Cladding (metalworking) - Wikipedia

Cladding is the bonding together of dissimilar metals. It is different from fusion welding or gluing as a method to fasten the metals together. Cladding is often achieved by extruding two metals through a die as well as pressing or rolling sheets together under high pressure.

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The United States Mint uses cladding to manufacture coins from different metals. This allows a cheaper metal to be used as a filler. For example, dimes and quarters struck since have cores made from pure copper, with a clad layer consisting of 75% copper and 25% nickel added during production. Half dollars struck from to for circulation and in for collectors also incorporated cladding, albeit in the case of those coins, the core was a mixture of 20.9% silver and 79.1% copper, and its clad layer was 80% silver and 20% copper. Half dollars struck since are produced identically to the dimes and quarters.

Laser cladding is an additive manufacturing approach for metal coatings or precise piece restorations by using high power multi-mode optical fiber laser.[1]

Roll bonding

In roll bonding, two or more layers of different metals are thoroughly cleaned and passed through a pair of rollers under sufficient pressure to bond the layers. The pressure is high enough to deform the metals and reduce the combined thickness of the clad material. Heat may be applied, especially when metals are not ductile enough. As an example of application, bonding of the sheets can be controlled by painting a pattern on one sheet; only the bare metal surfaces bond, and the un-bonded portion can be inflated if the sheet is heated and the coating vaporizes. This is used to make heat exchangers for refrigeration equipment.[2]

Explosive welding

In explosive welding, the pressure to bond the two layers is provided by detonation of a sheet of chemical explosive. No heat-affected zone is produced in the bond between metals. The explosion propagates across the sheet, which tends to expel impurities and oxides from between the sheets. Pieces up to 4 x 16 metres can be manufactured. The process is useful for cladding metal sheets with a corrosion-resistant layer.[2]

Laser cladding

Laser cladding[3][4] is a method of depositing material by which a powdered or wire feedstock material is melted and consolidated by use of a laser in order to coat part of a substrate or fabricate a near-net shape part (additive manufacturing technology).

It is often used to improve mechanical properties or increase corrosion resistance, repair worn out parts,[5][6] and fabricate metal matrix composites.[7] Surface material may be laser cladded directly onto a highly stressed component, i.e. to make a self-lubricating surface. However, such a modification requires further industrialization of the cladding process to adapt it for efficient mass production. Further research on the detailed effects from surface topography, material composition of the laser cladded material and the composition of the additive package in the lubricants on the tribological properties and performance are preferably studied with tribometric testing.

Process

A laser is used to melt metallic powder dropped on a substrate to be coated. The melted metal forms a pool on the substrate; moving the substrate allows the melt pool to solidify in a track of solid metal. Some processes involve moving the laser and powder nozzle assembly over a stationary substrate to produce solidified tracks. The motion of the substrate is guided by a CAM system which interpolates solid objects into a set of tracks, thus producing the desired part at the end of the trajectory.

Automatic laser cladding machines are the subject of ongoing research and development. Many of the process parameters must be manually set, such as laser power, laser focal point, substrate velocity, powder injection rate, etc., and thus require the attention of a specialized technician to ensure proper results. By use of sensors to monitor the deposited track height and width, metallurgical properties, and temperature, constant observation from a technician is no longer required to produce a final product. Further research has been directed to forward processing where system parameters are developed around specific metallurgical properties for user defined applications (such as microstructure, internal stresses, dilution zone gradients, and clad contact angle).

Advantages

• Best technique for coating any shape => increase lifetime of wearing parts.
• Particular dispositions for repairing parts (ideal if the mould of the part no longer exist or too much time is needed for a new fabrication).
• Most suitable technique for graded material application.
• Well adapted for near-net-shape manufacturing.
• Low dilution between track and substrate (unlike other welding processes and strong metallurgical bond.
• Low deformation of the substrate and small heat affected zone (HAZ).
• High cooling rate => fine microstructure.
• A lot of material flexibility (metal, ceramic, even polymer).
• Built part is free of crack and porosity.
• Compact technology.

See also

• Additive manufacturing
• All-Clad
• Copper-clad aluminum wire
• Copper-clad steel
• Goldbeating

References

As much as we love cooking with our stainless cookware, we know all too well that not all stainless steel is created equal. Price points vary wildly, and it’s tough to decide whether or not it’s worth it to spring for a pricier pan—especially when it looks virtually the same as a cheaper one.

So what exactly makes up the difference between different stainless steel cookware products? It all, more or less, comes down to cladding, or the process of bonding different metals together to form a single, solid piece of cookware. We’ll explain exactly why cladding is important, why certain metals need to be combined with others, and—most importantly—how this actually matters to you, the cook.

What Is Cladding?

In cookware, “cladding” refers to the process of layering (or “sandwiching”) stainless steel with other metals, like aluminum and High Grade Ferritic 430, then bonding those layers together to form a single sheet of metal. In a fully clad pot or pan (like our Stainless Clad collection), those layers extend all the way through the base and up the sides to make for more even heat distribution, better conductivity, and an overall more durable piece of cookware.

What are the Different Types of Cladding Materials?

There are a few different types of materials typically used for cladding, thanks to their heat conductivity abilities.

Aluminum

Stainless steel is durable, beautiful to look at, and makes for a smooth and nonreactive cooking surface, but it’s not the best at conducting heat. This is where aluminum comes in. By sandwiching stainless steel with a layer of aluminum, you get all the benefits of stainless steel along with the excellent conductive properties of aluminum.

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Copper

Copper is sometimes used in place of, or in addition to, aluminum, as it’s also an extremely efficient conductor of heat. Since it’s a more expensive metal to work with, however, the inclusion of copper can also raise the price point of stainless cookware.

How Does Cladding Work?

Each layer in a piece of stainless clad cookware is called a “ply.” Cookware labeled 3-ply is made with three layers of different metals, while 5-ply is made with five layers—easy enough to remember.

But is there really any significant difference between 3-ply and 5-ply, and is 5-ply worth the additional cost? We say yes—especially when it comes to durability and searing quality. While you can find plenty of solid 3-ply options on the market, 5-ply is even more resistant to scratching and warping, and will heat more quickly and evenly than 3-ply.

Here’s the general layout of how cladding works with cookware like our Stainless Clad collection.

1. Top Layer: Stainless Steel

Stainless steel is the icing on top of the stainless clad cake. Highly resistant to rust and corrosion, as well as virtually scratch-proof, it’s an ideal cooking surface—at least when it’s combined with other metals, as we get into below.

2. Middle Layer(s): Conductive Material (e.g., Aluminum or Copper)

Beneath that top layer of stainless steel is a layer of aluminum or copper, both of which are extremely conductive. In our Stainless Clad line, each piece of cookware is made with two layers of aluminum along with a layer of aluminum alloy, which has magnesium and manganese added for increased strength and hardness.

3. Bottom Layer: Stainless Steel

The bottom layer of our Stainless Clad cookware is composed of High Grade Ferritic 430, another type of stainless steel that’s even more durable as well as induction compatible.

Benefits of Cladded Stainless Steel Cookware

A fully clad stainless steel frying pan or pot isn’t just a stack of different metals: it’s a single, wildly efficient piece of cookware that offers much more than the sum of its parts. On their own, neither stainless steel nor aluminum are particularly efficient or durable cookware materials; when combined, however, they work beautifully.

Where aluminum is a reactive material and more prone to warping and other damage than stainless steel, it’s a much better conductor of heat than stainless—which makes up for its lack of poor conductivity by offering a tough, warp-resistant cooking surface.

Here are just a few more of the many reasons cladded cookware is worth the price.

Even Heat Distribution

Through the cladding process, the different metals used in our Stainless Clad cookware are bonded together, combining the excellent conductivity and heat distribution of aluminum with the food-safe, anti-rust and corrosion-resistant properties of stainless steel.

Enhanced Cooking Performance

A piece of fully clad stainless steel cookware isn’t just durable, of course; it’s also an absolute joy to cook with. Because stainless clad conducts and distributes heat so evenly, without any cold spots, you’ll be able to better control the temperature of your pan.

Versatility in Cooking Styles

While stainless clad is excellent for searing steaks and chops, it’s also responsive enough to cook delicate things like eggs or fish that require more delicate heat. Plus, if you remember to properly preheat it, your stainless clad pan can even offer a virtually non stick cooking surface (though not quite on par with non stick).

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