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Electron Beam Welding

What Is Electron Beam Welding?
In simple terms, electron beam welding (EB Welding) is accomplished by heating a tungsten filament which then releases a stream of electrons through an electromagnetic field, focusing them into a precise beam of energy less than .010" (0.254 mm) in diameter. As the beam penetrates the surface of the work piece, using no filler and with a heat concentration of up to 500 times that of conventional welding methods, electrons transform metal beneath the beam through a molten state to a gas, allowing the beam to travel deeper and deeper. As the beam penetrates the material, the small gas hole produced closes rapidly, and the surrounding molten metal then fuses, causing minimal distortion and heat effect outside the weld zone.

Click here for a summary of Acceleron's EB Welding services.

Electron beam welding machine

Close-up of 6061-T6 to 2024-T6 electron beam weld with full depth of penetration (0.060") and weld travel speed of 50 IPM.
High-power 25 Kw electron beam welding machine, capable of 3” penetration. Large chamber (60” x 72” x 108”), updated with new 2006 CNC multi-axis control to simplify complex applications.
Close-up of 6061-T6 to 2024-T6 electron beam weld with full depth of penetration (0.060") and weld travel speed of 50 IPM.



Electron Beam Welding
Information referenced from the American Welding Journal and reproduced with permission of the American Welding Society (dated 7/02).
 
EB Welded Parts
PARTS, clockwise from top left: 1” penetration in a stainless steel stepped butt weld; Side view of a typical weld profile of stainless steel; 1.125” Titanium stepped butt weld, welded at a speed of 40 IPM; Cylindrical lap weld.
Advantages of Electron Beam Welding
Total energy input is approximately 1/25 of conventional welding energy
Low heat input results in minimal distortion
Able to hold close tolerances
Weld deep penetrations with extremely limited heat-affected zones
Repeatability of weld parameters job to job, lot to lot
High-strength weld integrity (clean, strong and consistent)
No fluxes or shielding gases to affect the
properties of the weld
Penetration control to within 10% welding in vac. 1x10-TORR, producing contamination-free welds
Joins similar and dissimilar metals
Cost-effective joining meets difficult design requirements and restraint
Little or no cleanup after welding – ready for N.D.T
Weld in areas that are not possible to reach with other processes
Magnified optical viewing for additional
weld accuracy (20-40x typical)

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Acceleron
21 Lordship Road, East Granby, CT 06026
(860) 651-9333 • Fax: (860) 651-5881 • info@acceleroninc.com
NADCAP Accredited for Welding and Nonconventional Machining