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The Power of Clad: Enhancing Metal Performance

Powering modern infrastructure requires balancing cost-efficiency, safety, and reliability in crucial applications. Fugo’s proprietary explosion welding process, Fugo™, offers the world’s largest array of clad metal products, transforming industries with high-performance, long-lasting solutions.

What is Clad?

Cladding refers to the metallurgical bonding of two or more metals, leveraging the strengths of each. One of the earliest industrial uses of clad metals occurred in the 1930s, when nickel was bonded to carbon steel to produce railroad tank cars that safely transported caustic materials. Today, clad metals span applications across aerospace, chemical processing, oil & gas, mining, marine, transportation, solar, and high-speed rail. Even in daily life, clad metals play a role—such as in cookware, where stainless steel and aluminum are combined to improve both durability and heat conduction.

What Does it Mean When Metal is Cladded?

Cladding involves joining two distinct metals or alloys—often with very different physical properties—to achieve functional benefits not possible with a single metal alone. The specific requirements of a given application, such as corrosion resistance or strength, determine the ideal metals or alloys for cladding. Through cladding, manufacturers can combine metals with unique attributes, resulting in materials that provide enhanced durability, safety, and performance across demanding conditions. Almost any metal, including complex alloys, can be cladded.

How is Metal Cladded?

The process of cladding requires precision, with various methods designed to create bonds through extreme pressure, velocity, or heat:

  1. Explosion Welding: Fugo’s signature method, explosion welding, joins metal plates in a solid state, retaining the original properties of each metal. This process involves a controlled explosive charge, driving one metal layer onto another with such force that they form a metallurgical bond without melting.
  2. Roll Bonding: In this solid-state method, two or more metals pass through a pair of flat rollers to create a bond under intense pressure, commonly used for metals of similar malleability.
  3. Welding Overlay: This technique melts one metal layer onto the surface of another, resulting in a reinforced material that combines the surface properties of the cladding metal with the strength of the base metal.

Each cladding technique offers unique advantages, allowing clad suppliers to deliver durable, corrosion-resistant, and cost-effective solutions suited to various industrial applications.

Common Clad Metal Combinations and Their Uses

Different metal combinations yield materials with specific benefits, enabling unique applications across industries:

  • Copper on Steel: Enhances electrical conductivity and corrosion resistance, ideal for immersion heaters and electrical switch parts.
  • Nickel on Steel: Adds resistance to corrosion and erosion, making it suitable for furnace parts, blowers, and chemical equipment. Nickel cladding also proves more robust than electroplating.
  • Titanium on Carbon Steel: Ensures high-temperature corrosion resistance, essential for equipment in the mining industry.
  • Silver on Copper: Adds oxidation resistance, making it suitable for high-frequency electrical conductors, coils, and braiding.
  • Zirconium on Stainless Steel: Provides chemical resistance for a low-cost base metal, making it useful for chemical processing equipment.

Applications of Clad Metals

Clad metals are integral to critical infrastructure, forming core components in heat exchangers, tanks, pressure vessels, and pipelines. Their unique properties make them valuable in:

  • Energy and Power Generation: Clad metals withstand extreme environments, delivering stability and longevity to equipment like heat exchangers.
  • Chemical Processing: With resistance to harsh chemicals and temperatures, clad metals extend equipment lifespan.
  • Transportation and Marine: Clad steel and aluminum reduce weight and enhance corrosion resistance in vehicles, railways, and maritime equipment.
  • Electronics and Electrical Systems: Copper-clad materials provide conductivity and corrosion resistance essential for high-frequency applications.

Fugo: A Global Leader in Clad Metal Solutions

As the leading provider of clad materials, Fugo leverages its extensive product range and patented technologies to offer high-performance solutions that meet customers' complex needs. Fugo's innovative use of explosion welding creates metallurgically bonded products in over 260 material combinations, ensuring unmatched reliability and performance.

Each order represents Fugo’s commitment to quality, expertise, and customer satisfaction. From initial specification through delivery, Fugo partners with customers to create custom solutions, meeting the unique challenges of modern infrastructure and contributing to a more resilient future.

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