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Introduction to Metal Composite Panels

2021-06-16View Original

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Composite panels: Metal composite panels refer to panels in which one layer of metal is covered with another layer of metal, in order to save resources and reduce costs without compromising the performance characteristics such as corrosion resistance and mechanical strength. Metal material composite technology can leverage the advantages of each constituent material, achieve optimal allocation of resources among these materials, save precious metal materials, and meet performance requirements that cannot be satisfied by single metals. It has a wide range of applications, brings significant economic and social benefits, and is readily supported and assisted in various aspects. Composite methods typically include explosive bonding, explosive rolling bonding, rolling bonding, etc. Composite materials can be classified into composite plates, composite pipes, composite rods, etc. It is mainly used in industries such as anti-corrosion, pressure vessel manufacturing, as well as electric power construction, petrochemicals, pharmaceuticals, light industry, and automotive. Explosive clad plate: An explosive clad plate is a metal composite plate produced using the explosive cladding method (also known as explosive welding). Generally, explosive clad plates refer to explosive metal composite plates. The production method for explosive composite plates involves placing the prepared composite sheet on a substrate, and then applying a layer on top of it; the instantaneous ultra-high pressure and ultra-high-speed impact energy generated during the explosion are used to achieve solid-state metallurgical bonding between the metal layers. Although the production process of explosive composite plates is simple and flexible, it requires high technical skills and precise control. The selection of base material properties (toughness, impact resistance, etc.), **properties (stable detonation speed, safety, etc.), initial parameters (amount per unit area, distance between the base material and the composite plate, etc.), and dynamic parameters (collision angle, collision speed of the composite plate, etc.), along with their interaction within the system, have a direct impact on the yield and quality of the composite plates. The composite interface consists of a direct bonding zone, a melting layer, and vortices. Atomic diffusion occurs at the bonding interface; severe plastic deformation accompanied by work hardening takes place in the bonded zone. The joint surface has a wavy structure, which is beneficial for improving the bonding strength and tensile strength. Explosion welding of composite plates does not alter the chemical composition and physical state of the original materials; accordingly, the materials to be compounded can be individually processed to achieve the desired optimal state according to practical requirements. Explosive clad plates have excellent performance; they can withstand cold and hot processing without altering the thickness ratio of the composite material. Composite materials have very high bond strength, usually higher than that of the component materials with the lower strength, which is something that other technologies cannot achieve. Composites do not develop delamination or cracking during subsequent production processes such as heat treatment, leveling, cutting, winding, and spinning. Composites produced by the explosion bonding method include aluminum/steel, lead/steel, titanium/steel, silver/copper, etc. It has been widely applied in industrial fields such as petroleum, chemicals, shipbuilding, electronics, power, metallurgy, machinery, aerospace, and nuclear energy. Hot-rolled stainless steel composite sheet: Hot-rolled stainless steel composite sheets are stainless steel composite sheets that are produced by using medium and heavy plate rolling mills or hot continuous rolling mills. The hot rolling process enables the continuous and large-scale production of stainless steel composite sheets. High production efficiency, low costs, and large product sizes are its main features. The hot-rolling composite process is as follows. ①Design and manufacturing of composite slab billets. Based on the specifications of carbon steel and stainless steel raw materials, as well as the process parameters of the rolling mills and heating systems, the combination ratio of the composite billets is designed appropriately to achieve precise dimensions for the final composite plates. The manufacturing process of composite steel billets involves raw material surface treatment, brazing and diffusion welding techniques, as well as isolation and vacuum technologies. Ensure good physical process properties of the composite interface. ②Heating of composite slabs. Composite billets are usually heated in pusher-type or walking-beam continuous reheating furnaces. Thicker composite sheets also need to be placed in a pit furnace for heat homogenization. The pusher-type reheating furnace was developed relatively early on. When billets are pushed along support beams, “black marks” are formed, and there is also a risk of scratching. Consequently, the heating quality is poor. The length of the billets that can be pushed is limited; otherwise, “arching of the steel” may occur. Therefore, the productivity remains low. Mainly due to the aforementioned drawbacks, Americans invented the step furnace in the 1970s. As the name implies, in a stepping furnace, the billets move forward step by step, rather than being pushed in and out as in a pusher furnace. The furnace of a stepping furnace is equipped with a stepping beam and a fixed beam; the stepping beam moves the steel billets step by step from the feed end to the discharge end through cyclic actions of rising, moving forward, descending, and moving backward. Pusher furnaces are now very rare; the old ones have been converted into step-type furnaces during renovation. For heating furnaces with low production capacity, a pusher-type heating furnace can also be considered, as its cost is relatively low. ③For rolling composite plates, a larger reduction rate and a larger compression ratio should be used as much as possible. Various container composite panels utilize controlled rolling and controlled cooling processes to ensure the physical properties of the products. Thicker composite sheets also need to undergo normalizing treatment in a normalizing furnace. ④Finishing and inspection of composite panels. Composite panels are cut to the desired length and width using a shear machine or plasma cutter, and straightening is carried out with a roller-type cold straightener or a press. Large straightening machinery is required. Composite plates manufactured by the explosive rolling method first undergo initial welding of the composite base material using an explosive method, and then are rolled and welded to form the composite plate.

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