Prime component is placed either parallel or at an angle to the base. Explosive is distributed over top surface of prime component.

Upon detonation, prime component collides with base component to complete welding.
Weld

Detonation

Prime component
Jet Base component

Action between components during explosion welding.

Variables:
Explosive Pressure

These are Controlled By:

= Plate density
V = charge velocity

Results from ABAQUS model:

Test No. 1 2 3 4 5 6 Measured Flyer Velocity (m/s) 300 330 245 300 340 400 Predicted Flyer Velocity (m/s) 294 324 337 310 358 394 Predicted Collision Velocity (m/s) 2250 2250 2400 2400 2400 2400 Predicted maximum Pressure (GPa) 5.28617 5.81482 4.26927 5.55757 6.39333 7.01322 Predicted maximum shear stress (GPa) 0.264 0.290 0.213 0.277 0.319 0.350

flyer plate eventually attained a terminal velocity for sufficiently large stand-off distance

vertical velocity profile for the flyer obtained from the ABAQUS analyses are shown in red in Fig. velocity increases from zero to its highest at the collision point and then the velocity reaches zero

Vertical velocity of flyer and base plate

Pressure gradient is negative ahead of a stagnation point and positive behind. Decreasing from zero at infinity to a minimum value and reaching again at x = 0; to rise to a maximum positive value behind the collision point.
Pressure gradient profiles of flyer plate at 0.3 m from the edges of the plates

Normal stress contours Parallel arrangements

Normal stress contours Inclined arrangements

Relationships between operational conditions and physical parameters, such as local stresses, strains and particle velocities which determine the success or failure of the weld were identified.
Bonding is dependent on the level of induced plastic strain in the two materials exceeding a threshold level. In the case of simulations of the bonded plates the shear stresses were of opposite sign but had the same sign for non-welded plates.

Common industries that use explosion welding

Chemical Processing Petroleum Refining Hydrometallurgy Aluminum Smelting Shipbuilding Electrochemical Oil & Gas Power Generation Cryogenic Processing Pulp & Paper Air conditioning & Chillers Metal Production