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