EBW is used widely in the Aerospace Industry
Electron Beam Welding
Electron Beam Welding is a method which uses a focussed stream of high energy electrons generated by a filament and directed to the joint requiring to be welded. The heating is very localised and the bulk of the assembly therefore remains cold and stable. This results in a very narrow weld with a minimal heat affected zone. There is no need to use filler metal as the parent metal of the assembly is melted. As this is a line of sight method it is not possible to weld around corners or re-entrant angles. Weld depths of up to 30mm can be produced and computer controls ensure minimal operator dependence, thus providing good reproducibility throughout a batch of components, even though this is a piece part process. Since the heat input is very localised it is possible to weld together previously heat treated components, which is a very economical method for producing composite gear shafts, with for example a case hardened gear on a hardened and tempered shaft.
The key benefits
- Minimal Distortion - Welds finish machined parts
- Welds difficult and dissimilar materials
- Exceptional Quality and Repeatability
- High Weld Speeds
- Deep narrow welds of close to Parent Metal strength
Producing savings in
- Lead time
EBW is a machine controlled welding process with welding carried out in a vacuum with no filler material resulting in exceptional weld quality and repeatability.
Weld spees are typically 1-2 metre/minute and result in deep, narrow welds requiring less than 5% of the heat input needed for a comparable depth TIG weld.
The remarkably low distortion resulting from Electro Beam welds means precision parts can be finished machined prior to welding, ever ground gears.
Industry who require the high quality weld that is produced by Electron Beam welding are Aerospace, Electronics, Scientific research, Nuclear and General manufacturing both industrial and commercial.
More benefits of Electro Beam Welding
- Low heat input for the welded parts;
- Minimal distortion;
- Narrow melt zone (MZ) and narrow heat affected zone (HAZ);
- Deep weld penetration from 0.05 mm to 200 mm (0.002” to 8”) in single pass;
- High welding speed;
- Welding of all metals even with high thermal conductivity;
- Welding of metals with dissimilar melting points;
- Vacuum process yields in clean and reproducible environment;
- Natural welding process for oxygen greedy materials such as titanium, zirconium and niobium;
- Machine process guaranteed for reliability and reproducibility of the operating conditions;
- Cost-effective welding process for large production in automatic mode; and
- Parts can mostly be used in the as welded condition - no sub-machining required.
Application & Materials
- Jet engine components
- Parts of structures
- Transmission parts
- Power generation
- Vacuum systems
- Transmission parts
- Parts of turbocharger
- Electrical/electronic industries
- Fuel housing
- Parts of structure
- Research centres
- Copper parts
- Superconductivity material components
- All metals even with high thermal conductivity
- Steel and stainless steel
- Aluminium and alloys
- Copper and alloys
- Nickel alloys and refractory metals
- Titanium and alloys
- Zr, Mo, Ta, Hf, W, Nb, etc
- Welding of metals with dissimilar melting points
- Copper to steel
- Copper to nickel alloys
- Steel to nickel alloys
- Tantalum to tungsten
View a video here of a EBW in action.
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