Explosion-proof electrical materials are typically made from beryllium bronze and aluminum bronze. These alloys are specially designed to prevent the generation of sparks when they come into contact with other materials through impact or friction. This makes them ideal for use in environments where flammable, explosive, magnetic, or corrosive substances are present.
The BeA-20C alloy, for example, was tested under extreme conditions, including 30% oxygen and 6.5–10% methane air mixtures, with an impact energy of 561 IJ. In 20 test shots, no combustion or shock occurred. The reason behind this is the excellent thermal conductivity of copper, which quickly absorbs and dissipates heat generated during friction or impact. Additionally, since copper is relatively soft, it can absorb a lot of mechanical energy without producing tiny metal particles—thus preventing the formation of sparks. As a result, these tools are often referred to as non-sparking tools.
These explosion-proof tools are widely used in industries such as petroleum refining, petrochemicals, coal mining, oil fields, natural gas processing, chemical fibers, paint manufacturing, fertilizer production, pharmaceuticals, and more. They are also essential in places like oil terminals, liquefied petroleum gas (LPG) vehicles, aircraft, warehouses handling flammable materials, electrolysis workshops, communication equipment assembly areas, and locations requiring rust-resistant, wear-resistant, and magnetically resistant tools.
In contrast, ordinary carbon steel tools can generate static electricity and sparks upon impact, making them unsuitable for hazardous environments. Explosion-proof joint tools, on the other hand, do not produce static electricity or sparks, making them safe for use in flammable and explosive areas. These tools are primarily used in large-scale machinery, industrial equipment, petrochemical systems, mining operations, pipeline installations, and maintenance tasks involving pressure vessels.
Common materials used in explosion-proof joint tools include:
1. **Beryllium Bronze**: This alloy is based on copper with niobium as the main alloying element, typically containing 1–2.5% niobium, along with 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 the surface temperature from reaching ignition levels. The stable compounds in beryllium bronze have high melting points and resist oxidation, ensuring safety in explosive environments.
2. **Aluminum Bronze**: There are two common types: one with less than 9.4% aluminum, forming a single α-phase solid solution, and another with 1.8–9.4% aluminum, consisting of α + β1 + small amounts of α + γ2. Aluminum bronze has excellent thermal conductivity, allowing it to absorb and dissipate heat quickly during friction, reducing the risk of igniting flammable mixtures.
3. **J892 Copper Alloy**: This alloy is suitable for various gas applications and offers higher hardness than beryllium bronze, approaching that of steel. However, its toughness is still lower than steel, so it should not be used in overloads or for extended lever arms. It should also not be exposed to acidic or alkaline substances, as this may cause corrosion.
Overall, explosion-proof tools play a crucial role in maintaining safety in high-risk industrial settings by minimizing the risk of sparks and ignition. Their unique material properties make them indispensable in environments where even a small spark could lead to catastrophic consequences.
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