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Electron Beam Welding: Submitted by

Electron beam welding is a fusion welding process where a beam of high-velocity electrons is applied to materials to be joined. The kinetic energy of the electrons is transformed into heat upon impact, melting the workpieces. It provides narrow welds with minimal heat-affected zones and distortion. The process takes place in a vacuum chamber and does not require filler metals or gas shielding. It is well-suited for applications such as welding inaccessible areas, thin materials, and sealing instruments.

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Tanmay Walke
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48 views13 pages

Electron Beam Welding: Submitted by

Electron beam welding is a fusion welding process where a beam of high-velocity electrons is applied to materials to be joined. The kinetic energy of the electrons is transformed into heat upon impact, melting the workpieces. It provides narrow welds with minimal heat-affected zones and distortion. The process takes place in a vacuum chamber and does not require filler metals or gas shielding. It is well-suited for applications such as welding inaccessible areas, thin materials, and sealing instruments.

Uploaded by

Tanmay Walke
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Electron

Beam
Welding Submitted by :
Ajay Kumar
(SL/14/4705
Introduction :-
i. Electron Beam Welding is a fusion welding process in which a beam of high-
velocity electrons is applied to the material to be joined.
ii. The work-piece melt as the kinetic energy of the electrons is transformed
into heat upon impact.
iii. The EBW process is well-positioned to provide industries with highest quality
welds and machine designs that have proven to be adaptable to specific
welding tasks and production environments.
EBW
SET UP
About an Electron Beam :-

i. In an electron beam welder


electrons are boiled off
as current passes through
filament which is in a
vacuum enclosure.

ii. An electrostatic field,


generated by a negatively
charged filament and bias
cup and a positively
charged anode, accelerates
the electrons to about 50%
to 80% of the speed of light
and shapes them into a
Beam.

Fig :Electron beam source for EB


disposal
How does the Process Work :-

i. The electron beam gun has a tungsten filament


which is heated, freeing electrons.

ii. The electrons are accelerated from the source


with high voltage potential between a cathode and
anode.

iii. The stream of electrons then pass through a hole


in the anode. The beam is directed by magnetic
forces of focusing and deflecting coils.

iv. This beam is directed out of the gun column and


strikes the work piece. The potential energy of the
electrons is transferred to heat upon impact of the
work piece and cuts a perfect hole at the weld
joint.
Comparison with different welding techniques on the basis of
Parameter :-
PARAMETER TIG PLASMA LASER EB

Power input to W-P 2kW 4kW 4kW 5kW

Total power used 3kW 6kW 50kW 6kW

Traverse speed 2mm/s 5.7mm/s 16mm/s 40mm/s

Positional welding Good penetration Good penetration Yes Require optics to Requires mechanism
move the beam to move the beam
Distortion shrinkage Nominal significant Nominal significant Small Minimum
in V-shaped weld in V-shaped weld Minimum Minimum

Special process Normal light Normal light Safety interlock Vacuum chamber-ray
requirement screening screening against misplaced screen
beam reflection
Comparison of conventional weld and
EB weld :-
i. EBW is suitable for a variety of difficult applications, such as welding structures on
which the reverse side of the butt is inaccessible ; gravity welding of thin metal ; and
welding in various spatial positions.

ii. This Provides a low level of over all heating of the structures ; and has the ability to
vacuumed the inner volume simultaneously, which is suitable for sealing instruments.
Because EBW is an automated process , the welded joint quality is consistent .

iii. The process does not require shielding gases , tungsten electrodes , or edge
preparation for welding thick metal .

iv. Finally , it can be used to weld some joints that cannot be made by other welding
processes.
v. Compared with arc welding processes, EBW
improves joint strength 15 per cent to 25 per
cent.

vi. It has a narrow heat-affected zone(HAZ), which


results in lighter-weight products.

vii. Geometric shapes and dimensions are highly


stable, particularly when it is used as a finish
operation.

viii. It eliminates oxide and tungsten inclusion sand


removes impurities.

ix. The weld metal has a fine crystalline structure.


Advantage of EBW :-

In Vacuum
a) Thin and thick plate welding.
b) Extremely narrow seams (t:b = 50:1).
c) Low overall heat input implies for low distortion means Welding of completely processed
components.
d) High welding speed possible.
e) No shielding gas required.
f) High process and plant efficiency.
g) Material dependence, often the only welding method.
Disadvantage of EBW :-
In vacuum
a) Electrical conductivity of materials is required.
b) High cooling rates implies for hardening it causes increase cracks.
c) High precision of seam preparation.
d) Beam may be deflected by magnetism.
e) X-ray formation.
f) Size of work piece limited by chamber size.
g) High investment.
At atmosphere
h) X-ray formation.
i) Limited sheet thickness (max. 10 mm).
j) High investment.
k) Small working distance.
Field of applications :-
Industrial areas
Automotive industries
Aircraft and space industries
Tool construction
Nuclear power industries
Power plants
Fine mechanics and electrical
Industries
Reference: All data and pictures used
for better understanding has been taken
from Wikipedia and Google.
THANK YOU

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