The Roll Bonded Clad Plate is the metal clad plate processed under the rolling mill's strong pressure. The backer and cladding metal’s oxide layers are ground down and form a clean and activated fresh metal. The diffusion of the two metals during rolling achieves complete metallurgical bonding. The rolling method here is the hot-rolled compound method, which is quite mature and widely chosen in clad plates production.
Using large or medium plate rolling mill and hot continuous rolling mill, The production efficiency and supply speed both increase. The thicknesses can be easily chosen, Stainless steel coating over 0.5mm clad plate can be produced.
Limited by the compression ratio of rolling steel, hot rolling production can not produce clad plates with a thickness of more than 50mm, and it is not convenient to produce small batches, round and other special shapes of clad plates.
The special advantage of hot rolled clad plate is the production of 6,8,10mm thin clad plates, under the condition of hot continuous rolling clad plate, the clad plate can achieve to be coiled.
Hot rolled clad plate can be produced on a large scale, not limited by the weather. Its high production efficiency, low cost and large product sizes are preferred by customers.
Under the current technology, the hot rolling process can not directly produce titanium, copper, aluminum and other non-ferrous metal clad plates.
Strong Metallurgical Bond: The process creates a strong metallurgical bond between the base material and the cladding layer, ensuring excellent adhesion and integrity.
High Bonding Strength: The cladding achieved through hot roll bonding has high bonding strength, making it suitable for high-pressure and high-stress applications.
Uniform Clad Layer: Hot roll bonding produces a uniform clad layer across the entire surface of the base material, ensuring consistent protection against corrosion and wear.
Large Surface Area Cladding: This method is ideal for cladding large surface areas, which is beneficial for producing large sheets or plates used in manufacturing large components like pressure vessels and heat exchangers.
Cost-Effective: Compared to other cladding methods, hot roll bonding is cost-effective for large-scale production, especially when cladding expensive materials onto less costly base metals.
Versatility in Material Combinations: A wide range of material combinations can be used in hot roll bonding, allowing customization for specific applications. Common combinations include stainless steel on carbon steel or nickel alloys on carbon steel.
Enhanced Mechanical Properties: The process improves the mechanical properties of the base material due to work hardening and the formation of a high-strength bond with the cladding material.
Thickness Control: Hot roll bonding allows precise control over the thickness of both the base material and the cladding layer, which is crucial for meeting specific engineering requirements.
Improved Surface Finish: The process often results in an improved surface finish, which can reduce the need for additional machining or finishing operations.
High Production Efficiency: The continuous nature of the hot roll bonding process allows for high production efficiency, making it suitable for large-volume manufacturing.
Thermal Stability: The materials bonded through hot roll bonding exhibit good thermal stability, making them suitable for high-temperature applications.
| Feature | Specification |
| Manufacturing Process | Roll bonding under high temperature and pressure |
| Standards | Typically ASME A-263, A-264, A-265 or equivalent |
| Base Metal | * Carbon Steel * Low Alloy Steel |
| Cladding Material | * Stainless Steel (Commonly 304, 316L) * Nickel Alloys * Other Corrosion Resistant Alloys |
| Overall Thickness | 3/16" to 1" (customizable) |
| Cladding Thickness | 5% to 40% of total thickness |
| Width | Up to 120" (customizable) |
| Length | Up to 480" (customizable) |
| Bond Strength | Exceeds ASTM minimum shear strength of 140 MPa |
| Quality Control | Typically includes tensile tests, shear tests, hardness tests, bend tests, ultrasonic testing, and impact tests (depending on application) |
1. Material Selection and Preparation
Base Metal and Cladding Material: The base metal (e.g., carbon steel) and the cladding material (e.g., stainless steel, nickel alloy) are selected based on the desired properties of the final product.
Surface Cleaning: Both the base metal and cladding material surfaces are thoroughly cleaned to remove any contaminants, oxides, or residues that could affect the bonding process. This often involves mechanical cleaning, chemical cleaning, or both.
2. Assembly of the Metal Stack
Layering: The cladding material is placed on top of the base metal. Sometimes, multiple layers of cladding material are used.
Edge Welding: The edges of the metal stack are welded together to hold the materials in place during the rolling process. This ensures proper alignment and prevents slippage.
3. Heating
Furnace Heating: The assembled stack is heated in a furnace to a temperature where both metals become plastic but not melted. The exact temperature depends on the materials but is typically in the range of 1000-1200°C (1832-2192°F).
4. Hot Rolling
Rolling Mill: The heated stack is passed through a rolling mill. The pressure exerted by the rollers causes the cladding material to bond metallurgically with the base metal.
Reduction Passes: Multiple passes through the rollers are often required to achieve the desired thickness reduction and to ensure a strong, uniform bond.
5. Cooling
Controlled Cooling: After rolling, the bonded material is cooled in a controlled manner to prevent warping or residual stresses. This can be done in air or using water sprays, depending on the material requirements.
6. Finishing Processes
Edge Trimming: The edges of the clad material may be trimmed to remove the welded sections and any irregularities.
Heat Treatment: Depending on the application, the clad material might undergo heat treatment processes such as annealing to relieve stresses and improve mechanical properties.
Surface Finishing: The surface of the clad material is often finished to meet specific roughness or appearance standards. This can involve grinding, polishing, or other finishing techniques.
7. Inspection and Testing
Non-Destructive Testing (NDT): Techniques such as ultrasonic testing, radiography, and dye penetrant inspection are used to ensure the integrity of the bond and to detect any defects.
Destructive Testing: Samples may be taken for mechanical testing, including tensile tests, bend tests, and shear tests to verify the bond strength and material properties.
Dimensional Inspection: The final dimensions of the clad material are checked to ensure they meet the required specifications.
8. Cutting and Shaping
Customization: The clad material is cut and shaped into the desired forms and sizes for its intended application, whether it be plates, sheets, or specific component shapes.
9. Quality Assurance
Documentation: Detailed records of the manufacturing process, material properties, and inspection results are maintained to ensure traceability and compliance with industry standards.
Oil and Gas Industry: Hot roll bonded clad plates are used in the oil and gas sector for components exposed to corrosive environments, such as offshore platforms, pipelines, and processing equipment. They provide reliable performance in demanding conditions, including high temperatures and aggressive media.
Chemical Processing: These plates find applications in chemical processing equipment like reactors, vessels, and piping systems where corrosion resistance is critical. The hot roll bonding process ensures a strong metallurgical bond between the base metal and the cladding, enhancing corrosion resistance.
Power Generation: In power plants, hot roll bonded clad plates are utilized in boilers, heat exchangers, and other components subjected to high temperatures and aggressive environments. They offer excellent resistance to corrosion, oxidation, and thermal stress, ensuring reliable operation.
Desalination Plants: Hot roll bonded clad plates are used in desalination plants for components exposed to seawater and brine solutions. Their corrosion resistance properties make them suitable for use in evaporators, heat exchangers, and other critical equipment involved in the desalination process.
Shipbuilding and Marine Industry: Clad plates find applications in shipbuilding and marine engineering for hulls, decks, and other structures exposed to marine environments. The combination of strength, corrosion resistance, and weldability makes them suitable for use in various marine applications.
Aerospace and Defense: Hot roll bonded clad plates are employed in aerospace and defense applications for their high strength-to-weight ratio, corrosion resistance, and thermal stability. They find applications in aircraft structures, armor plating, and missile components.
Automotive and Transportation: Clad plates are used in automotive and transportation industries for components requiring high strength, corrosion resistance, and wear resistance. They find applications in automotive body panels, chassis components, and fuel tanks.
Food Processing: Hot roll bonded clad plates are utilized in food processing equipment where hygiene and corrosion resistance are essential. They find applications in vessels, tanks, and processing machinery for handling food products safely and efficiently.
The manufacturing process involves placing two metal plates together, heating them to a specific temperature, and then passing them through a rolling mill. The heat and pressure cause the metals to bond at the atomic level, creating a strong, durable composite material.
Commonly bonded metals include stainless steel, carbon steel, aluminum, copper, nickel, and their alloys. The choice of metals depends on the desired properties and the application requirements.
Industries that frequently use these plates include oil and gas, chemical processing, power generation, marine, aerospace, and construction. They are particularly valued in environments requiring high corrosion resistance and strength.
· Pressure Vessels: Used in chemical and petrochemical industries.
· Heat Exchangers: Ideal for transferring heat in power plants and refineries.
· Shipbuilding: Used for hulls and other critical components.
· Structural Components: Employed in construction for bridges and buildings.
The thickness of the cladding layer can influence the overall performance of the clad plate. Thicker cladding provides better corrosion resistance and durability, while thinner cladding can be more cost-effective and suitable for applications with less stringent requirements.
Yes, hot roll bonded clad plates can be customized in terms of metal combinations, dimensions, and thicknesses to meet specific application needs and performance criteria.
Quality assurance involves rigorous testing and inspection processes, including ultrasonic testing, shear testing, tensile testing, and corrosion resistance tests. Manufacturers also adhere to industry standards and certifications to ensure high-quality products.
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