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Electron beam welding converts around 85% of the electrical input into usable power. The NVEBW machines are provided with high-efficiency pumps and special electron beam discharge orifices to ensure the highest vacuum decrease gradient between the electron gun and atmosphere. Further advantages are; minimal distortion, a very narrow HAZ (heat affected zone) and as the welding normally takes place within a vacuum environment the risk of hydrogen contamination of the weld is minimised. As one of our welders once put it, "Titanium welds like butter in an EB machine. The molten low and medium carbon materials mix together without posing any problems. Equipment Required for Electron Beam Welding (EBW) 3. Based on the ability to control the beam location relative to the joint and utilize oscillation, it provides a melt pool that "floats" on the workpiece (FIGURE 4).
The result is a deep, narrow, vapor-filled hole, or keyhole, surrounded by molten metal. Electron beam technology had advanced for decades reaching its current highest level. Again, a deflection pattern in combination with a continuous adjustment to beam power permits the development of a robust set of welding parameters that hold up in daily production on the manufacturing floor. Make sure the workpiece parts have been thoroughly cleaned. However, with the advent of computers, EB machines quickly evolved into full CNC control. Further improvements to weld quality can be achieved by using different weld patterns to eliminate undercuts and irregular penetrations. The tack weld is also helpful in maintaining the concentricity of mating parts in rotary welds, although an interference fit is preferred.
Our machines are built and manufactured at our Cambridge Headquarters. These electrons are accelerated using a high voltage, typically in the range of 30kV to 150kV and with the aid of a focus (convergence) coil and a deflection coil, the electrons can be formed into a narrow convergent beam and accurately positioned on the work piece. Then the beam narrows into an hourglass shape until it becomes in focus at its smallest point. Joint Access and Postprocessing. The electron beam is generated in high vacuum and at high accelerating voltage of 150–220 kV. This system has the ability to provide various inclination angles to accommodate alterations in joint position for two- and three-layer welds as flange heights change relative to one another. This melt moves very dynamically to the back of the beam and rapidly solidifies in this position. This is done by going over the weld bead again using a lower power beam with either beam spin or weave applied by the deflection coils.
Generally, it is the most practical and most efficient configuration to use. Characteristics of an Electron Beam Weld. The process requires highly skilled machine operators. 125 mm; however aluminium alloys can tolerate somewhat larger gaps than steels. The vacuum is only maintained in the small chamber.
The kinetic energy from electrons is converted to heat upon contact, thus melting the workpiece and creating a joint. As the name implies, it is a hole with a high vapor pressure in the middle that presses the molten material firmly against the side walls. "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. Solid Bar Butt Joint — Figure 9. 15, in such a way as to minimise the flow of atmospheric gases into the gun column. Elmer [45] pointed out that this could substantially vary from operator to operator and from machine to machine. On top of that, EBW works at a rapid rate, making it one of the fastest processes in assembly welding. This style of fixturing is common for butt welding and edge welds for tubular or rectangular parts. 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. Authored by: John Lucas, Process Development Technician, Joining Technologies.
With all of laser welding's process considerations also come myriad opportunities. Angular Beam — Figure 5. Fillet Weld – Ex 1 & Ex 2 — Figure 19a & 19b. As noted, the laser's high power density results in small heat-affected zones and ensures that critical components are unharmed. Manufacturing cost and quality are key goals to consider in the fabrication of components. Sensitive to faying surface conditions. Narrow and deep welds are typically more subject to porosity, most often at the root but also in the middle of the weld. It is also important to select the correct spot size at the part. Medium volume production is typically performed in chamber machines with specialized tooling.