Explobond Electrical Transition Joints

Explobond Electrical Transition Joints are inserts used for joining dissimi1ar metals in a current carrying system. The fact that during explosion bonding, the surfaces undergo a cleansing process is reflected in the practically zero electrical resistance of the bond interface. This is unlike other alternatives such as braze welding, weld deposition, etc. where large amounts of inter-metallic / alloy layers coupled with defects like shrinkage cavities contribute to electrical resistance of joints.

Applications

Explobond Electrical Transition Joints are widely used in the electrochemical industries like chlor alkali and electrometal1urgical industries such as aluminium smelters, zinc electrolysers apart from electrical contacts.

These processes usually employ very high current (at low voltages) and reduction of voltage drops at the joints, result in considerable power savings. Explobond transition joints serve to providing reliable, energy saving, maintenance free and strong electrical connections between dissimilar metals.

In the potlines of modern aluminium smelters, the electrode holders are steel and bus bars usually aluminium. Aluminium and steel cannot be welded by conventional processes. Explobond electrical clad transition joints are interposed between the bus bar and the electrodes to complete the circuit.

Standard Explobond electrical transition joints for Aluminium smelters are:

Type-A

Aluminium 99.5% purity 12.7 mm thick

Carbon Steel AISI 1008 38.1 mm thick

Minimum tensile strength: 80 MPa in as clad condition

Minimum tensile strength: 65 MPa after 24 hours soaking at 300 degree centigrade

Type-B

Aluminium 99.5% purity 12.7 mm thick

Titanium SB 265 Grade 1. 2 mm thick nominal

Carbon Steel AISI 1008 38.1mm thick

Minimum tensile strength: 150 MPa in as clad condition

Minimum tensile strength: 80 MPa after 24 hours soaking at 500 degree centigrade

Most combinations and dimensions are possible depending on customer requirements like Aluminium + Copper, Copper + Aluminium + Copper, Copper + Steel and many others.