Electron Beam Welding is ideal when your application requires a very precise, clean weld with minimal heating of the material outside the primary area of the weld. Additionally, EB Welding is excellent for joining dissimilar and hard to weld metals.
EB Industries is the preeminent Electron Beam Welding services provider throughout the United States, Canada and Mexico, since 1965. Our electron beam welding services have produced millions of parts, and our customers range from small manufacturers to some of the biggest companies in the Aerospace, Medical and Energy industries. We are ISO 9001:2015/AS9100D and NADCAP certified, have full engineering and metallurgy capabilities as well as extensive pre and post processing services.
What is Electron Beam Welding
Electron beam welding is the ultimate fusion welding process. Electrons are generated (via an electron gun) and then accelerated to very high speeds using electrical fields. This high speed stream of electrons is then focused using magnetic fields and precisely applied to the materials to be joined. As the electrons impact the materials their kinetic energy is converted to heat, which causes the metals to melt and flow together. Electron beam welding generally occurs in a vacuum as the presence of gas molecules can scatter the beam.
Because of the high voltages involved in EB welding, and the required vacuum, the entire process is computer controlled and heavily automated. The precise nature of the technology often calls for specialized fixtures to secure parts for joining, and CNC tables are commonly used to move the fixtures and workpieces within the welding chamber.
Electron beam welders are very expensive, must be tightly maintained, and the support required by the high voltage and high vacuum technologies can be demanding. However, electron beam welds are incredibly precise, strong and pure, the entire process accurately repeatable, and for many applications and materials, electron beam welding is the best joining technology there is.
Application Advantages of Electron Beam Welding
Precise Control, Excellent Weld Depth
Weld penetration can be closely controlled — from a minuscule 0.001 inches to a depth of up to 2 inches.
Small Heat Affected Zone
Electron beam welding has a very high depth-to-width ratio. This allows for a deep and very narrow heat affected zone, which minimizes material shrinkage and distortion and allows welds in close proximity to heat sensitive components.
EB welds retain up to 95% of the strength of the base materials.
Because electron beam welding takes place in a vacuum environment, impurities such as oxides and nitrides are eliminated and impurities in the materials are simply vaporized. This results in extremely clean welds perfect for joining a wide range of metal alloys.
Electron Beam welding is excellent for joining refractory and dissimilar metals which are not weldable with the conventional welding process.
Our CNC controlled welders ensure precise control and repeatability at feed rates from 1 to 200 inches per minute.
A comparison of welding processes:
Typical Weld Cost
Limited to vacuum chamber size
None if done manually
Good w/ stir welding
Depth (max penetration)
Shallow w/out multipass & notch
Width to Depth ratio (min w/d%)
Low (pulsed)/High (CW)
Purity (no electrode/filler)
Limited based on process
Highly with CNC
Highly with CNC
Limited/manual w/out CNC
Hard to reach area
Good – gas coverage concerns
Capital Investment (barrier to entry)
Service: Electron Beam Welding
Product: Thruster Valves
ValveTech makes thrusters that are used on spacecraft. They need welds that are 100% reliable, and they need exceptional customer service to help them keep pace with development and delivery. ValveTech relies on EB Industries as a trusted partner to help hit those launch dates. Find about it. Click the link below.
A Typical Electron Beam Welding Procedure
While every Electron Beam welding job is different, there is a base procedure we follow at EB Industries that allows us to maintain both weld quality and production rate.
The parts to be assembled are thoroughly inspected and cleaned;
Fixtures to hold the parts securely in place during the welding process are devised. We try to maximize the number of parts that can be welded per vacuum cycle to maintain high production rates. If necessary, fixtures are custom made in our complete machine shop;
Parts are loaded into their fixtures and the fixtures attached to the Electron Beam welder’s CNC table. The CNC table is programmed to precisely move the parts into position under the electron beam during the welding process;
The vacuum chamber is secured and the air pumped out of it to achieve the necessary partial or full vacuum required by the customer specification;
If necessary, test welds are performed to check for proper beam alignment and focus, beam power, weld penetration and overall quality of the weld. Parameters are adjusted as needed, and continually monitored during all welding operations;
If it is a production weld cycle, the welding operator initiates the CNC table programming and Electron Beam firing cycle. The parts are then Electron Beam welded;
At the end of the welding cycle, the vacuum chamber is pumped down and the parts and fittings are removed from the welder;
The parts are carefully removed from their fixtures and then subjected to a full quality control inspection.
Quality Management for Electron Beam Welding
Because much of our EB Welding work is for high performance/high risk applications in the Aerospace and Medical sectors, EB Industries maintains the highest levels of quality in the industry.
ISO 9001:2015 / AS9100D and NADCAP certified organization delivering international quality standards;
We weld to AMS 2680C and AMS 2681B specifications for electron beam welding aerospace components in soft to hard vacuum atmospheres;
Services delivered in compliance with the aerospace quality system AC7110/3 Rev. E and AC7004 standards;
All welding equipment and operators meet MIL-STD-1595A, AMS-STD-1595A, and AWS D17.1:2000 specifications;
Full quality control and inspection system in compliance with MIL-I-45208A;
Metrology program in accordance with MIL-C-45662A standards.
All our electron beam welding technicians are highly trained to meet MIL-STD-1595A, AMS-STD-1595A, and AWS D17.1:2000 specifications, and industry leading average 15 years of experience – this is high for the industry. Additionally, they are supported by full engineering and maintenance staff, a dedicated quality control department and an in-house machine shop.
EB Welding Equipment
All of our EB welders are equipped with automated rapid vacuum cycling for faster production speeds, full computer controls and digital displays for precision and accuracy, and CNC tables for precise part manipulation and feed. We custom make our own weld fixtures in our in-house machine shop to ensure top quality at high production volumes.
36” H x 36” W x 76” L
150 KV, 50 mA (CNC add-on)
36” H x 36” W x 52” L
150 KV, 50 mA (CNC 3 axis)
40” H x 36” W x 52” L
150 KV, 100 mA (CNC 5 axis)
36” H x 36” W x 52” L
150 KV, 100 mA (CNC add-on)
11.8” H x 11.8” W x 11.8” L
60 KV, 50 mA (CNC 5 axis)
Chamber extensions, data loggers and joint tracking options available as needed.
Because parts that require EB welding often require additional processing before and after the parts are welded, EB Industries offers a wide array of additional services.
CAD/CAM Product Design and Weld Design
Tooling Design & Fabrication
Parts Cleaning & Assembly
Strategic Sourcing and Subcontractor Contract Management
Destructive and Non-Destructive Testing
Post Weld Thermal Treatment
Our Customers Tell Our Story
Their technical skills are what sets them apart. They are easy to work with, and they have a good technical team.
Engineering Manager at a major Aerospace/Defense manufacturer
A top strength is their commitment to delivery. They always meet our delivery requirements. We’ve used several suppliers, but we continually use this one because they consistently maintain their commitment dates, which is critical to both us and our customers.
Mfg/QA Director at a Microwave and RF Device Manufacturer
We are very happy with the quality of the work. They really know what they’re doing.
Purchasing Agent at a Precision Machining Shop for Aerospace and Medial OEM’s.
They are good communicators, very reliable with on-time delivery. They seldom miss the date they committed to.
Purchasing Agent at a Custom Parts Manufacturer used by Aerospace OEM’s
They are always available when we need welding. Their facilities can handle our needs, and that’s unique to them.
Purchasing Agent at an Aerojet Rocketdyne Company
The people who work there are exceptional. They get things done for us in a timely fashion.
Senior Buyer at an Aerospace Component Manufacturer
Our EB Welding Customers Include:
Talk to an Engineer
EB welding requirements can be complex – between the materials, the standards and the cost effectiveness. Our engineers are available to answer any questions you might have, and suggest solutions to make your project more viable. You can even upload prints and documents if you wish, so that we can look things over and get you an answer fast.