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Explosion CladdingAn Enabling Technology for
Zirconium in the ChemicalProcess Industry
John G. Banker
V.P. Customers & TechnologyDynamic Materials Corporation
Boulder, Colorado USA
Zirconium and the Chemical ProcessIndustry (CPI)
ØCorrosion is a major equipment concern inmany CPI facilities
Ø Zirconium exhibits superior corrosionresistance over a broader range of chemicalenvironments and temperatures than virtuallyany other metalØAcids – both organic and inorganicØStrong AlkalisØSalt solutions
In Severe Corrosion Environments-
ØZr 702 and 700 are commonly usedØZr is the material of choice forØTanks, Columns, Heat Exchangers,
Autoclaves, Reactors, Valves, Pumps…
ØIn conditions requiring thin wallequipment, Zr 702 is clearly a bettervalue than other, often much lower costCorrosion Resistant alloys
For Heavier Wall Equipment-
The cost/benefit justification for Zr isoften more challenging.
Table 1: Comparative Costs of someCorrosion Resistant Alloys
Alloy Cost Ratio
S31603 (Stainless Steel) 1.0
R50400 (Titanium) 3.0
N10276 (Hastelloy) 5.0
R60702 8.0
R05200 (Tantalum) 20.0
Clad Can Significantly ImproveCompetitive Position for Thicker
Applications
3 mm Zr 30 mm Steel
Cost Savings – Zr Clad vs Solid Zr 702
Explosion Cladding
Ø The only proven industrial technology for joining Zr toSteels and most other metals
Ø Highly robust and reliable technologyØ Broad range of metal combinationsØ Discovered and industrialized in 1960’sØ Over 30 explosion cladding companies produce over
200,000 mt of clad worldwide todayØ Zr clad is the most challenging to makeØ Dynamic Materials Corp. developed Zr cladding
technology and is World Leader today
Explosion Cladding ProcessØThe energy of an explosive detonation accelerates the Zr and base metalplates together causing a high velocity collision.ØThe momentum exchange creates conditions which result inmetallurgical welding.
Explosion Weld Interface
500 nm
Zr – Steel Explosion Weld Interface
ØDiffraction studies indicate interface layer isamorphous
ØResult of very fast heating and cooling,estimated to be > 1 x 107 ° C/sec
ØThermodynamically stable intermetalliccompounds do not have time to form.
Ø Zr-Steel interface typically > 200 MPa shearstrength, highly resistant to disbonding infabrication and service
Heat Exchanger – Nitric Acid - 200°C
Zr Tubes
Stainless Steel Shell
Zr – Stainless SteelExplosion CladTubesheet
Zr Clad Pressure Vessel
Ø50,000 liter reactor
Ø3 mm Zr cladding oninside for corrosionresistance
Ø30 mm Carbon Steelshell for pressurecontainment
ØSteel water jacket onoutside for temperaturecontrol
Tube Coupling: Zr-to-Stainless Steel
12 mm long Zr
38 mm longstainless steel
Explosion weld Zrto Stainless
Conclusion
ØExplosion cladding enables the costeffective use of Zr as a corrosionresistant material is many severe CPIapplications.ØToday virtually all Zr CPI equipment
requiring wall thickness > 20 mm isexplosion clad
Acknowledgments
ØATI Wah Chang, especiallyØTerry WebsterØRichard Sutherlin
ØDynamic Materials Corp.ØMy Family and teammates
Thank You
For More Information aboutExplosion Cladding please visit
www.dynamicmaterials.com