Defense Welding

Precision welding for U.S. Department of Defense contractors and Tier 1 defense suppliers has been a core part of EB Industries’ work for decades. From missile systems and radar housings to military electronics, defense manufacturers rely on advanced joining processes to produce assemblies that survive vibration, thermal cycling, pressure differentials, and harsh operating conditions. We provide Electron Beam Welding, Laser Welding, and Laser Hermetic Sealing services engineered for the integrity, repeatability, and material performance these programs demand.

Welding Services for the Defense Industry

EB Industries has supported defense manufacturing programs since the company’s earliest days, with deep experience joining the high-strength alloys, dissimilar metals, and tight-tolerance geometries common to mission-critical assemblies. Our work spans missile components, guidance and sensor housings, armor systems, propulsion hardware, military electronics, and the thermal management assemblies that surround them.

For aerospace-overlap programs, see our Aerospace Welding page.

Defense Industry Challenges

The defense industry has unique requirements that EB Industries is specifically built to support.

Exotic and High-Strength Materials

Defense assemblies use materials selected for strength-to-weight, thermal performance, corrosion resistance, or ballistic capability. EB Industries has experience working with titanium, Inconel, stainless steel, Waspaloy, copper alloys, nickel alloys, Hastelloy, molybdenum, aluminum, and tantalum. For a complete list, see our weldable materials page.

Dissimilar Metal Joining

Defense systems frequently combine materials to optimize strength-to-weight, thermal conductivity, corrosion resistance, ballistic performance, or high-temperature capability. EB Industries specializes in joining difficult and dissimilar combinations using Electron Beam and Laser Welding. Examples include stainless steel to copper, nickel alloys to stainless steel, high-strength steels, and specialty aerospace alloys. These capabilities are especially valuable for propulsion, thermal management, and electronic packaging applications.

Hermetic Sealing for Military Electronics

Modern defense systems depend on sealed electronic assemblies that must remain protected from moisture, oxygen, dust, corrosive environments, and pressure fluctuations. EB Industries’ glovebox laser sealing systems provide tightly controlled inert environments with oxygen and moisture monitoring for high-reliability hermetic sealing. Applications include RF packages, microwave housings, guidance electronics, sensor packages, communications modules, and electronic control assemblies.

High Quality Standards

Mission-critical components cannot fail. EB Industries has built its business around welding and testing processes that essentially eliminate the chances of weld defects impacting completed parts or assemblies. We meet ISO 9001:2015, AS9100D, MIL-SPEC 45208A, and NADCAP standards, and we have been certified by primes including Lockheed Martin, Boeing, and others. For a complete list, see our industry certifications page.

Part Heat Sensitivity

Many alloys used for defense applications have high thermal conductivity or crack sensitivity, which can make them difficult to weld. A small heat-affected area is one of the key benefits of our Laser and EB welding services compared to TIG and other techniques. We also use specialized heat-sinking techniques to keep parts protected from warping and cracking.

Case Study

  • Service: Laser Hermetic Sealing for High-Reliability Electronic Packaging
  • Sector: Aerospace, Defense, and High-Frequency Electronics
  • Customer: MACOM®
  • Product: High-reliability electronic components and RF packages for aerospace and defense systems

MACOM® manufactures high-reliability electronic components and RF packages used in aerospace and defense systems. These applications require hermetic sealing that protects sensitive electronics from moisture, oxygen, and environmental contamination across long operational lifecycles. EB Industries provides laser hermetic sealing for these packages in a glovebox-controlled environment with oxygen and moisture monitoring.

Our Equipment and Expertise

At EB Industries, we believe the best way to serve our customers is to have an array of welding equipment available to meet varied requirements. We also have multiple redundant systems and operators so production capability is never compromised.

  • Three 150 KV Hamilton Standard Electron Beam welders with a maximum chamber size of 36″ high x 36″ wide x 76″ in length
  • IPG Photonics YLS-4000 continuous wave Ytterbium fiber laser with power ratings from 400 W to 4 kW, supporting continuous wave (CW) and pulsed operating modes
  • Lumonics JK 701H 550 Watt Nd:YAG with PPL 4-Axis Laser Operating Control System including coordinated 3-axis concurrent motion
  • Raytheon SS550 400 Watt Nd:YAG with Allen Bradley 8400 4-axis control, 3D compound curvature capable
  • Trumpf HL-304 350 Watt Nd:YAG Laser with Aerotech 3200 4-axis workstation
  • Multiple laser tacking systems by Trumpf and LaserStar with power ranges up to 50 Watts
  • All welders are equipped with enhanced computerized controls and CNC capabilities, allowing tight control of beam characteristics and work piece movement
  • Machines are operated by a dedicated and highly trained staff. Our operators have an average of 15 years of experience and undergo constant retraining and certification.

For more information on our equipment, please click here.

Our Quality

Defense and aerospace require tight quality controls due to the mission-critical and flight-critical nature of customer parts and assemblies. EB Industries uses a quality system that meets the highest industry standards.

  • We are an ISO 9001:2015, AS9100D, and NADCAP certified organization delivering international quality standards.
  • All our welding equipment and operators meet the requirements of MIL-STD-1595A, AMS-STD-1595A, and AWS D17.1:2000 specifications.
  • Our quality control and inspection system is in compliance with MIL-I-45208A standards, with a metrology program in accordance with MIL-C-45662A.
  • We have a long history of meeting proprietary or customer-specified quality standards.
  • Inspection methods include visual inspection, fine and gross leak testing, cross-sectional metallurgical analysis, process validation and documentation, and 3rd party NDT including X-ray and fluorescent penetrant inspection (FPI).

For more information on our quality system, please follow the link.

Additional Services

In addition to welding, defense parts often require additional processing. EB Industries offers a wide array of services that make us a one-stop shop for welding-related services.

Pre Processing: – CAD/CAM Product Design and Weld Design – Tooling Design and Fabrication – Package Assembly – Strategic Sourcing and Subcontractor Contract Management

Post Processing: – Metallurgic Evaluations – Leak Testing – Radiographic Inspection – Non Destructive Testing – Electrical Testing

For more information, see our Add On Services page.

Are you working on a defense program?

We have decades of experience supporting defense OEMs and Tier 1 suppliers across missile, propulsion, electronics, sensor, and thermal management applications. Our engineers can help you at any phase, from development through production.

Ask Engineering

Frequently Asked Questions

Why is Electron Beam Welding used for defense manufacturing?
Electron Beam Welding provides deep penetration, minimal distortion, and exceptionally clean welds due to the vacuum environment. These advantages make it well suited for high-performance military and defense components where weld integrity and material performance are essential.
Can laser welding be used for military electronics?
Yes. Laser welding is widely used for electronic housings, RF packages, sensors, and hermetically sealed defense electronics because of its precision and low heat input.
What materials are commonly welded for defense applications?
Common defense materials include titanium, stainless steel, Inconel, copper alloys, aluminum, nickel-based superalloys, Hastelloy, molybdenum, and tantalum.
Can EB Industries weld dissimilar metals?
Yes. EB Industries specializes in joining difficult and dissimilar materials using advanced Electron Beam and Laser Welding processes, including stainless steel to copper, nickel alloys to stainless steel, and combinations used in propulsion and electronic packaging.
What inspection methods are available?
EB Industries supports visual inspection, fine and gross leak testing, cross-sectional metallurgical analysis, and 3rd party inspections including X-ray and fluorescent penetrant inspection (FPI) for critical defense assemblies.
What certifications does EB Industries hold for defense work?
EB Industries is certified to AS9100D for aerospace and defense quality management, ISO 9001:2015 for general quality management, and NADCAP for electron beam welding. We also meet MIL-SPEC 45208A and have been approved by primes including Lockheed Martin and Boeing.