爆炸焊接对炸药性能要求的探讨

为了保证爆炸焊接复合板达到良好的质量和能否在爆炸焊接中使用非理想爆轰炸药,对所使用的炸药性能进行了探讨。结合爆炸焊"窗口"理论以及工程实例对用于爆炸焊接的炸药爆速、密度、爆轰状态等参数进行计算,得到了爆炸焊接中炸药爆速的上、下限,密度的取值范围以及提高炸药能量利用率的途径,并在铝-钢焊接工程中取得了较好的效果,以期对爆炸焊接工作有所裨益。     

铜-A3钢爆炸焊接SE型专用炸药实验研究

炸药爆速不稳定和爆速过高是造成复合板结合质量差的主要原因.以2#岩石硝铵炸药为主体,通过加入一定比例的食盐、膨胀珍珠岩配制成了爆速可调的SE型爆炸焊接专用炸药,其加工方便,成本较低,最低爆速为2048m/s.铜-A3 钢爆炸焊接实验表明,该炸药具有爆速低、爆轰稳定、能量适中特点,较好地解决了猛炸药焊接时所出现的问题.研究和配置爆速更低、能够适应更多金属板材以及管状物体焊接的专用炸药是需要进一步研究的课题.     

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。     

玻璃微球含量对乳化炸药爆速的影响及蜂窝炸药研究

针对传统爆炸复合炸药的缺点,采用玻璃微球作为稀释剂,通过改变玻璃微球含量,研究其对乳化炸药密度与爆速的影响,通过乳化炸药制备蜂窝结构炸药,用于金属板的爆炸焊接。T2铜板和Q235钢板分别作为覆层和基层,其相应尺寸分别为2 mm×150 mm×300 mm和20 mm×150 mm×300 mm,选用两种爆速(2596 m/s和3089.5 m/s)的蜂窝结构炸药作为爆炸复合炸药,进行铜-钢爆炸焊接,然后利用微观形貌分析观察复合板结合性能。实验结果表明:玻璃微球含量大于5%小于35%时,炸药密度和爆速均随着玻璃微球含量的增加而降低;玻璃微球含量为40%时,发生拒爆现象。炸药爆速随着炸药密度的降低而下降。铝蜂窝板可以降低乳化炸药临界直径,爆速也有所提高。爆速低的蜂窝结构炸药进行爆炸焊接,T2/Q235复合板界面呈小波状,结合性能良好。     

爆炸焊接用低爆速粉状乳化炸药研究

为降低岩石粉状乳化炸药的爆速,选择了一种HW矿物粉,通过筛混方式将该分散剂与炸药混合,并测定了该分散剂加入量和布药厚度对炸药爆速的影响。结果表明,岩石粉状乳化炸药中掺入44.5%~50%的HW矿物粉时,爆速为1913m/s~2378m/s,经钢与不锈钢板爆炸焊接试验表明,爆炸结合率达100%,可满足金属爆炸焊接用炸药的要求。     

爆炸焊接用低爆速粉状乳化炸药研究

为降低岩石粉状乳化炸药的爆速,选择了一种HW矿物粉,通过筛混方式将该分散剂与炸药混合,并测定了该分散剂加入量和布药厚度对炸药爆速的影响。结果表明,岩石粉状乳化炸药中掺入44.5%⁵0%的HW矿物粉时,爆速为1913m/s50%的HW矿物粉时,爆速为1913m/s²378m/s,经钢与不锈钢板爆炸焊接试验表明,爆炸结合率达100%,可满足金属爆炸焊接用炸药的要求。     

爆炸焊接专用炸药实验研究

以2#岩石硝铵炸药为主体,通过加入一定比例的食盐、膨胀珍珠岩配制成爆速可调的SE型爆炸焊接专用炸药,其加工方便、成本较低,最低爆速为2048m/s。经铜-钢爆炸焊接实验表明,该炸药具有爆速低、爆轰稳定、能量适中特点,较好地避免了猛炸药焊接时所出现的问题。研究、开发爆速更低、能够适应管状物体焊接需要的可塑性炸药,是有待进一步研究的课题。     

爆炸焊接专用炸药实验研究

以2#岩石硝铵炸药为主体,通过加入一定比例的食盐、膨胀珍珠岩配制成爆速可调的SE型爆炸焊接专用炸药,其加工方便、成本较低,最低爆速为2048m/s。经铜-钢爆炸焊接实验表明,该炸药具有爆速低、爆轰稳定、能量适中特点,较好地避免了猛炸药焊接时所出现的问题。研究、开发爆速更低、能够适应管状物体焊接需要的可塑性炸药,是有待进一步研究的课题。     

炸药爆速的连续测量技术研究

爆速是研究炸药性能的重要指标,虽然传统的爆速测量方法操作简单,但是由于测量点少、精度低,经常无法采集到有效的数据,而且也很难反映出炸药在整个爆轰过程中爆速的变化。为了弥补目前炸药爆速测量的缺陷,提出一种爆速的连续测量技术,采用高速数据采集与连续电阻丝探针相结合的方法来测试水下爆炸、工程爆破、爆炸焊接等工况下的各种炸药爆速,爆轰行程每米测量点数为2.5万,测量范围从50 m/s到10 000 m/s,测量精度可以控制在小于1.0%,通过数学拟合算法和编制程序对测量数据信号进行图形可视化分析,并绘制出连续行程-爆速分析曲线,可以满足不同形式炸药爆速测量的试验研究。     

1Cr18Ni9Ti-20G爆炸焊接+轧制工艺研究

为了研究在不同爆炸焊接工艺条件下获得的复合板的轧制效果,本文对大波、小波、微波状3种界面的1Cr18Ni9Ti／20G复合板进行轧制实验研究．实验表明：只有用下限获得的微小波状界面的爆炸焊接复合板,才能实现成功轧制,而大波状复合板界面存在一定的缝隙、空洞等微观缺陷,在轧制时由于分层会使轧制失效．爆炸焊接 轧制工艺获得的复合板结合界面的组织、强度和性能的测试结果表明：轧制复合板结合界面的剪切和分离强度虽比爆炸态略低,但延伸率、冲击韧性都大大增强,轧制复合板的耐蚀性能也未降低．     

厚板爆炸焊接窗口理论的应用

厚板爆炸焊接的焊接质量，焊接与否都比薄板更加强烈地依赖于爆速，复板加速间抛掷角，打击速度等焊接参数，该文根据可焊窗口理论，对厚板爆炸焊接参数选择时应注意的总理２进行了分析，尤其对焊接上限问题进行了较深入地讨论。     

Research on honeycomb structure explosives and double sided explosive cladding

In order to resolve the current issues about the backward method of charge and low energy efficiency of explosives, honeycomb structure explosives and double sided explosive cladding were used in the present study. Honeycomb structure explosives are used to ensure the quality of charge. Double sided explosive cladding can clad two composite plates simultaneously. Honeycomb structure explosives and double sided explosive cladding, which significantly reduce the critical thickness of stable detonation of explosives, are used to increase the energy efficiency of explosives and save the amount of explosives. Emulsion explosives with the thickness of 5 mm can be stable detonation. In this paper, the experiment of double sided explosive cladding for two groups of steel of No. 45 with the thickness of 2 mm to steel of Q235 with the thickness of 16 mm and two groups of stainless steel with the thickness of 3 mm to steel of Q235 with the thickness of 16 mm were successfully investigated. Without constraints, the critical diameter of emulsion explosives is 14–16 mm. Compared to the existing explosive cladding method, the consumption of explosives for steel of No. 45 to steel of Q235 and stainless steel to steel of Q235 are reduced by 83% and 77% in the case of cladding the same number of composite plates. The explosive cladding windows and collision velocity of flyer plate were calculated before experiment. It shows that the calculation prefigures exactly the explosive cladding for steel of No. 45 to steel of Q235 and stainless steel to steel of Q235.     

钛/钢多层爆炸焊接界面的实验研究

为探究膨化硝铵炸药作用下,厚度均为2 mm的钛(Ti)、钢板的最优爆炸焊接参数以及验证一种新的爆炸焊接试验方案,实验采取阶梯型多层基板的爆炸焊接试验方案,以控制药量和间距为变量,并将Ti板作为复板,同时对多层阶梯型钢基板进行爆炸焊接试验;利用金相显微镜对焊接复合板进行观察,并分析多层基板同时焊接的方案可行性以及不同实验参数对界面波形的影响。试验结果和分析表明:通过观察Ti/钢复合板界面波形呈正弦微波状且无明显过渡层,验证了新方案的可行性,同时突出了阶梯型多层基板的同时爆炸焊接方案,能够在单次试验下对比分析不同基复板间距情况下的焊接效果的能力;并经分析得出在单位面积装药为1.048 g/cm~2及装药间距范围为(9~11)mm时,能得到质量较佳的Ti/钢爆炸复合板。     

双金属爆炸焊接参数设计理论

针对爆炸焊接参数设计问题,从爆炸焊接基本理论出发,分步介绍了飞板爆轰驱动的理论和双金属爆炸焊接窗口理论。首先归纳总结了一维爆轰驱动飞板的终速公式,并详细说明了其应用范围与原因。对于二维滑移爆轰驱动飞板问题,主要针对Richter理论和特征线法进行了介绍,并推导出新的近似计算公式。接着,对于爆炸焊接参数窗口理论,详细比较了以往传统单一金属爆炸焊接窗口理论与公式,并针对部分已有公式进行了重新推导与修正,重新界定了其适用范围。利用这些爆炸焊接窗口的基本理论,作者对所发展的双金属可焊下限、双金属可焊上限、双金属流动限以及声速限构成的双金属爆炸焊接窗口理论进行了系统地介绍。最后,以飞板爆轰驱动和爆炸焊接窗口构建成了整个爆炸焊接工艺技术参数设计理论,并结合二元合金相图进行爆炸焊接设计,针对调控原材料硬度的必要性、焊接界面波纹及气孔的控制方法等问题进行了讨论。     

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。     

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.     

Explosive welding of stainless steel–carbon steel coaxial pipes

Bi-metallic corrosion resistant steel pipes were produced through explosive welding process. The weldability window of the stainless steel pipe (inner pipe) and the carbon steel pipe (outer pipe) was determined by the use of available semi-empirical relations. The impact velocity of the pipes as the most important collision parameter was calculated by the finite element simulation. Direct effect of the explosive mass reduction on the bonding interface of the pipes was studied. Optical microscopy study showed that a transition from a wavy interface to a smooth one occurs with decrease in explosive load.     

Recent developments in explosive welding

Explosion welding (EXW) is one of the joining methods consisting of a solid state welding process in which controlled explosive detonation on the surface of a metal. During the collision, a high velocity jet is produced to remove away the impurities on the metal surfaces. Flyer plate collides with base plate resulting in a bonding at the interface of metals. The metal plates are joined at an internal point under the influence of a very high pressure and causes considerable local plastic deformation at the interface in which metallurgical bonding occurs in nature and even stronger than the parent metals. Similar and dissimilar materials can be joined by explosive welding. In this paper, after detection the theories of welding and wave formation, experimental research and numerical studies on explosive welding are reviewed for the last four decades. Also, future developments in explosive welding are predicted and criticized in an outlook.