Explosion Welding in the Energy Industry Warren Salt February 06, 2014 © 2013 NobleClad. All rights reserved. A DMC Company NobelClad (a DMC Company) Warren Salt Director of Business Development 5405 Spine Road Boulder, CO 80301 [email protected] Explosion Welding for the Energy Industry NobelClad.com WHAT IS EXPLOSION WELDING? Explosion Welding for the Energy Industry NobelClad.com WHAT IS EXPLOSION WELDING? Explosion Welding for the Energy Industry NobelClad.com WHAT IS EXPLOSION WELDING? Explosion Welding for the Energy Industry NobelClad.com INTRODUCTION • Started operation in 1965 • Headquarters – Boulder, CO • Public Company • Traded on NASDAQ – BOOM • ~480 employees • 2012 Revenue ‐ $202M Explosion Welding for the Energy Industry NobelClad.com BRAND RELATIONSHIPS | NEW LOGOS Explosion Welding for the Energy Industry NobelClad.com 3 Manufacturing Locations US – Mt. Braddock, PA France – Rivesaltes Germany – Burbach 220 employees Structured for 70,000 sqm of capacity Explosion Welding for the Energy Industry NobelClad.com The Process Explosion Welding Explosion Welding for the Energy Industry NobelClad.com PROCESS DEFINITION/CLASSIFICATION • Filler metal: • None • Heat Input: • V=0/I=0 • Travel Speed: • Really fast (2000‐3000 m/s) Explosion Welding for the Energy Industry NobelClad.com THE PROCESS Key Process Elements • Good Quality Materials • Explosion Bonding Parameters • Standoff Distance • Explosive Load • Explosive Burn Rate • Final Inspection Explosion Welding for the Energy Industry NobelClad.com BONDZONE – HOW DOES IT WORK? Many National Laboratories, Research Institutes and Universities have performed high magnification nano‐scale studies of explosion welds in recent years Consensus: Solid State Welding Process Explosion Welding for the Energy Industry • No intermetallic formation • No heat affected zone NobelClad.com BOND STRENGTH • High shear strength: • Typically >400MPa for stainless and nickel alloys • Lower strength CRA’s (Cu alloys, Ti, Zr): ≈ 200 Mpa • Virtually impossible to separate during forming and fabrication • Internal attachments can safely be welded to clad surface Shear test – SSteel/Csteel Explosion Welding for the Energy Industry NobelClad.com The Process Capabilities Explosion Welding for the Energy Industry NobelClad.com Clad plates for reactors (9m x 2m x 140 mm) CAPABILITIES 50 t 13 m 5m Large clad tubesheets (dia 2,3 m x 400 mm) Cladder : 0.25 to 50 mm Base: 0.25 to 1000 mm Flat plates and Concentric Cylinders Limits: • Cannot clad contoured surfaces • Cannot clad brittle materials • need > 10% elongation • need > 20 joule impact Explosion Welding for the Energy Industry NobelClad.com DETACLAD® EXW RANGE OF ALLOYS Typical Clad Metals Typical Base Metals • A 240 Type 410S • Carbon steel (A 516, 533, 537,…) • A 240 Type 304 L, 316L • Cr‐Mo steel (A 387,…) • A 240 Type 321/347 • Cr‐Mo‐V steel (A 542) • A 240 Type 904L • Stainless steels (316L, DUPLEX) • Alloy 625, Alloy 825, Alloy 600 • API 5L / DNV pipe grades • Alloy 59, Alloy C276, C22 • Monel 400 • Duplex 2205, 2207 • Aluminum and Al alloys • Copper and Cu‐Ni‐alloys • Titanium, Zirconium, Tantalum Explosion Welding for the Energy Industry NobelClad.com DETACLAD EXW FEATURES • Cold Welding Technology – No Diffusion, Intermetallic formation or Heat Affected Zones • Metal properties are not altered by Detaclad® operation • Corrosion resistance • Mechanical properties • Produces a strong, ductile, continuous metallurgical weld over full clad surface • Detaclad® will not disbond when fabricated by proper thermal and mechanical procedures • Virtually any metal combination with good fracture toughness can be welded • • Dissimilar alloys, such as Ti or Al to Steel • Similar alloys, such as Stainless Steel to Steel Low cost and high value for many metal types and thicknesses Explosion Welding for the Energy Industry NobelClad.com DETACLAD® EXW VS. WELD OVERLAY • Detaclad® has no dilution ‐ alloy chemistry is constant over full thickness • All overlay has some dilution • Virtually no heat affected zone • Explosion cladding has much faster production rate • Overlay typically requires 5mm deposition • Results in higher weight and cost • Internals can be directly attached to Detaclad® • Cannot be done with overlay • Is suitable for virtually all metal types • Is lower cost for many alloys and thicknesses Explosion Welding for the Energy Industry NobelClad.com DETACLAD® EXW VS. ROLL BOND • Superior shear strength (ie bond strength) • Typically 200 to 500 mPa dependent upon alloy • Translates into a guaranteed bond upon subsequent forming with appropriate procedures • Attachments can weld directly to Detaclad® • Improved corrosion performance from low temperature process which minimizes sensitization • Production profile • Large fix asset that is shared vs. relatively low fix assets that are dedicated • Translates into more stable pricing and more stable lead times • Nobelclad maintains 4 week flow for standard product Explosion Welding for the Energy Industry NobelClad.com Application Industries Explosion Welding for the Energy Industry NobelClad.com INDUSTRIES •Armoring •Shipbuilding •Railway industry •Electrochemical processing •Hydrometallurgy •Refrigeration •Steel Mills Explosion Welding for the Energy Industry Energy • • • • • • • Upstream Oil and Gas Refineries Power Generation Coal Gasification LNG Alternative (IWind, solar, OTEC), • Chemical & Petrochemical Industry NobelClad.com GORGON SLUG CATCHER • 153 plates – 625 + 5LX65M •17 @ 37mm x 3,248mm x 12,650mm •136 @ 37mm x 3,248mm x 12,300mm Explosion Welding for the Energy Industry NobelClad.com TMCP + EXW FOR CLAD PIPE, ALLOY 625 Comparative ASTM G28 Method A Corrosion Testing Alloy 625 Clad, EXW & Hot Roll Bond 1.00 0.90 Corrosion Rate (mm/y) 0.80 0.70 0.60 0.50 0.40 NobelClad EXW: Sour Service rated, Excellent CVN, CTOD and DWTT 0.30 0.20 Voest TMCP: No Mechanical Properties Reported, No SPWHT 0.10 0.00 Special Metals Typical NobelClad EXW As‐Clad NobelClad Gorgon EXW with PWHT TMCP Clad (Voest ‐ NACE Corrosion 2013) NobelClad.com Application Co‐Extruded Boiler Tubes Explosion Welding for the Energy Industry NobelClad.com COAL FIRED POWER PLANT • Basic Process • Burn Coal • Heat Water/Steam • Generate Electricity with Steam Turbine • Water wall • Efficiency Improvements • Staged Combustion • Reducing Environment • Accelerated Corrosion Explosion Welding for the Energy Industry NobelClad.com COEXTRUDED ALLOY 622 TESTING • Baseline Steel Tubes • • • Massive corrosion First Step Weld Overlay • Significant improvement • Still shorter life than desired • Weld structure is susceptible to corrosion Second Step Coextruded • Cold welding process • Extruded structure J. N. DuPont, W. Van Geertruyden, A. Caizza and A. Esposito, Paper No. 10201: Corrosion Behavior of Alloy 600 and 622 Coextruded and Weld Overlay Coatings, NACE Corrosion 2010 Explosion Welding for the Energy Industry NobelClad.com COEXTRUDED BOILER TUBE Tube Manufacturing • Step 1 Clad Billet • Concentric Clad • Inside F11 • Outside Alloy C22 • 6” OD x 24” Billet • Step 2 Extrude Boiler Tube • 2.25” OD Explosion Welding for the Energy Industry NobelClad.com Other Applications Oil and Gas Industry Explosion Welding for the Energy Industry NobelClad.com DMC CLAD REFINERY COLUMN Base Metal SA‐516‐70 Cladding changes with height: 304L, 317L, 625 Explosion Welding for the Energy Industry NobelClad.com COKE DRUM SA 516 G70 + 410S or 316 L (40+3mm) Explosion Welding for the Energy Industry NobelClad.com REFINERY COLUMN Cr‐Mo steel + Stainless 321 (102 mm + 3 mm ) 5 m diam x 35 meters long Explosion Welding for the Energy Industry NobelClad.com CLAD CRUDE VACUUM TOWER Explosion Welding for the Energy Industry NobelClad.com Thank you Warren Salt 5405 Spine Road Boulder, CO [email protected] [email protected] © 2013 NobleClad. All rights reserved. A DMC Company
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