Electron Beam Welding Explained: The Benefits Along With Its Applications

Electron beam welding

Electron beam welding can be defined as the procedure which uses a steady stream of high-energy electrons which is generated by a filament and is thereby directed towards a particular joint which requires it to be welded. 

Since the heating is localized, the bulk of the assembly remains very cold and stable - thereby resulting in a narrow weld zone where the affected heat zone stays minimal. In this article guide, we’ll be discussing some of the most common benefits of electron beam welding along with its major applications. 

EBW Processes

The List Of Key Benefits

• The process welds highly finished machined parts with very minimal distortion.
• Can weld dissimilar and difficult materials.
• Can perform welding at very high speeds.
• It provides exceptional repeatability and overall quality.
• Narrow and deep welding could be done, representing almost the strength of parent metal. 
• Helps in the production of savings in terms of weight, cost, size, lead-time and also inventory.

The List Of Other Major Benefits

• The parts that are to be welded need low heat input.
• The procedure has a Narrow Melt Zone (NMZ) along with Narrow Heat Affected Zone (NHAZ).
• Deep weld penetration can happen from just 0.05 mm to almost 200 mm - depending on the needs and desires of the project.
• Materials (especially metals) having high thermal conductivity can be welded as well, such as copper. 
• A clean and reproducible environment can be obtained with the help of a complimentary vacuum procedure.
• Metals that have a higher affinity towards oxygen, such as zirconium, titanium and niobium can also be welded using this process.
• The eb welding process includes the introduction of various machines which improves the productivity and reliability of the operating conditions. 
• Automatic modes are available for large productions and therefore turn out to be cost-effective as well.
• With the help of this process, the welded parts can be used in their welded condition - without any need to perform any sub-machining. 

The List Of Major Applications 

• Used in aerospace engineering for the production of jet engine components, transmission and structure parts along with sensors. 
• Used in the generation of energy or power.
• Used in various automotive applications such as gear systems, transmission parts along with turbocharger parts as well. 
• Used in medical and vacuum systems.
• Used in the electronics industry and also used in the manufacturing of various electrical supplies especially copper.
• Used in the nuclear industry such as for fuel housing, manufacturing of valves & equipment and so on. 

Checking The Quality Of Work Done By Electron Bean Welders

Electron Bean Welders

Electron beam welding has been a vital part of numerous core industries. A few of these industries include oil and gas, aerospace, and medical equipment. Invented back in the 1950s, EB took over the trend of fusion welding. 

EB served as a welding method, using which metals can be bonded in a way that’s safe and reliable. This welding technique is all about quality and precision. But how do you check the quality of work performed by these machines, here are few of the significant ones: 

Visual Inspection

When it comes to precision tig welding, the surface of the metals plays a crucial role. It can make a big difference in precision welding. 

For metals, microscopic visual inspection is essential. With it, you can identify any significant cracks and other visible flaws. Also, it can help in calculating fatigue. Many a time, a fluorescent dye is also used to flag tiny details.

Radiography 

In electron beam welding, the quality of the whole metal piece is as crucial as the quality of the machine. Although, some critical issues such as fatigue can be ignored. In these cases, radiography can prove to be a useful associate. 

It can either be used as a sample measurement or can confirm metallurgic suitability. 

Batch Control Testing 

It’s one of the forms of quantitative testing. 

Batch control testing enables a weld to be meticulously divided into macro and micro quality control pieces at any random point during the production process. This testing process provides a good overview of an entire production run, establishing the quality of overall parts. 

Ultrasonic Testing 

Sound-waves in the production industry are an excellent detailed visualization tool.

Ultrasonic testing (UT) is a non-destructive technique of quality checking. It’s a highly effective way to explore the deep structures of a metal or joint. It’s efficient in identifying the invisible cracks and uncover tiny defects. Further, it’s more preferable due to its precise readings in testing. 

The above methods are an effective way to check the quality of the work done by Electron Beam Welders. Do let us know what testing process do you employ at your workshop?

Why to use electron beam welding to join metals?

Electron Beam Welding

For the ones who aren’t aware of what exactly electron beam welding is? It‘s a fusion welding process that utilizes a beam of high-velocity electrons to generate a high integrity weld. A thick beam of high energy electrons hits the surface of the materials to be welded and generates an enormous amount of heat, which melts and joins the two elements.

The electron beam is generated under high vacuum conditions; it then passes through a series of specially-designed chambers and orifices to offer welds with the maximum possible purity and higher depth-to-width ratios. 

As the electron beam welding (EBW) process takes place in a vacuum, the welds are therefore clean and free from any impurities (oxides or nitrides). Multiple-pass welds are eliminated with a high depth-to-width ratio and deeper penetration of 0.001 to 2 inches. This welding type can be employed for welding thick material to thin material. Further, it can also be used for joining dissimilar metals, i.e. the ones with different thermal conductivities and melting points. There are numerous combinations of dissimilar metals that are un-weldable with other processes and thus are readily electron beam welded. 

Few electron beam welding applications

• EBW generally joins aerospace components in titanium and nickel-based superalloys. 
• Bi-metal saw blades and transmission assemblies are also built-in large numbers by electron beam welding.

Further, with low distortion during the welding, components can be accurately joined. With a clean welding vacuum environment, there’s no risk of oxygen pick-up and consequent weld embrittlement when an electron beam welds these titanium alloys. 

Application advantages of electron beam welding (EBW)

• Small heat affected zone: minimizes the distortion and material shrinkage. 
• Precise control: tightly controlled
• Excellent weld depth: 0.001 to 2 inches
• Strength: 95% retainment of the base materials
• High Purity: impurities such as nitrides and oxides are eliminated with a vacuum environment
• Versatile: preferable option for joining dissimilar and refractory metals
• Production Capability: feed rates from 1 to 200 inches per minute.