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.
