Explosion-proof electrical materials are typically made from beryllium bronze and aluminum bronze. These alloys are specially designed to prevent sparking when they collide or rub against other surfaces, making them ideal for use in environments where flammable, explosive, or corrosive materials are present. They are widely used in the production of tools and equipment that require high safety standards.
The BeA-20C alloy, for example, was tested with 561IJ of impact energy in a 30% oxygen environment and in a 6.5–10% methane-air mixture. During 20 consecutive impacts, no sparks or combustion occurred. This is due to the excellent thermal conductivity of copper, which quickly absorbs and dissipates heat generated during friction or impact. Additionally, the soft nature of copper allows it to deform slightly under stress, reducing the likelihood of generating fine metal particles that could ignite. As a result, these tools are often referred to as non-sparking tools, and they are essential in industries such as oil refining, petrochemicals, mining, gas processing, chemical fiber production, paint manufacturing, fertilizer production, pharmaceuticals, and more.
These tools are also used in places like oil tankers, liquefied petroleum gas (LPG) vehicles, aircraft, warehouses handling flammable materials, electrolysis plants, and communication equipment assembly areas. They are especially valuable in settings where rust resistance, wear resistance, and magnetic resistance are required.
In contrast, ordinary tools made of carbon steel can generate static electricity and sparks upon impact, making them unsuitable for use in hazardous environments. Explosion-proof joint tools, on the other hand, do not produce sparks or static electricity, ensuring safer operations in flammable or explosive areas. These tools are commonly used for large-scale machinery, industrial equipment installation and maintenance, pressure vessel operations, and similar applications.
The materials used in explosion-proof joint tools include:
1. **Beryllium Bronze**: A copper-based alloy containing niobium as the primary alloying element, with a niobium content ranging from 1% to 2.5%. It also contains small amounts of cobalt, magnesium, and iron. When subjected to high-speed impact or friction, the mechanical energy is converted into heat, but the material’s high thermal conductivity rapidly transfers this heat away, preventing ignition. The stable compounds in beryllium bronze have a high melting point and are resistant to oxidation, further enhancing their safety performance.
2. **Aluminum Bronze**: This alloy comes in two main types depending on the aluminum content. When aluminum content is below 9.4%, it forms a single alpha phase solid solution. At higher aluminum levels, it consists of α + β1 phases and a small amount of γ2. Its excellent thermal conductivity allows it to absorb most of the heat generated during contact with other materials, reducing the risk of ignition.
3. **J892 Copper Alloy**: This alloy is suitable for all types of gas applications. After treatment, its hardness is even higher than that of beryllium bronze, making it closer in strength to steel tools. However, its toughness is still lower than that of steel, so it should not be used under excessive load or for tasks like extending the handle of a wrench or hitting with a hammer. Additionally, J892 copper alloy tools should not come into contact with acidic or alkaline substances to avoid corrosion.
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