Most grades of stainless steels can be easily welded with the electron beam and most importantly, the welds are corrosion resistant as the parent material. Although this joining method produced a joint of adequate strength, the post-weld machining, grinding and heat treatment operations were expensive and time consuming. Acetone is a preferred solvent for cleaning the components for EBW; however acetone being highly inflammable needs to be handled very carefully. Product Description: This assembly is a vacuum chamber used in a particle accelerator laboratory. Custom Tooling: Electron Beam Welding: Overall Dimensions: Part Dimensions: Length: 126". The weld parameters, all of which are readily adjustable, are accelerating voltage, beam current, beam focus, and transverse speed. However, nothing can compare to the cleanliness of welding in a vacuum.
- Electron beam welding joint design and function
- Electron beam welding joint design and engineering
- Electron beam welding applications
- Electron beam welding joint design and welding symbols
- Electron beam welding joint design and development
Electron Beam Welding Joint Design And Function
Rugh gave the example of gas turbine components where EB welds are used for the deeper welds and welds requiring minimal distortion. The energy density of the electron beam is around 1, 000 times more than that can be achieved from a traditional arc weld. Near parent metal strength. Modified Integral Backup — Figure 3. Equipment Required for Electron Beam Welding (EBW): The equipment used for EBW is quite compact and consists basically of two main parts viz., the EBW gun and the work chamber. As a result, deep-penetration welding is distinguished by great efficiency and fast welding speeds. 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. Note: Often known as bead-on-plate (BOP) weld. 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. Weld Penetration Depth:.
Electron Beam Welding Joint Design And Engineering
The 2-dimensional weld pattern shown in Figure 8, has total weld length of up to 300 inches which introduces a high amount of heat into the plate. EBW generally needs to be performed in a vacuum environment without the use of shielding gas, which provides excellent protection against atmospheric contamination. These new technologies offer added benefit from a weld reliability standpoint to be able to meet the welding requirements needed for materials such as aluminum, boron, and ultra-high strength steels. It must be possible to properly vent the product in the vacuum chamber. In these cases, a plug with a "top scab", as depicted in Figure 12, is recommended. Electron beam welding principles and some aspects of the technology, which permits intricate and complex fabrications in various materials and material combinations, are discussed below. Lap welds must be wider to increase their strength. A narrow heat-affected zone allows for welding delicate assemblies. As the electron beam is moved forward, material melts at the front of the beam. These are caused by the quenching effect after welding and can be influenced by the width of the weld and the welding speed. It is essential to widen the beam to ensure a fusion of both abutting surfaces of the weld joint.
Electron Beam Welding Applications
The electron beam welding process can accommodate different welding speeds while still achieving deep welds. This makes the electron beam welding process simple and more cost effective. In heat conduction welding, the laser beam melts the mating parts along a common joint, and the molten materials flow together and solidify to form the weld. Depending upon the extent of vacuum in the work chamber, all these types of welding guns are also classified as high vacuum, medium vacuum, and non-vacuum types.
Electron Beam Welding Joint Design And Welding Symbols
The welds are staggered to equalize the heat distribution in the base plate. A Virginia nuclear physics laboratory asked us to improve the quality of welds in vacuum chambers used in its' research equipment. Laser beams require high welding speeds since it vaporises the base materials, creating fumes. Our skilled technicians offer the latest welding processes, system design, weld joint design, metallurgical expertise, and programming skills. The final products are made from many components, and these components need to be joined in some way. We have the capability to weld large assemblies up to 24 feet in length and 92 inches in diameter, as well as tiny parts that fit in the palm of your hand. Clean welds since EBW is done in a vacuum environment. It is truly a high-quality process for joining high-quality materials. Filler material is not typically used to join the majority of components hence the metallurgy does not change. The diversity of EB welding allows the ability to weld metals with varying thicknesses, making it a flexible option for welding complex parts such as transmission assemblies or small electronic components. Can the joint be designed as self-locating or will a fixture be required? This ability to apply exceptionally high levels of heat energy to a very small area makes it the preferred welding method for many hard-to-weld materials. Introduction to Electron Beam Welding (EBW) 2.
Electron Beam Welding Joint Design And Development
It has become common practice in the automotive industry to preheat gears prior to welding in order to reduce the quenching effect in the HAZ. This style of fixturing is common for butt welding and edge welds for tubular or rectangular parts. And now be more broadly applied, opening up opportunities not feasible in the past. Adaptation of technologies such as real-time seam tracking, gap bridging, beam oscillation, and integrated clamping to laser-related processes allows for them to be used in a more mainstream approach. Some martensitic steels have high carbon content, and this is detrimental to good welding performance. 1mm) is typically mandatory to ensure that the zinc has a place to escape as it vaporizes at a temperature more than half that of the base material. LBW is normally performed with argon or helium shielding gases to prevent oxidation. Laser welding is also useful for joining parts that are not suitable for processing inside a vacuum chamber. Unleashing Creativity. 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. Edge joints are generally used with sheet materials such as hermetically sealed cans, etc.
EB Welding Job Shop Services. The electrons penetrate the material at the atomic level, imparting their kinetic energy as they strike molecules. Note, there is a difficulty in relocating the weld joint for the full penetration weld if 100% tacking is used, so an occasional interruption is preferred as an aid in centerline joint location.
"Since the heat source in this type of welding process is the energy of light, the weld material's reflectivity should be considered. In heat conduction welding, energy is coupled into the workpiece solely through heat conduction. Basically, EB welding works by shooting a high velocity beam of electrons into a part being welded. Metallurgical Analysis. Parts have to fit in a vacuum chamber, and the welding beam has to be able to follow the path of the joint. Tack welds are made at less than the power needed for full penetration (20% to 40%). Welding Stainless Steel. Use butt welding (butt joint), or blind welding if this is not possible. By aiming the beam at a joint and then moving the joint under the beam a fully homogeneous fusion of the mating surfaces can be achieved. A challenge greater than the sheet metal design is posed by joint segments with varying thicknesses that require a change of power not only at the beginning and the end of the joint but also in between. Superior Welding of Materials with High Thermal Conductivity or Unique Properties. Laser Technology Specialist. Authored by: John Lucas, Process Development Technician, Joining Technologies.
Edge, seam and lap fillets are primarily used for joining sheet metal only. In a medium vacuum EBW gun the beam is generated in high vacuum and then projected into the welding chamber with soft or quick vacuum, as shown in Fig. This results in a very concentrated (approx. The most direct approach to welding tubular sections is illustrated in Figure 6. For those manufacturers and many others not specifically mentioned here, welding processes have to meet increasingly stringent standards that have become more prevalent over the years. 82 × 10-12 mm and a mass of 9. Lap welding has many different considerations. Custom Part Fixturing and High Throughput Fixturing. Light and medium duty planet carriers are made of low carbon steel sheet metal.
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