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Tuesday, 30 July 2024

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In an electron beam welder electrons are "boiled off" as current passes through a filament which is in a vacuum enclosure. The use of 4000 series aluminum filler wire changes the metallurgy and prevents cracking. Angular Beam — Figure 5. What Is Electron Beam Welding? Susceptibility to liquation cracking in the 'nail-head' region of the HAZ is promoted by the stress/strain. The following examples illustrate the remarkable versatility of the electron beam welding process in a range of weld penetrations and material combinations. Sciaky's welding job shop offers a wide range of affordable Electron Beam (EB) welding services for customers in a wide variety of industries all over the world. Joint and fixture design also plays a role. The electron beam focus is typically achieved by controlling the accelerating voltage, beam current, focus coil current, vacuum levels in the gun and in the chamber, and the working distance. The joint information below helps define and clarify the tooling and fixture options for a new welding project. Laser welding allows for creativity and some freedom in part design, as long as all the essential variables are considered.

Electron Beam Welding Joint Design And Maintenance

One of the biggest challenges in welding involves minimizing the impact of the molten metal's interaction with ambient gases. Because it is a noncontact process, welding in holes and in tight spaces is possible if the beam width as it comes into focus is considered. If welding through the top sheet (3 in Figure 2), the laser beam must penetrate through the top sheet and into the bottom sheet, and all that energy spent penetrating the top sheet doesn't add any weld strength. All grades of steel can be welded, as well as low melting alloys such as aluminum and magnesium, and high melting materials such as Nickel- and Cobalt-based alloys. For more information on our capabilities or if you have a project that you'd like to quote, fill out the form to the right, give us a call at (413) 734-4544, or email us at! All of these technologies grew up together. The range of components to be welded typically includes a variety of designs for shaft assemblies as well as planet carriers. Good distortion control: Welds shrink evenly and are less likely to distort. Vapour hole with molten walls, shown in Fig. The end result is one where the laser spot position relative to the seam is controlled in a dynamic nature, not simply shooting to a programmed point in space. This type of welder typically employs a 2-station dial index with one part in each of the stations. Hence, electron beam welding must occur in a vacuum, and often this is viewed as a criticism: The welding chamber has to be pumped down, and this takes time. Can the joint be accessed by a beam of electrons? 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.

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The purpose of this Electron Beam Welding Guide document is to provide engineers not familiar with electron beam welding a basic understanding of the process. Compared with other processes, laser welding offers the highest weld quality, lowest heat input, and highest penetration in a single pass. Figure 4 shows a typical fixture design. Plug Weld — Figure 11. Welding Stainless Steel. Solutions to specific weld challenges using the EB process will be shown. Lap welding has many different considerations. Pretty groovy, right? CVE design systems to meet requirements with work chamber and work handling systems to suit product size and throughput. Electron Beam Welding vs Laser Welding. A beam of accelerated electrons cannot be created or maintained in air because the electrons strike gas molecules and are deflected and scattered. A reliable and simple inspection method is also desirable. Ensure nothing can eclipse the path of the beam. With both methods, the laser beam is optically focused on the workpiece surface to be welded.

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Figure 3 shows a typical medium-size chamber on a CVE electron beam welding machine. Widely accepted across many industries, EBW permits the welding of refractory and dissimilar metals that are typically unsuited for other methods. Running the machine in keyhole mode can penetrate up to 300mm of steel and is known to create stable, good-quality welds for material thicknesses over 200mm. In the case that a lap fillet is the functional joint that needs to be processed, similar issues are seen here as well regarding joint location and required overlap. The absolute shortest cycle times can be achieved with the so-called nonvacuum electron beam welder which welds parts in atmospheric pressure. The lap joint configuration in Figure 18 is fairly common in use, especially in sheet-metal thicknesses.

Electron Beam Welding Applications

This technology produces welds that are wider than those produced in a vacuum. A weld is usually stipulated to be of full penetration with a good sized under bead (in the context of the piece part dimensions), and as such, it has the merit of being easy to inspect. Acetone is a preferred solvent for cleaning the components for EBW; however acetone being highly inflammable needs to be handled very carefully. The step typically is on the order of 0. Electron beam welding of the 316L Stainless Steel component satisfied the full penetration requirement of. In comparison, laser welding only converts up to 40% of electricity to usable power, even with the use of modern tools. 1, AWSC7-3, Mil-W-46132, ASME Boiler & Pressure Vessel Code.

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Compared with butt joints, such lap configurations lead to higher energy input, a larger HAZ, and more distortion. This is better than conventional deburring techniques. 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 solutions noted hereafter can offer strong potentials for weight reduction and open up enhanced design opportunities. Square butt edge preparation demands the use of fixtures to keep the work components in the required alignment; however when fixtures are to be avoided the joint may be modified to rabbet type as shown in Fig. If finished parts are to be welded the amount of weld shrinkage will need to be considered.

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Assembly and Finish Machining. 2 gives a schematic representation of most of the components of a typical EBW gun. The use of this design assumes accessibility to both surfaces for machining and inspection purposes. Aerospace Control and Quality Standards. Some might use a vision system to ensure part positioning, but this will add some cycle time and complexity to the programming for production. This eliminates the need to do a lot of postweld machining and cleanup. How does the Process Work?

However, nothing can compare to the cleanliness of welding in a vacuum. In this technique the stream of electrons penetrate the surface of the work to a distance of about 25 microns. The use of stainless steel is very common in the industry because of its corrosion resistance to many substances, gas or liquid, which contact its surface. These parameters finally control the beam power density. Also, the size of the weldment may not be limited by the chamber. Other welding processes rely mainly on heat conduction to transfer energy from the welding device into the part at the point where the welding device touches the surface of the material. Thanks to the high speed, the heat-affected zone (HAZ) is small and distortion is minimal. The distance from the focus surface to the smallest point is called focal length. Tier Joint — Figure 17. Most materials will lose some of their mechanical properties after welding so an assessment of strength requirements will need to be made. Customer-Specific Certifications. Will the design incorporate finish sized details or parts that require post weld machining?