ELECTRON BEAM WELDING

The electron beam gun has a

tungsten filament which is heated,
freeing electrons.
The electrons are accelerated
from the source with high voltage
potential between a cathode and
anode.
The stream of electrons then
pass through a hole in the anode.
The beam is directed by magnetic
forces of focusing and deflecting
coils. This beam is directed out of
the gun column and strikes the
workpiece.
The potential energy of the
electrons is transferred to heat
upon impact of the workpiece and
cuts a perfect hole at the weld
joint. Molten metal fills in behind
the beam, creating a deep finished

How an Electron Beam Machine Works

The EB system is composed of an
electron beam gun, a power supply,
control system, motion equipment and
vacuum welding chamber. Fusion of base
metals eliminates the need for filler
metals. The vacuum requirement for
operation of the electron beam equipment
eliminates the need for shielding gases
and fluxes.

 The electron beam stream and

workpiece are manipulated by means
of precise, computer driven controls,
within a vacuum welding chamber,
therefore eliminating oxidation,
contamination.

ELECTRON BEAM WELDING

Slide 16 of 18

ELECTRON BEAM WELDING

Slide 15 of 18

Electron Beam Welding

Electron Beam Welding joins ferrous metals, light
metals, precious metals, and alloys, to themselves or
each other.
Multi-axis EB control
High ratio of depth-to-width
Maximum penetration with minimal distortion
Exceptional weld strength
Ability to weld components up to 10 feet in diameter
High precision and repeatability with virtually 0% scrap
Versatility from .002" depth to 3.00" depth of
penetration

Electron Beam Welding Facts

Electron Beam Welding Advantages

Maximum amount of weld penetration with the least amount of
heat input reduces distortion
Electron beam welding often reduces the need for secondary
operations
Repeatability is achieved through electrical control systems
A cleaner, stronger and homogeneous weld is produced in a
vacuum
The electron beam machine's vacuum environment eliminates
atmospheric contaminates in the weld
Exotic alloys and dissimilar materials can be welded
Extreme precision due to CNC programming and magnification of
operator viewing
Electron beam welding frequently yields a 0% scrap rate
The electron beam process can be used for salvage and repair of
new and used components

Electron Beam Welding Speeds/Depth of Penetration

 Electron Beam
Welding
Limitations
The necessity of an
electron beam
welding vacuum
chamber limits the
size of the workpiece
EBTEC's
maximum chamber
size is 11' 4" wide x
9' 2" high x 12' deep
Electron Beam Welding Speeds/Depth of Penetration

 Electron Beam Welding (EBW) is a unique way of

delivering large amounts of concentrated thermal
energy to materials being welded. It became viable,
as a production process, in the late 1950's. At that
time, it was used mainly in the aerospace and
nuclear industries. Since then, it has become the
welding technique with the widest range of
applications. This has resulted from the ability to
use the very high energy density of the beam to weld
parts ranging in sizes from very delicate small
components using just a few watts of power, to
welding steel at a thickness of 10 to 12 inches with
100 Kilowatts or more. However, even today most of
the applications are less than 1/2" in thickness, and
cover a wide variety of metals and even dissimilar
metal joints

Two welding modes are used in the (EBW):

1-Conductance mode:
Mainly applicable to thin materials, heating of the weld joint to melting
temperature is quickly generated at or below the materials surface followed by
thermal conductance throughout the joint for complete or partial penetration.
The resulting weld is very narrow for two reasons:
a- It is produced by a focused beam spot with energy densities concentrated
into a .010 to.030 area.
b- The high energy density allows for quick travel speeds allowing the weld to
occur so fast that the adjacent base metal does not absorb the excess heat
therefore giving the E.B. process it's distinct minimal heat affected zone.
2-Keyhole mode:
It is employed when deep penetration is a requirement. This is possible since
the concentrated energy and velocity of the electrons of the focused beam are
capable of subsurface penetration. The subsurface penetration causes the rapid
vaporization of the material thus causing a hole to be drilled through the
material. In the hole cavity the rapid vaporization and sputtering causes a
pressure to develop thereby suspending the liquidus material against the cavity
walls. As the hole is advanced along the weld joint by motion of the workpiece
the molten layer flows around the beam energy to fill the hole and coalesce to
produce a fusion weld. The hole and trailing solidifying metal resemble the
shape of an old fashion keyhole.
Both the conductance and keyhole welding modes share physical features such
as narrow welds and minimal heat affected zone .The basic difference is that a
keyhole weld is a full penetration weld and a conductance weld usually carries a
molten puddle and penetrates by virtue of conduction of thermal energy.