For example, gold, silver, copper and aluminum require more intense energy input. Distortion that may show up in the workpiece does not necessarily impact the finished quality due in part to the adaptive nature of the process. Duplex and Super Duplex Stainless Steels. It is truly a high-quality process for joining high-quality materials. Our skilled technicians offer the latest welding processes, system design, weld joint design, metallurgical expertise, and programming skills. 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. 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.
Extreme precaution is required from radiation. The high vacuum EBW process is an excellent tool for welding dissimilar metals of different thicknesses as well as for repair welding of components impossible to salvage by other processes. Lap welding requires less robust fixturing. This combination of dynamic movement and fast solidification may result in vapor pockets created by a too rapid solidification of the molten material behind the beam. About the Publication. The '300' series of steels are all readily welded by the electron beam process, exhibiting near parent metal strength and fusion zones free from cracks and porosity. Similarly to plasma welding, the EBW process can be run in low power, medium power and high power aka keyhole mode. Whether it's creating high temperature exhaust nozzles for rockets or jet aircraft, or joining cutting-edge 3D printed parts, EB welding has advantages that other welding processes simply don't. The precise control of both the diameter of the electron beam and the travel speed allows materials from 0. Thanks to the high speed, the heat-affected zone (HAZ) is small and distortion is minimal. The design of the clamping unit allows for reaching into openings or structures where flanges might be present, and its fast open-and-close clamping mechanism (200ms) provides a good foundation for high-volume applications. This is not usually a problem with joint thicknesses up to 0. Process Characteristics of Electron Beam Welding (EBW): The welds produced by EBW are typical in shape as they are formed fry nailhead penetration which differentiates it from finger penetration of high current gas metal arc welding (GMAW) process, as shown in Fig. Essentially, the weld pool becomes a mirror reflecting energy away, again resulting in poor penetration or the over application of power, which can result in melting and distortion of the part.
This requires more energy input, achieved either through a larger spot size or by oscillation with a smaller spot size. These are caused by the quenching effect after welding and can be influenced by the width of the weld and the welding speed. 82 × 10-12 mm and a mass of 9. This provides the ability to weld difficult or "impossible to weld" alloys. The weld strength is determined by the amount of weld along the seam, so the amount of penetration determines the amount of weld strength. Keyhole welding (see Figure 1) requires extremely high power densities of about 1 megawatt per square centimeter. Modern vacuum chambers are equipped with state-of-the-art seals, vacuum sensors and high performance pumping systems enabling rapid evacuation. The step must be consumed by the narrow electron beam, therefore any steps much greater than 0. The inert atmosphere of electron beam welding ensures an excellent piece part appearance after welding. Clean welds since EBW is done in a vacuum environment. Make sure the workpiece parts have been thoroughly cleaned. When welding this type of "scab" joint, as in any blind weld, the use of scribe lines is recommended to aid in the optical tracking of the joint.
This has particular advantage for surgical instruments, electronic components, sensor assemblies and many other precision devices. Vapour hole with molten walls, shown in Fig. 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. For especially critical welds, a single large fixture, designed with the weld path machined out, can ensure ideal part fit-up. Because of the required vacuum, EB welding cannot be performed by hand. Work Handling Capacity up to 20 tons. The excited molecules heat up, resulting in a significant amount of energy in a very small area. These gases can react with the metal, creating oxides and other compounds that change the metallurgy of the weld pool and lead to impure welds.
Solutions to specific weld challenges using the EB process will be shown. This joint design may be used for materials as thin as 0. But there are a number of tips and tricks that can be used to ensure that a good weld is achieved, and a high-quality product is produced. Most materials will lose some of their mechanical properties after welding so an assessment of strength requirements will need to be made. However, high vacuum EBW is a low production and a high cost process. Laser welding allows for creativity and some freedom in part design, as long as all the essential variables are considered. Tack welds are made at less than the power needed for full penetration (20% to 40%). In these cases performing both types of welding at the same facility streamlines the manufacturing process.
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