The explosion welding process, is a method of joining dissimilar metals, such as steel and aluminum, together. In this process, one metal plate is propelled at high velocity towards another metal plate by an explosive detonation. The impact of the collision creates a bond between the two metals.
Explosion welding is a superior method to using insulated bolt joints for joining steel and aluminum for several reasons. First, explosion welding creates a continuous bond between the two metals, whereas an insulated bolt joint leaves a gap between the metals. This gap can create a weak spot in the joint, and it can also allow for the ingress of moisture and other corrosive elements.
Second, explosion welding does not require the use of any fasteners, which can be a source of corrosion and fatigue. Third, explosion welding can be used to join metals of different thicknesses, whereas insulated bolt joints are typically limited to joining metals of the same thickness.
Finally, explosion welding can create a joint that is stronger than the base metals themselves. This is because the high velocity impact of the collision creates a metallurgical bond between the two metals.
Of course, there are also some disadvantages to explosion welding. First, it is a relatively expensive process. Second, it can be difficult to control the quality of the weld. And third, it can only be used to join simple shapes.
Overall, explosion welding is a versatile and effective method for joining dissimilar metals. It is a good choice for applications where a strong, corrosion-resistant bond is required.
Here is a sketch of the explosion welding process:
Explosion welding sketch