What is electron-beam welding used for?
Electron beam welding is used to join components requiring high precision, controlled heat input, deep penetration (high strength), high purity (without the use of filler material) and repeatable results.
Is electron-beam welding expensive?
The cost for electron beam welding does tend to be higher than other welding methods like laser welding and TIG welding as there’s a restriction on how many parts can be welded per batch due to the size of the vacuum chamber. Each assembly is different and there may be some parts that would be cheaper using electron beam welding. It’s on a case-by-case basis.
Does electron-beam welding require a vacuum?
Yes, electron beam welding must be done inside of a vacuum for several reasons:
The acceleration of electrons required to melt and fuse the components can only be done under high vacuum.
Welding inside of a vacuum protects the electron beam from air and gas particles that will scatter and diffuse the electrons leading to an inefficient joining process as the energy won’t be uniformly applied to the workpiece
The vacuum chamber protects the weld pool from contaminates that would negatively affect the quality of the weld leading to potential cracks and blowouts from outgassing and contamination.
What are the problems with electron beam welding?
Because of the need for a vacuum chamber, the process is limited in terms of part size as too large of a part won’t fit inside of the vacuum chamber.
The limited size of the chambers can lead to parts being more expensive than traditional joining methods as less parts can be processed per hour.
Electron beam welding is a less effective joining process for rough cut parts with gaps as filler material is required to fill in those areas which is more common in conventional welding like TIG welding.
What are the hazards of electron beam welding?
Radiation – Electron beam welding emits radiation through the welding process. That’s why the machines need to be lead lined to avoid exposing technicians to this harmful welding byproduct.
Welding fumes – Fumes are a typical byproduct of other welding processes. Because the welding is done inside of a chamber, technicians are well protected against this hazard.
How efficient is electron beam welding?
Electron beam welding is a very efficient process as compared to other welding methods. Electron beam welding can retain up to 97% of the strength of the parent materials due to the precise and localized heat input as well as the fact that no filler material is required.
What is the speed of electron beam welding?
Electron beam welding can be done at speeds up to 200 inches per minute. This is about 40 times faster than conventional welding methods like TIG welding. This makes it a great production process for higher quantities and minimizes the heat input.
