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Inert atmosphere (vacuum). It is better to attain 60-70% penetration to minimize porosity formation. Can the joint be designed as self-locating or will a fixture be required? A beam of accelerated electrons cannot be created or maintained in air because the electrons strike gas molecules and are deflected and scattered. Electron beam welding processes are usually carried out in a vacuum, yet there are also nonvacuum welding machines available. However, the EB welding process also has proven flexibility, adapting with the times such that it is an important part of even the most modern of manufacturing technologies.
The square groove butt joint, illustrated in Figure 1, is a basic joint design for electron beam welding. Solid Bar Butt Joint — Figure 9. Sensitive to faying surface conditions. Therefore, fixturing is critical in these joint configurations to ensure high positional repeatability and minimal gap.
An electrostatic field, generated by a negatively charged filament and bias cup and a positively charged anode, accelerates the electrons to about 50% to 80% of the speed of light and shapes them into a beam. However, in lieu of clamping, this offering comes equipped with "gap bridging" technology. Eventually, industry wide standards were developed, such as Aerospace Material Specification AMS 2680 and AMS2681. Edge joints are generally used with sheet materials such as hermetically sealed cans, etc. The addition of an integrated clamping unit on the head not only secures the part at a position directly related to the process tool center point, it also provides an opportunity for reduced tooling costs to clamp and hold the seam. The technology behind electron beam welding allows various metals to be welded together, including dissimilar metals, since it is mostly performed in a vacuum environment.
Each type of joint has its advantages and disadvantages, but the biggest advantage of the butt joint and square groove joint is its strength. 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. The electron beam travels through the abutting surfaces, and the joint surfaces are then progressively fused – creating a weld. The trapped air can cause porosity and expulsion of molten metal at the tie-in after a 360° weld. The width to penetration ratio upto 50, in steel welds, have reportedly been achieved.
With all of laser welding's process considerations also come myriad opportunities. "Some parts and their associated welding fixtures may be too large to fit into the EB welding chambers available, " said Rugh. The exit end of the nozzle is an assembly of Inconel 625 and Hastelloy, and the support stem is type 347 stainless steel. We consulted with the customer to design an electron beam-specific weld joint that optimized virtual leak performance at ultra-high vacuum. The excited molecules heat up, resulting in a significant amount of energy in a very small area.
This allows for a simple robot path. Modified Integral Backup — Figure 3. Since that time, many other welding methods—such as tungsten inert gas (TIG), metal inert gas (MIG), and laser welding—have evolved technically.