flyer and base metal.     

Testing of explosive welding and welded joints. The microstructure of explosive welded joints and their mechanical properties

The present essential models and some theories were applied to explain the wavy phenomenon, microstructure and mechanical properties of the characteristic joint area. Two phenomena occurring in the plate collision zone during welding were carefully tested. These phenomena were connected with forming the wavy joint surface and the interpass. The available data referring to forming the interpass were further developed.     

Testing of explosive welding and welded joints: joint mechanism and properties of explosive welded joints

In this study physical mechanism of explosive welding joint was analysed. The mechanism refers to wavy joint with interpass and without one. Plastic strain, viscosity and acoustic waves were applied to explain the problem. The own model of the mechanism of oxide removal for the direct joint and test results confirming the bonding mechanism were showed.     

防护层对爆炸焊接质量的影响

为了研究防护层在炸药爆轰过程中对复板表面的保护作用,依据实验数据,分析了复板在焊接完成后的表面平整度、是否发生熔融现象以及金属结合界面的波状纹理的变化情况。防护层隔绝高温的炸药爆轰产物对复板侵蚀,同时在爆轰初始阶段对于应力波透过防护层作用在复板上的应力有明显的增强效应。最终确定在爆炸焊接过程中对复板厚度为0.2cm时,在其表面均匀覆盖一层0.05⁰.15cm的黄油可以较好地保护复板不受高温的爆轰产物侵蚀。实验过程中,选取不同种类炸药进行了对比实验,发现粉状硝铵炸药更加容易装药和控制爆轰速度,本实验选用硝铵炸药完成。     

防护层对爆炸焊接质量的影响

为了研究防护层在炸药爆轰过程中对复板表面的保护作用,依据实验数据,分析了复板在焊接完成后的表面平整度、是否发生熔融现象以及金属结合界面的波状纹理的变化情况。防护层隔绝高温的炸药爆轰产物对复板侵蚀,同时在爆轰初始阶段对于应力波透过防护层作用在复板上的应力有明显的增强效应。最终确定在爆炸焊接过程中对复板厚度为0.2cm时,在其表面均匀覆盖一层0.05~0.15cm的黄油可以较好地保护复板不受高温的爆轰产物侵蚀。实验过程中,选取不同种类炸药进行了对比实验,发现粉状硝铵炸药更加容易装药和控制爆轰速度,本实验选用硝铵炸药完成。     

钛/钢双立式爆炸焊接参数优化

为解决大面积钛/钢爆炸焊接窗口窄,在结合区易出现"过熔"和"射流堆积"等微观缺陷的问题,开展了双立爆炸+轧制综合制造技术,进行了低爆速爆炸焊接用炸药试验优化,发明了一种最低临界爆速爆炸焊接用炸药,设计确定了刚性防护板和柔性防护墙构成的双立综合防护结构及参数,研究了钛/钢爆炸焊接装药厚度窗口.结果表明,双立钛/钢复合板结合界面成波状结合,几乎不存在金属熔化、漩涡等微观缺陷.     

钛-钢板爆炸焊接的影响因素及炸药配方

爆炸复合用炸药是影响爆炸焊接效果的最主要因素,不同的材料和工艺参数对炸药的爆速、比冲量和能量有不同的影响,其中炸药的密度直接影响复板斜碰撞基板的速度和角度。选用低合金高强度结构钢Q345B和工业纯钛TA2为实验材料,通过理论计算与实验研究,得到了一种较为适合钛-钢板爆炸焊接用的炸药配方,并对钛-钢爆炸焊接影响因素进行了探讨。     

钛-钢板爆炸焊接的影响因素及炸药配方

爆炸复合用炸药是影响爆炸焊接效果的最主要因素,不同的材料和工艺参数对炸药的爆速、比冲量和能量有不同的影响,其中炸药的密度直接影响复板斜碰撞基板的速度和角度。选用低合金高强度结构钢Q345B和工业纯钛TA2为实验材料,通过理论计算与实验研究,得到了一种较为适合钛-钢板爆炸焊接用的炸药配方,并对钛-钢爆炸焊接影响因素进行了探讨。     

Testing of explosive welding and welded joints. Wavy character of the process and joint quality

The basic defects occuring in explosive clad plates were properly systemized and the reasons of their formation were explained. Cases of cracks and delaminations in explosive clad plates were examined in this work. Various values of tensile stresses coming from loading and unloading waves were analysed, as they were the main reason of defects. The defects were connected with properties of welded materials in the joint area and beyond it. Some practical aspects of this process were shown as well.     

Effect of heat treatment on bonding interface in explosive welded copper/stainless steel

In this investigation, explosive welding and heat treatment processes provided an effective method for manufacturing high-strength and high-ductility copper/ austenitic stainless steel couple. In order to improve diffusion in the interface of copper/stainless steel, first the tensile samples were provided from the welded part, then they were subjected to annealing at 300 °C (below recrystallization temperature) for 8–32 h with 8 h intervals and then samples were cooled in the furnace. Optical microscopy (OM), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) were utilized to evaluate the possibility of diffusion in the joints. Moreover, in order to measure the hardness of the samples, microhardness test was performed. Microstructural evaluations showed that the stainless steel 304L had a wavy interface. Furthermore, the post heat treatment process resulted in great enhancement of diffusion. Microhardness measurements showed that the hardness of the sample near to the interface is greatly higher than other parts; this is due to plastic deformation and work hardening of copper and stainless steel 304L in these regions. The interface of samples with and without the post heat treatment was exhibited ductile and brittle fracture, respectively.     

Transformation characteristics of TiNi/TiNi alloys synthesized by explosive welding

Effects of severe deformation and heat treatment on the transformation behaviors of explosively welded duplex TiNi/TiNi shape memory alloys (SMAs) were investigated by the differential scanning calorimeter (DSC). The explosively welded duplex TiNi/TiNi plate of 0.7 mm in thickness was cold-rolled at room temperature to the extent of 60% reduction in thickness and then annealed at different temperatures (573–973 K) for different time (15 min–10 h). Low temperature (623–723 K) heat treatment led to amorphous crystallization. At higher temperature (873 K), the re-crystallization took place in the specimens. Analysis showed that the change of internal stresses is just the root cause of the change of transformation temperature. The relationships between the transformation behaviors and the heat treatment were discussed in the present report.     

Investigation of laser welding on butt joints of Al/steel dissimilar materials

Dissimilar metals of AA6013 aluminum alloy and Q235 low-carbon steel of 2.5 mm thickness were butt joined using a 10 kW fiber laser welding system with ER4043 filler metal. The study indicates that it is feasible to join aluminum alloy to steel by butt joints when zinc layer was hot-dip galvanized at the steel’s groove face in advance, and better weld appearance can be obtained at appropriate welding parameters. The joints had dual characteristics of a welding joint on the aluminum side and a brazing joint on the steel side. The smooth Fe₂Al₅ layer adjacent to the steel matrix and the serrated-shape FeAl₃ layer close to the weld metal were formed at the brazing interface. The overall thickness of Fe–Al intermetallic compounds layers produced in this experiment were varied from 1.8 μm to 6.2 μm at various welding parameters with laser power of 2.85–3.05 kW and wire feed speed of 5–7 m/min. The Al/steel butt joints were failed at the brazing interface during the tensile test and reached the maximum tensile strength of 120 MPa.     

Research on explosive welding of aluminum alloy to steel with dovetail grooves

In order to explore a new method for the explosive welding of aluminum alloy to steel, a 5083 aluminum alloy plate and a Q345 steel plate with dovetail grooves were respectively employed as the flyer and base plates. The parameters adopted in the explosive welding experiment were close to the lower limit of weldable window of 5083 aluminum alloy to Q345 steel. The bonding properties of 5083/Q345 clad plate were studied through mechanical performance tests and microstructure observations. The results showed that the aluminum alloy and steel plates were welded under the actions of metallurgical bonding and meshing of dovetail grooves. The tensile shear strength of 5083/Q345 clad plate met the requirements of the bonding strength of Al/Fe clad plate. The interfaces between aluminum alloy and the upper and lower surfaces of dovetail grooves were mainly welded through direct bonding, and discontinuous molten zone emerged in the local region; while the interface between aluminum alloy and the inclined surface of dovetail grooves was bonded by continuous molten layer. The brittle intermetallic compounds FeAl₂ and Al₅Fe₂ were generated at the bonding interfaces of 5083/Q345 clad plate. The fracture surface of the tensile specimen exhibited ductile and quasi-cleavage fractures.     

Microstructure and enhanced atomic diffusion of friction stir welding aluminium/steel joints

Lap joints of friction stir welding between aluminium and stainless steel sheets were conducted using a welding tool with a cutting pin. The atomic diffusion of Fe–Al system during the severe plastic deformation was investigated. The interfacial microstructure and metallurgical reaction was analysed. The metallurgical reaction layers were identified as a compounds containing a phase of Al₃Fe, partial solid solution of Fe and Al, and amorphous with a thickness of 0.9–3.3?μm which depending on the process parameters. The interdiffusion coefficient between Al and Fe atoms is about 4 orders of magnitude compared with that under thermal equilibrium state. The nanocrystalline and partial amorphous were formed near the interface which may caused by the enhanced atomic diffusion.     

Interfacial characteristics of electron beam welding joints of SiCp/Al composites

Abstract

The electron beam welding of SiCp/101Al composites has been carried out. The influence of welding parameters on weldability and mechanical properties of the welded joints was discussed. The welding parameters were therefore optimised under the current experimental circumstance. Results show that only weak interfacial reaction between SiC particle and liquid aluminium occurred. Minute quantity brittle Al₄C₃ compounds and single phase Si were generated in the welded joint. The interfacial reaction between SiC particles and Al matrix could be greatly suppressed by adopting appropriate technique measures such as high welding speed and low heat input. The content of Al₄C₃ can be therefore greatly decreased in the welded joint. Moreover, modification welding and electron beam scanning could further improve the appearance of weld, and the welded joint with better quality could be obtained.     

Experimental investigation of laser beam welding of explosion-welded steel/aluminum structural transition joints

The steel/aluminum structural transition joints are widely used in shipbuilding industry due to the advantages of joining these two materials with important weight savings while exploiting their best properties. The use of laser welding to strongly connect components made of Fe and Al alloys as base materials with Fe/Al structural transition joints is very attractive. The authors report results achieved during the laser welding of these particular joints with the scope to evaluate effects of the laser-induced thermal loads on the integrity of the Fe/Al bond interface, from metallurgical and mechanical points of view. The increase of both inter-metallic film thickness and extension were detected as a result of the laser beam induced heat on the Fe/Al bond interface. These increases did not cause severe reductions of the mechanical resistance of the investigated structural transition joint.     

Hierarchical microstructure of explosive joints: Example of titanium to steel cladding

The microstructure of explosive cladding joints formed among parallel Ti and steel plates was examined by electron microscopy. The bonding interface and the bulk materials around it form pronounced hierarchical microstructures. This hierarchy is characterized by the following features: at the mesoscopic scale of the hierarchy a wavy course of the interface characterizes the interface zone. This microstructure level is formed by heavy plastic shear waves (wavelength ≈ 0.5 mm) which expand within the two metal plates during the explosion parallel to the bonding interface. At the micro-scale range, intermetallic inclusions (size ≈ 100-200 μm) are formed just behind the wave crests on the steel side as a result of partial melting. Electron diffraction revealed FeTi and metastable Fe_9.64Ti_0.36. Most of the observed phases do not appear in the equilibrium Fe-Ti phase diagram. These intermetallic inclusions are often accompanied by micro-cracks of similar dimension. At the smallest hierarchy level we observe a reaction layer of about 100-300 nm thickness consisting of nano-sized grains formed along the entire bonding interface. Within that complex hierarchical micro- and nanostructure, the mesoscopic regime, more precisely the type and brittleness of the intermetallic zones, seems to play the dominant role for the mechanical behavior of the entire compound.     

炸药量对爆炸焊接界面波影响的数值模拟

为了保证金属复合材料的爆炸焊接质量,对爆炸焊接过程中的爆轰荷载大小起着决定性作用的炸药量及布药方式进行了探索。应用AUTODYN非线性显式动力学分析软件,模拟了基、复板爆炸焊接复合过程,得到了不同炸药量下爆炸焊接过程中的压力时程,结合理论公式,分析炸药量、爆轰荷载、碰撞速度和界面波状之间的关系,及炸药量对爆炸焊接界面波的影响。并在复板上、下表面等间距各设置了8个关键点,比较了炸药厚度均匀布药方式和厚度递减布药方式产生的波状形态。结果表明,在可焊性窗口内,炸药量多的会产生较大波状结合界面;厚度递减布药方式能够消除均匀布药方式下界面波的不均匀现象,其中方案2的速度波动效果最好。并且已经结合的界面受到后续压力的振动破坏明显降低。     

The influence of a steel rear barrier on the detonation response of a steel covered explosive struck by a steel projectile

Experiments by Weickert showed that the critical impact velocity of a shaped charge jet, required to cause detonation of a steel/explosive/steel laminate, reduced when the explosive thickness reduced. This paper examines the cause of this change using hydrocode simulations with and without a temperature based burn model. The simulations show that the change in critical impact velocity is caused by the reflected shock from the rear plate exceeding the shock at the cover plate. At this point the site of the detonation moves from the cover plate to the rear plate. Further reduction in explosive thickness causes further reduction in critical impact velocity due to the reduced dissipation of the shock reaching the back plate. The change in critical velocity for hemispherical-nosed projectiles is predicted to be not as sharply defined as for flat-nosed projectiles. This is due to a later, third stage reflection from the bulge of the advancing cover plate.