Part and scribe line locations are critical to the success of welding this joint design. Weld Characteristics and Quality of EBW: Due to high penetration-to-width ratios of EB welds two distinct advantages accrue, viz., relatively thick plates can be welded in a single pass and welding speeds much higher than those attainable in arc welding can be used. Have questions about joint design for laser welding or EB welding? When fast moving electrons hit a metal surface they are decelerated which transforms the kinetic energy of each individual electron in the beam into thermal energy in the component. These entrapped pockets show up as porosity in cross weld sections (Figure 4). As electron beam welding technology is highly automated and delivers a clean result with repeatable accuracy and minimal distortion, there is no need for post-weld machining. The beam stays collimated until it hits a focus surface. 005 to 2 inches (although much higher depth can be achieved for certain materials) when using a filler material with the latter, making it stand out compared to common welding techniques like MIG, TIG, and stick welding. Extreme precaution is required from radiation. Joint and fixture design also plays a role. 75 inch deep in aluminum and 0. 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. A further reduction in cycle times to this production machine has been achieved through a design change that integrates a load lock chamber in front of the vacuum processing chamber (Figure 11).
It some cases this may need to be even tighter. DC power is used in the electron beam welding method with 5-30 volts for small equipment and 70-150 volts for large equipment. For structural components, it is often necessary to join relatively dissimilar materials such as boron steels to either electrolytically galvanized or hot-dipped material. The weld parameters, all of which are readily adjustable, are accelerating voltage, beam current, beam focus, and transverse speed. The clamps are very close to the seam and apply pressure to ensure a minimal gap.
Magnetic materials interfere with this process. Assemblies can be welded using finished or part finished details using a vast range of materials. The weld strength is determined by the amount of weld along the seam, so the amount of penetration determines the amount of weld strength. Most of the welds in EBW are made without filler metal. It's also a great option for welding metals with different melting points and thermal conductivities. NDI—Leak checking, Die Penetrant inspection, Laboratory Testing and Demonstration Capabilities. Butt welding has many benefits. This method tends to create voids within the material lattice of the part. The use of electron beam welding can be found in virtually every market; aerospace, medical, automotive, nuclear, defence, oil and gas, civil engineering and even art.
The dependence of key-holing mechanism upon vapour formation and surface tension means that metals differ in the ease with which they can be penetrated by the electron beam. Selection of high vacuum (10-4 mbar) or partial vacuum systems (10-2 mbar) depends upon weld requirements. "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. These beam welding processes are even considered more suitable for alloys that are difficult to arc weld and can. 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. On the other hand, it offers a wide range of penetration depth, generally from 0. Ultra-high energy density enables deep penetration and high aspect ratios, while a vacuum environment ensures an atmospheric gas contamination free weld that is critical for metals such as titanium, niobium, refractory metals and nickel-based super-alloys. What is an Electron Beam? One commonality of these electron beam welders is that all beam parameters and all mechanical axes are numerically controlled either by a PLC or a CNC. It should be underlined that the erosion of cathode over time, changes in the alignment of various magnetic lenses, etc. The width to penetration ratio upto 50, in steel welds, have reportedly been achieved. The electron beam welding process can accommodate different welding speeds while still achieving deep welds.
Thanks to the high speed, the heat-affected zone (HAZ) is small and distortion is minimal. Making the weld strong and pure isn't an issue, and, fortunately, with a bit of well-engineered tooling and a degree of automation, these high quality welds can be achieved with very short cycle times and low cost. This welding technology is achieved by having only the electron beam gun inside a vacuum box while the workpiece itself remains outside of the vacuum chamber. 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. The kinetic energy of the electrons is converted to heat energy, which in turn is the driving force for fusion. Plug Weld with Top Scab — Figure 12. From a machine tool vendor's point of view these goals translate into different machine designs, such as welders for low to medium production or welders for mass production with short cycle times. Nevertheless, lap welding has many benefits. 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. 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. Clean welds since EBW is done in a vacuum environment. Joint Access and Postprocessing. As the electron beam is moved forward, material melts at the front of the beam.
If minimal distortion is critical, the weld should only partially penetrate the bottom sheet. A scribe line is used for weld joint alignment and weld tracking. Electron beam welding is the bombardment of a metallic surface by a tightly focussed stream of electrons. The fixturing required before welding is of the lightest construction as no forces are involved in the electron beam process. While the basic principle of electron beam welding and laser welding is similar on the surface, there are some distinct differences that make each of them unique: Heat source. The molten low and medium carbon materials mix together without posing any problems. A number of metals can be welded to give a depth-to-width ratio of upto 50. The electron beam hits the pins from the flat back of the plate which gets machined after the welding. As an example, plates with complicated cooling channels for the processing industry require weld penetrations of up to 0. Weld Joint Design and Preparation 5. As the laser beam advances along the weld joint, the keyhole moves with it through the workpiece. Such fixturing can be automated with pneumatic clamps. If not properly set up, this gas expulsion can get trapped in the solidifying molten pool and show up in the form of porosity in the finished weld. Electron beam welding's excellence at joining dissimilar materials comes into play at this point.
Postweld heat treatment is not needed in many cases because of laser welding's small HAZ and low overall heat input. The electron beam gun is located either inside the vacuum chamber or stationary on the outside (Figure 14). 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. 82 × 10-12 mm and a mass of 9.
Welding Stainless Steel. As with any rule, there are exceptions. Material Used: 316L Stainless Steel. This case study explores electron beam (EB) welding of stainless steels, including weld characteristics, joint design considerations, and examples of welded stainless steel components. Inert atmosphere (vacuum). This parameter, unique to the eb process, deflects the beam at a rate of a few hundred Hertz in a pattern, such as circle or arrow head (Figure 5). Basic Square Groove Welds. To achieve narrow weld and deep penetration, it is essential to focus the beam on the workpiece very accurately. Again, dynamically deflecting the beam in a pattern at a few hundred Hertz and adjusting the other deflection values helps decrease the power density in the focus spot and thereby prevents overheating of the alloy.
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