Clad plates AO Energometall

Clad plates are designed for manufacturing heat exchanger elements, as well as air cooled equipment, reactors, columns and vessels for the chemical and petrochemical industry and shipbuilding. The Clad plates are in line with technical standard TY-1880-002-15190236-2011, developed by AO EnergoMetall and OAO VNIINEFTEMASH. Technical Standard TY-1880-002-15190236-2011 is now part of National Standard GOST P52630-2012 “covering "Steel Welded apparatuses and vessels, General Technical Conditions."

Clad plates are normally made with the base layer of carbon low alloy or alloyed steel, nickel or copper alloys manufactured in accordance with the Russian and International standards.

The plate dimensions are normally limited by 35-40 square meters with various lengths and widths. We can also manufacture plates other than rectangular. Plate thickness lies in the range between 10 and 320 mm. The clad layer thickness is 2 to 12 mm.

The valid technical standard allows for using materials manufactured according to any internationally recognized standards, such as GOST, ASTM, ASME, EN, etc.

An important advantage of Clad plates manufactured by AO EnergoMetall is the guaranteed extra strength of the layer conjunction, minimum 220 MPa for the shear strength and minimum 220 to 260 Mpa for the tear strength.

The integrity of minimum class 1 according to GOST 22727-88 and GOST 10885-85 is guaranteed for all products of the company AO EnergoMetall.

Our customers are entirely welcome to discuss any additional requirements or exclusive properties of the Clad they need.

Clad Plates “Steel-Titanium Alloys” are meant for manufacturing heat exchanger elements as well as power generation and chemical industry vessels, electrochemical machinery.

The plates are manufactured in accordance with the applicable Russian and International standards and technical terms, including TY 5.961-11772-2011 “Clad Plates Steel-Titanium Alloys” by Research Center Prometey, ASTM B898-2011 and TY 1880-001-15190236-2011 “Clad Plates Steel-Titanium Alloy manufactured by explowelding” (Developed by Research Center Prometey for EnergoMetall).

Clad plates are being manufactured with the base layer of carbon, low alloy steel of domestic or foreign origin with the clad layer of titanium VT1-0 and VT1-00 according to GOST 19807-91, ASTM B-265 Gr.1, Gr.2.

Clad plates are made as rectangular billets with the thickness between 5 and 300 mm, width between 300 and 5000 mm and length between 400 and 9000 mm.

The titanium clad layer thickness may fall between 2 and 12 mm.

Large plates are normally made with the welded clad layer in accordance with the requirements of the Customer, such as OCT B5P.95118-2001.

Technical terms TY 1880-001-15190236-2011 feature a greater cladding quality compared to other standards, including the shear strength of at least 200 Mpa and tear resistance of min 180 Mpa (according to ASTM B898-2011, shear strength min 137,9 Mpa).

Besides the greater strength parameters, the integrity of at least class 1 is guaranteed by GOST 22727-88.

Based on multiple requests of Russian and foreign customers, AO EnergoMetall has manufactured pilot samples of Clad plates out of steel and special titanium alloys. Among others, the following compositions:

Steel 09Г2С – Titanium Alloy ПТ3-В

Steel 09Г2С – Titanium Alloy В265Gr.5

Steel 09Г2С – Titanium Alloy В265Gr.12

Triplet Composition:

Steel 09Г2С – Titanium Alloy В265Gr.1 – Titanium Alloy В265Gr.5

The exceptional parameters of new material have been confirmed by the Research Center Prometey, Research Center PolytechTest at the St.Petersburg State Polytechnical University.

We are looking forward to developing new products based upon Titanium Alloys as well as new technical standards meeting all demands of our Customers.

Large size Clad plates with the surface square between 20 and 40 m2 are manufactured in accordance with the valid Russian and International standards with the consideration of a number of additional requirements to the base and clad layers depending upon their dimensions and weights.

The base layer of carbon and low alloyed steel Clad plates of Russian and foreign origin is normally made seamless according to the technical requirements of the Customer and additional demands related to the precision of dimensions and flatness.

The clad layer of stainless steel as well as nickel and titanium alloys of Russian or foreign origin, may also be produced by extending with argon arc welding, with the mandatory radiographic control of the welding seem.

In 2013 we have made a pilot sample of a large size plate for the “Nuclear Reactor Emergency Cooling and Protection” (NRECP) (09Г2С-15 + AISI 321 with the dimensions of 90 (84+6) х 2600 х 10600 and the weight around 20 MT (billet dimensions considering the test routine is 2750x10800 mm.

The mechanical properties in the pilot version are much greater than those in the applicable standards (tear strength 476,59 Mpa, shear strength 410,38 Mpa), integrity class “0”.

Currently, in co-operation with the Research Center Prometey, our company is developing the new technical standards applicable to general conditions of nuclear power plants. On June 24, 2015 we have issued the protocol covering our discussion on the application of explowelded steel in the field of nuclear power generation. We have also developed the Technical Assignment related to the inspection procedure of explowelded Clad and in-depth technical standards covering plate Clad.

Above all, in co-operation with the Research Center Prometey, we have developed our Technical Assignment and Commercial Offer related to the manufacture of “Steel Titanium” tube plates with the dimensions of 45(40+5) х 4164 х 4950 for OAO “Silovye Mashiny”

Large size plates for petrochemical and chemical industry are manufactured according to Standard TY 1880-001-15190236-2011, ASTM A263, ASTM A264, ASTM A265 with the consideration of special requirements and weight.

Large size plates with the clad layer of Titanium are manufactured in accordance with Standard TY 5.961-11772-2011 “Clad Plates Steel-Titanium” (by the Research Center Prometey) and a number of additional requirements related to the welded clad layer.

Taking part in the international project of ITER, AO “EnergoMetall” manufactures billets for various thermonuclear reactor components which are being developed and manufactured by the D.V. Efremov Institute of Electrophysical Apparatus.

The main feature of all materials used in this project is the capability of working in the high vacuum media. Due to that, all initial metals used in both, base and clad layers, submit to the demands of the specification “ITER GRADE” and are subject to a number of additional tests, including those in cryogenic temperatures.

As part of the project, AO “EnergoMetall” manufactures two different types of billets.

Chrome-Zirconium Bronze and steel 316L-IG Clad plates are normally used for manufacturing heat exchanging elements of the reactor diverter. This Clad has a greater tear strength, minimum 300 MPa at 150 °С, as well as the absolute integrity which is confirmed by special 3D ultrasonic control equipment and the so-called “helium impermeability” tests.

Constructively, the entire load in the final product is concentrated around the plate counter with the 5 mm Clad edge. Therefore, the high vacuum operating area of the reactor is on the side, and the supercritical parameters cooling water is circulating on the other side.

In order to manufacture the case of the reactor poloidal field coil, AO Energometall had to solve a substandard problem of 3D cladding by developing a Clad plate with a non-flat cladding area.

Until recently, those contacts were manufactured by stamping on a flat billet press with the consequent extensive mechanical processing (company Nobelclad, France). AO EnergoMetall has produced the contact billet in one step with the exceptional quality of both, flat and radius connection areas to the Grade 316L stainless steel base.

All products are being accompanied by a set of quality approval documents, defined by the requirements of the State Corporation Rosatom and the project of ITER.

Clad flat plates /sheets/ of aluminum-magnesium alloys and stainless steel are used as semi-finished couplers in welded constructions in ship building and machine building industry, as well as billets in electrical industry and instrumentation.

Technical standard TY 1880-003-15190236-2012 “Clad Plates of Aluminum alloy АМг6УМ and general purpose steel 12Х18Н10Т (ТР321) were approved by the Russian Maritime Register of Shipping

Total Plate Thickness: 10 mm

Thickness of Clad layers: steel 12Х18Н10Т(ТР 321) – 5 mm, АМг6УМ – 5 mm

Plate Width: 300-1500 mm

Plate Length: 400-3000 mm

The following alloys are used as raw material for Clad plates:

• Aluminum Alloy АМг6УМ according to GOST 4784-97, GOST 21631-76 with a double side clad layer of pure aluminum (АД1, АД0)
• Corrosion resistant steel 08-12Х18Н10Т according to GOST 5632-72 or или X6CrNiTi18-10 (ISO), 321(AISI) according to ASTM A240/A240M.

Minimum cladding strength:

• Shear Strength – 60 MPa,
• Tear Strength –100 MPа.

Clad plates are subject to 100% ultrasonic control according to GOST 22727-88, ASTM A578/A578M.

The dimensions of the initial plate are defined by the size of the АМг6УМ and limited on top by the dimensions of 1500x3000 mm.

Additional Applications

Besides ship building, this type of Clad plates can also be used in electrical industry and instrumentation which allows for reaching a compromise between the low heat conductivity and corrosion resistance of stainless steel verses the high heat and electrical conductivity of aluminum alloy. Those Clad plates also allow for easier mechanical processing from the side of the aluminum alloy.

Trimetal Electric Power Joints “Al-Ti-Steel” are normally used in the construction of the anode holder bar to ensure the proper technological cladding of steel and aluminum by means of the titanium layer which excludes the formation of fragile intermetallic compounds of aluminum and iron.

The device operates in high temperature media (around 350 °С) and requires the confirmation of the guaranteed service life. Tests were run on samples manufactured by the order of the Nadvoitski Aluminum factory belonging to the company Rusal. All parameters were properly confirmed by the Inspection Protocol.

Such Trimetal Electric Power Joints are produced by Nobelclad (France). In Russia, Power Joints of a different type seem to be more common. Therefore, this device falls into the category of perspective solutions.

Clad Rods with a copper core and titanium сasing of Titanium ВТ1-0 ОСТ 190013-81 are used as сurrent conductors operating in the corrosion media.

The cladding strength of the titanium casing and copper core is expected to withstand multiple cyclic heating up to 500 °С and cooling down to 60 °С with the capacity of at least 25 cycles. The axial load tests are normally run on a random cylindrical Clad rod sample with the length of 15 mm (minimum 400 H).

This item is used in the new construction of anodes when producing nickel.

The company EnergoMetall is invariably regardful to the potential demands of our partners and the market as well as the opportunities being discovered in process of the current production schedule. Most of the today’s mass production items have earlier been falling into the category of “Perspective Solutions”.

We have made a significant step forward in the field of explosion welding of high-strength titanium alloys, which were earlier labeled as “unweldable”. We have prepared experimental compositions out of low alloyed steel and titanium alloys ПТ3-В ГОСТ 19807 – 91, ASTM B265 Gr.5, ASTM B265 Gr.12 demonstrating the technical possibility of obtaining high quality double and triple layer claddings with exceptional mechanical properties. This product appeared to be of interest to Italian manufacturers of equipment for offshore oil platforms.

We have also made a Clad sample for the ice crushing belt of perspective icebreakers. Materials with armor properties of both, base and clad layers, were welded together with equal success. This job was done in co-operation with the Research Center Prometey.

Above all, we have manufactured a sample of welded Clad pipe. This item is not produced in Russia, even though appears to be demanded by the company “KirishiNefteOrgSyntez”.

Currently, with the Research Center Prometey, we’re discussing practical issues of obtaining a Clad pipe billet for the consequent pipe rolling for Nuclear Power Plants, as well as implementing the technology of “explosion+rolling” for manufacturing Clad plates.

We are looking forward to receiving your commercial inquiries!