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This paper provides a technical overview of the unique features of the electron beam welding process including several applications. Duplex and Super Duplex Stainless Steels. Thinking of using electron beam welding in the design of a new product, then download this fantastic free guide about with the process. Equipment Required for Electron Beam Welding (EBW) 3. Figure 5 shows a fuel spray nozzle for a gas turbine engine. The fixturing required before welding is of the lightest construction as no forces are involved in the electron beam process. As the electron stream travels deeper into the material the electrons are scattered, slowed down and stopped by collisions with atoms of the material structure, resulting in the heating of a pear-shaped volume. Each industry applies its own criteria to reach these goals. Joint Access and Postprocessing. The ability to add varying levels of adaptivity as an integral part of the laser welding process allows for greater robustness, less rework, and higher first-pass quality to the finished product. Electron beam welding uses a stream of finely focussed electrons to melt and fuse joint surfaces. This process was sufficiently large to be machined to parent metal diameter and give a smooth bore. The EBW equipment uses magnets to focus the electron beam. A welcome side effect of preheating in mass production is that welding speeds can be safely increased, making the process more economical.

Electron Beam Welding Working

If the focus position shifts outside this area, expect the process results to change. Whenever possible, hollow areas should be vented to the outer surface of the part. It centers on improvements to the electromagnetic focus and deflection system to shorten their response times. For certain applications, the quality to cost provided by automated electron beam welding is impossible to beat. A tight slip fit to an interference fit is recommended for proper welding. Some martensitic steels have high carbon content, and this is detrimental to good welding performance.

Electron Beam Welding Joint Design And Design

Keep a gap of maximum 0. Electron beam welding (EBW) uses a high-velocity beam of electrons to melt and fuse metals together. Where problems have occurred, they are probably linked to one of the following causes:-. The FABRICATOR is North America's leading magazine for the metal forming and fabricating industry. Filler wire diameters are generally small with a maximum of about 0-5 mm and the wire is fed into the leading edge of the small weld pool. At first, these specifications were created by NASA, Grumman, Lockheed Martin, and other leading aerospace companies. Most of the welds in EBW are made without filler metal. In some cases, sinusoidal beam deflection transverse to the direction of weld travel is employed as a means to provide greater weld interface per unit length. The indexing table welder design was established as a reliable machine tool for high-volume production of assemblies several decades ago. This nailhead type of penetration is achieved through a phenomenon called key-holing.

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Again, the pattern generator is the perfect tool to balance these different technical requirements by allowing continuous adjustments to be made to the width of the weld with almost parallel sides. Here's an example: Pros of Groove Joint Design. Eventually, industry wide standards were developed, such as Aerospace Material Specification AMS 2680 and AMS2681. In conclusion, the electron beam welding process has the merits of: - Deep penetration. Beam energy output can be highly controlled and modulated to produce arbitrary pulse profiles.

Electron Beam Welding Joint Design And Manufacturing

The size of the hole diameter can be enlarged which results in more time for metal vapor to escape and, in turn, prevents the creation of vapor pockets. There are materials where it is advantageous to use filler metals, e. avoiding weld cracking in 6000 series aluminum. However, these advantages are gained at the expense of low weld depth to width ratios, reduced weld penetration and small gun-to-work distances. Depth-to-width ratios of up to 40:1 have been achieved in production for many years. As an electron is a very minute particle with a radius of 2. This provides the ability to weld difficult or "impossible to weld" alloys. Thus, it is a process which ha s been basically established to fabricate costly and difficult-to-weld reactive and refractory metals. Essentially, the weld pool becomes a mirror reflecting energy away, again resulting in poor penetration or the over application of power, which can result in melting and distortion of the part. Electron Beam Welding Consultation: Have a Sciaky EB welding expert show you how to get the most out of your Sciaky EB welding system. With both methods, the laser beam is optically focused on the workpiece surface to be welded. This allows for flexibility when designing your parts and weld locations. An example of the cleaning action for the weld can be seen in the case of zero-gap welding of galvanized material. The electron beam welding (EBW) and laser beam welding (LBW) processes are high-energy density welding processes that offer several possible advantages, including low welding heat input, high weld depth-to-width ratio, narrow heat-affected zone (HAZ), and reduced distortion. Puddle welding is accomplished by manual manipulation of the workpiece under the beam, at low power, to locally fuse surface defects in materials or welds.

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"The cleanliness of the welding environment is one variable that you just don't have to worry about. Laser beams require high welding speeds since it vaporises the base materials, creating fumes. A conventional electron beam welding machine, as shown in Figure 1, consists essentially of a device for producing a focussed beam of electrons (an electron beam column) mounted on, or in, an evacuated chamber that contains devices for holding and moving a workpiece. Electron Beam Welding vs Laser Welding. The square groove butt joint, illustrated in Figure 1, is a basic joint design for electron beam welding. Of course, to take full advantage of all these benefits and to ensure a high-quality, repeatable process, fabricators need to consider how laser welding compares to other fusion welding processes. It is reported that the penetration increases as the heat of formation of vapours decreases. However, nothing can compare to the cleanliness of welding in a vacuum. Fillet Weld – Ex 1 & Ex 2 — Figure 19a & 19b. The product's ability to accommodate variation in real time enables a stability that has typically hampered similar process approaches in the past. The deflection coils, situated below the focus coil, move the electron beam in circles or more complex patterns for fusion zone improvement when supplied by appropriate voltages and waveforms.

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The electron beam is generated in high vacuum and at high accelerating voltage of 150–220 kV. This type of welder typically employs a 2-station dial index with one part in each of the stations. Joining Technologies, Inc. 17 Connecticut South Drive. Laser welding also allows for access to joints that were previously not achievable.

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We have the capability to weld large assemblies up to 24 feet in length and 92 inches in diameter, as well as tiny parts that fit in the palm of your hand. Electron beam will be the primary choice when the completed assembly must be sealed with internal components under vacuum; when weld penetrations exceed 1/2"; when the material is challenging to initiate laser coupling; or when the weld must not be exposed to atmospheric conditions until it has cooled to an acceptable temperature. This requires more energy input, achieved either through a larger spot size or by oscillation with a smaller spot size. Also, there is a probability of evaporation of high vapour pressure metals during welding. Material Used: 316L Stainless Steel. But in the vacuum chamber of an EB welder, pumped down to 10 -4 Torr, these problems simply disappear. Whether it's creating high temperature exhaust nozzles for rockets or jet aircraft, or joining cutting-edge 3D printed parts, EB welding has advantages that other welding processes simply don't.

However, high vacuum EBW is a low production and a high cost process. Joining of these metals by the then established welding processes of fusion welding resulted in the absorption of oxygen, nitrogen, and hydrogen rapidly by reactive metals during the welding and post-weld cycles which resulted in their reduced ductility. Consider welding titanium: When heated, titanium becomes extremely reactive to the gases in air, resulting in carbides, nitrides, and oxides, which cause brittleness and can reduce fatigue resistance and notch toughness in the heat affected zone of the weld. The pins of the implant, shown in Figure 9, need to be welded into the base plate. Edge, seam and lap fillets are primarily used for joining sheet metal only. The electron beam travels through the abutting surfaces, and the joint surfaces are then progressively fused – creating a weld. The electron beam gun is located either inside the vacuum chamber or stationary on the outside (Figure 14). LBW is normally performed with argon or helium shielding gases to prevent oxidation.

The molten material absorbs the laser beam almost completely, and the efficiency of the welding process rises. See list in section 2. As a result, deep-penetration welding is distinguished by great efficiency and fast welding speeds. Joint and fixture design also plays a role. The material, meanwhile, continues to melt. Current laser welding is done with direct fusion between two materials.

When alignment is critical, the self-fixtured butt joint in Figure 10 eliminates the need for elaborate tooling and extensive tack welding. The solutions noted hereafter can offer strong potentials for weight reduction and open up enhanced design opportunities. Lap Joint — Figure 18. The tack weld is also helpful in maintaining the concentricity of mating parts in rotary welds, although an interference fit is preferred.

Lap welding requires less robust fixturing. "Some parts and their associated welding fixtures may be too large to fit into the EB welding chambers available, " said Rugh. "EBW parts require a minimum of post weld machining and heat treatment and, unlike other fusion welding processes, EBW requires no shielding gases, " he said. Narrow fusion zone of controllable shape. A penetration weld is the commonly used trial weld technique to determine the welding parameters for a specific part thickness. Manufacturing cost and quality are key goals to consider in the fabrication of components. However, with remote welding, it is not feasible to bring wire to the joint with any sense of consistency, especially when using optical seam tracking for beam placement in the joint. "Aside from size, if the components being welded contain liquids that would interfere with vacuum pumping, laser welding would be a good choice. " After you've selected the right material for your welding project, the next important consideration is joint design. The allowable gap is typically 10% of the thinnest material or less than 50% of the weld beam diameter.