Notes on electron beam machining ebm me mechanical. The pair tested three welding processes to see how they would function in a depressurized environment. Electron beam welding ebw methods useful for welding of thick copper material. Electron beam welding is a welding process that uses the heat produced by a beam of high energy electrons. Mar 08, 2005 process selection can simplify the need for joint preparation. In laser welding, the absorption of energy by a material is affected by many factors such as the type of laser, the incident power density and the base metals surface condition. Emerging materials, processes, and design technologies are expected to stimulate increased use of these and other sophisticated techniques. Electron beam welded joints shall meet the requirements of the applicable engineering drawing. Otherwise the electrons would interact with the air molecules, thus they would loose their energy and cutting ability. At low beam power densities eb unit operates in shallow penetration mode. Electron beam welding process, applications and equipment. The answer to this question depends on the welding application. It has already a long history of successful applications in a large range of different fields, like aerospace and nuclear but also for general use for most exacting requirements.
Apr 14, 2017 today we will learn about electron beam welding, principle, working, equipments, application, advantages and disadvantages with its diagram. Weld pool has the shape char acteristic for arc welding processes. Let note the maximal depths of single pass ebw at beam powers of 60. The workpiece melt as the kinetic energy of the electrons is transformed into heat upon impact. Schultz, electron beam welding, is an excellent technical reference for anyone involved in ebw whether just beginning to weld or currently experienced with eb welding. Electronbeam welding ebw is a fusion welding process in which a beam of highvelocity electrons is applied to two materials to be joined. In this machining process metal is removed by melting and vaporization of metal particle from surface of work piece. Liquid state welding are those welding processes in which, the metal to metal joint form in liquid or molten state. The laser beams have enough energy and when it strikes the metal pieces produce heat that melts the material from the two metal pieces and fills the cavity.
Electron beam welding was used for joining al6061t6, precision machined, cylindrical sections. Good parameterregions for electron beam welding, which yield full penetration welds without holes or weld spatters, aresurveyed. Banas united aircraft research laboratories i summary a direct comparison was made of electron beam, laser beam and arc welding processes in ti6alw alloy in nominal thicknesses of 0. Narrow beams of electrons carrying high kinetic energy can be. In this regard, the eb welding process is wellpositioned to provide industries with the highest quality welds and machine designs that have proven to be adaptable. Electron beam welding produces a minimal heat affected zone haz in the materials being joined but requires the welding to be done in a vacuum atmosphere. Electron beam, laser beam and plasma arc welding studies by c.
The power delivered by an electron beam can be massiveto 10,000 kwmm 3. Principle electron beam welding ebwis a fusion welding process in which a beam of high velocity electrons is applied to the materials being joined. Trends of welding plant design, the application regions and place of the ebw among the. By defocusing the beam, the fillet weld may be enlarged and will present a smoother surface. Electron beam machining is same as laser beam machining process in which except laser, high speed electron beam impinges on work piece. Study on optimum electron beam welding condition for. This study investigates the effects of chemical modifications to the weld pool, speed of welding, and beam patterns in the electron beam welding environment on the metallurgical and mechanical properties of al6061t6 without the benefit of postweld heat treatment. Electron beam engineering provides services throughout the u. Some observations on the electron beam welding of copper. In electron beam welding, as the name of the process implies, heat is generated in the work by the degradation of the kinetic energy of a fastmoving stream of electrons which are caused to.
Electron beam welding ebw is the first and foremost high energy density process. Electron beam machining process electron beam is generated in an electron beam gun. Laser beam welding lbw is a fusion joining process that produces coalescence of materials with the heat obtained from a concentrated beam of coherent, monochromatic light impinging on the joint to be welded. Electron beam welding of cmn steelstoughness and fatigue. May 04, 2017 characteristics of laser beam welding. Electron beam welding is a liquid state welding process. Electron beam welding an overview sciencedirect topics. The main applications for this high efficiency welding process are. She says, these results may vary between laser systems and are. Laser beam welding process principle, advantages, disadvantages principles. Certificate of registration electron beam engineering, inc. Electron beam welding advantages,disadvantages and. Ptr is an electron beam welding systems manufacturer and contract welding service provider on the leadingedge of electron beam and vacuum welding technology. Electron beam welding ebw is fusion welding technology.
Certificate of registration this certifies that the quality management system of electron beam engineering, inc 1425 s. Electron beam welding process applications and equipment. Electron beam welding ebw is a fusion welding process in which a beam of highvelocity electrons is applied to two materials to be joined. Ebw is often performed under vacuum conditions to prevent dissipation of the electron beam. Klas weman, in welding processes handbook second edition, 2012. Today we will learn about electron beam welding, principle, working, equipments, application, advantages and disadvantages with its diagram. Electron beam welding advantages,disadvantages and application. Mar 31, 2017 it is a nontraditional machining process in which no physical tool is used. Scribd is the worlds largest social reading and publishing site. Electron beam welding, despite a long history and widespread arc and laser technology, is still widely used in industry. Laser beam machining is a thermal machining process which uses laser beam to produce heat. Electron beam welding parts, working, applications with. The higher the potential difference, the higher would be the acceleration of the electrons. The workpieces melt and flow together as the kinetic energy of the electrons is transformed into heat upon impact.
The nuclear industry requires rapid and high quality joining of large scale components. Electron beam welding eb welding services eb industries. The aim of nuclear advanced manufacturing research centre nuclear amrc is to. Flaws such as a constantly open vapour cavity and subsequent continuous weld solidification could be avoided by selection of jobsuitable welding parameter combination and in particular of beam oscillation characteristics, it has to be seen to a constantly. Electron beam welding ebw is a fusion joining process that produces a weld by impinging a beam of high energy electrons to heat the weld joint. Summary specifications during this process a high energy elecrtron beam melts a narrow region at the oining interfaces. Research electron beam welding of thick copper material. So, these are the very typical and very simple way to presence the typical components of the electron beam welding machine. Electron beam welding ebw is a fusion welding in which coalescence is produced by heating the workpiece due to impingement of the concentrated electron beam.
The fillet weld joint design is generally useful in thicknesses up to 0. A leading edge electron beam welding company since 1966, we partner with our customers to provide high performance quality results. Electron beam welding machines are engineered for high performance with advanced computer controls, data logging and beam. Welding in space american welding society education online. The welded assembly exhibited a minimum amount of distortion, but a better understanding of the effects of several key welding parameters on the structural integrity of the weld was required. Temperature measurements were obtained for many different machine power settings and. In extreme working conditions, the rapid temperature increase can even lead to evaporation, making an electron beam an excellent tool in heating applications, such as welding. Electron beam welding ptrprecision technologies, inc. Free electrons in vacuum can be accelerated, with their paths controlled by electric and magnetic fields. Electron beam machining is required to be carried out in vacuum. This will generate high heat energy and melts and vaporize metal from work piece. This high speed stream of electrons is tightly focused using magnetic fields and applied to the materials to be joined.
In addition to building advanced eb systems, ptr provides electron beam welding services using stateofthe art equipment supported by experienced welding engineers. Electron beam welding advantages,disadvantages and application introduction to e beam welding. Mar 22, 2017 electron beam welding process is carried out in vacuum. Thus the work piece to be machined is located under the electron beam and is kept under vacuum. In electron beam welding, the workpiece is bombarded with a dense stream of highvelocity electrons. Apr 21, 2017 principle electron beam weldingebwis a fusion welding process in which a beam of high velocity electrons is applied to the materials being joined. In fact, an electron beam welding system can throw enough power to simply vaporize metal a process called electron beam machining. Allec street anaheim, california, 92805, united states has been assessed by nsfisr and found to be in conformance to the following standards. Electron beam welding 124 2005 weld speed and this is defined as a turbulent process. The electrons kinetic energy is then transformed, for the most part, into thermal.
Jan 18, 2011 video of electron beam welding taken using laserstrobe. These electrons are accelerated by applying high potential difference 30 kv to 175 kv between cathode and anode. Handbook of electron beam welding by bakish, robert a. Laser is an acronym for light amplification by stimulated emission of radiation. Applications range from fully automated, high productivity and low cost automotive inline part production to single part batch processes in the highcost aircraft engine industry at the other end of the industrial spectrum. The electron beam has a higher energy content than a laser beam, and is also smaller. Electron beam technology is used in cableisolation treatment, in electron lithography of submicrometer and nanodimensional images, in microelectronics for electron. A 2 m3 chamber, 100 kw, electron beam welding machine, showing the open. The electron beam eb welding process is used in a variety of industries. Electrons hit the workpiece and their kinetic energy is transformed to the thermal energy heating the metal so that the sides of the workpiece can be joined and a weld can be formed after freezing the electron beam welding is also a liquid state welding process.
As shown in figure 19a and figure 19b, the unique capability of the electron beam welding process can produce a fillet weld having a large depth to width ratio, resulting in a superior strength joint. Pdf in this chapter a general description of electron beam welding ebw and. The use of filler materials in electron beam welds shall be permitted when certified filler wire is used. In most cases, it is very beneficial to utilize both processes at different stages, especially with more complex. The relatively recent development of high energydensity joining techniques, both electron and laser beam, has broadened the scope of joining. Steigerwald conceived and developed the first practical electronbeam welding machine, which began operation in 1958. Because of this high energy density, it has small heataffected zones. Electron beam welding is a fusion welding process in which a beam of highvelocity electrons is applied to the material to be joined. May 01, 2016 electron beam welding, despite a long history and widespread arc and laser technology, is still widely used in industry. Pdf me6302 manufacturing technology i books, lecture. The beam of electrons creates kinetic heat as it impacts with the workpieces, causing them to melt and bond together. The laser beams are focused to the cavity between the two metal pieces to be joined. Electron beam welding ebw is a fusion welding in which coalescence is produced by heating the workpiece due to impingement of the concentrated electron beam of high kinetic energy on the workpiece. Provides process definitions and requirements, safe practices, and inspection criteria for electron beam welding.
Download me6302 manufacturing technology i books lecture notes syllabus part a 2 marks with answers me6302 manufacturing technology i important part b 16 marks questions, pdf books, question bank with answers key, me6302. Electron beam gun provides high velocity electrons over a very small spot size. Laser beam welding equipment, principle, working with. Microscopicstructures,suchaspitsorbumps due to poor welds, have greater in a uence on cavity perfor. Eb welding machines generally come in two power classifications, low voltage 60 kv or high voltage 150 kv.
Electron beam welding ebw and laser beam welding lbw are two very popular methods of joining multiple metallic components. The commercial application of electron beam welding ebw was. Note the excess weld metal extruded on the weld face due to thermal contraction. Laser beam welding energy transfer is different than arc welding processes. In addition to making eb and laser welding equipment, ptr assists customers with weld process development and provides maintenance and spares support for electron beam welding systems. Electron beam welding uses a very highenergy electron beam to produce deep, narrow penetration. Electron beam welding electron beam engineering, inc. A beam focusing device is included, and the workpiece is usually placed in an evacuated chamber to allow uninterrupted electron travel. Electron beam welding ebw of titanium alloy ti6al4v is not an easy task and. This article throws light upon the seven main equipments required for electron beam welding ebw. Electron beam welding ebw has the potential to respond to these requirements. Our electron beam welding services have produced millions of parts, and our customers range from small manufacturers to some of the biggest companies in the aerospace, medical and energy industries. Eb industries is the preeminent electron beam welding services provider throughout the united states, canada and mexico, since 1965.
Electron beam welding is fusion welding process in which a beam of high velocity electrons is applied to two materials to be joined. Electrons are accelerated by a high difference electrical potential and concentrated on a target. The electron s kinetic energy is then transformed, for the most part, into thermal. Pdf experience on electron beam welding researchgate. Electron beam welding ebw was employed in joining the thinwalled. Electron beam eb welding is a fusion welding process whereby electrons are generated by an electron gun and accelerated to high speeds using electrical fields. The concept of other important welding processes and topics such as thermit welding, atomic hydrogen welding, electron beam welding, laser beam welding, friction stir welding, under water welding, welding automation in aerospace, nuclear and surface transport vehicles are elaborately discussed in unit iv. Steigerwald conceived and developed the first practical electron beam welding machine, which began operation in 1958. As an example, consider that electron beam welding is suitable for simultaneous double or multipletier welding in separate positions. Mar 17, 2016 electron beam machining ebm is a thermal process. Investigations into the effects of electron beam welding on. In addition to making eb and laser welding equipment, ptr assists customers with weld process development and provides maintenance.
This vacuum all but elimintats the introduction of impurtities. The workpiece melt as th slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Plasma arc welding thermit welding electron beam welding friction welding diffusion welding submerged arc welding submerged arc welding saw is a common arc welding process. In this chapter a general description of electron beam welding ebw and developed ebw equipment are given. Depending upon the intensity of heating the workpiece can melt and vaporize. Some observations on the electron beam welding of copper beadonplate welds show the effects of impurities, focus position and energy input, and high rates of heat input can retard recrystallization effects by l.
Electron beam welding cambridge vacuum engineering. Pdf electron beam welding of large components for the. Combining laser beam welding and electron beam welding offers. It requires a continuously fed consumable solid or tubular flux cored electrode. Dobeneck over and over again, people have asked me to write down all the details, stories, anecdotes and facts related to the history of electron beam welding. The laser beams produced are coherent having the same phase and monochromatic i. Laser beam welding is a fusion welding process in which two metal pieces are joined together by the use of laser. Examples of recommended joint details are not the full story.