The hottest electron beam welding extremely narrow

Electron beam welding: extremely narrow welds and reliable connections

for very deep and narrow plane welds, electron beam welding technology is a very reliable process. It can minimize angular deformation, lateral shrinkage and other non ideal effects

application

the application of electron beam welding covers from film welding to one-time welding of 200mm workpieces. In addition, it can weld different metal materials and combinations of these materials

value

when designing mechanical parts, we will face the problem of how to save cost by selecting the appropriate design scheme. Electron beam has great potential in this regard. Due to the fast welding speed, electron beam technology has shown a high production capacity in the mass production of electronic products and automobile manufacturing. In the single piece processing and small batch production of some products in aerospace, shipbuilding or railway industries, electron beam technology also reflects its accuracy and repeatability. Because this process has advanced electronic measurement and electrical control technology, it is an optimization premise for automatic production lines

our advantages:

stable welding technology, economy and reliability

application field

electron beam welding technology is applied in almost all fields, and can complete standard and high technical requirements of welding tasks

automotive industry: mass production is carried out with a high degree of economy. For example, the accuracy and force measurement stability (engine, transmission mechanism) of the experimental machine are determined by the quality of the sensor of the whole power transmission system (Fig. 1)

aerospace industry: process some components with high technical requirements and special purposes, such as helicopter parts (Figure 2) or satellite fuel tanks

energy and electronic industry: mass processing of copper products and other products that can only reflect their surface phenomena and contact materials, such as circuit breakers (Figure 3)

railway, shipbuilding and pharmaceutical industries: safe and reliable connections, such as the clasps of German high-speed trains (Figure 4) and implants suitable for human bodies (Figure 5)

machine and equipment manufacturing and food industry: products that process stainless steel products and other combinations of different steels in small and large batches. Workpiece weighing up to 50 tons can be welded by electron beam

R & D: it can realize the processing of products with complex design, high cost and high requirements. The materials of these products are tungsten, platinum and other special materials

process

electron beam welding will generate necessary energy in the processing area through electrons (accelerated by kV high voltage). The formation of beam is always in vacuum. Welding is also carried out in vacuum, and some equipment realizes welding in atmospheric environment. When electrons hit the workpiece, most of the kinetic energy is converted into heat energy for welding

the energy density reaches 105 to 109 w/cm2 in the focus diameter range of less than 0,1mm to 2mm. At high efficiency, electron beam welding can achieve almost the same energy density as laser welding (laser energy utilization ratio:%, electron beam energy utilization ratio: about 70%). In high-speed welding, electron beam can weld very deep and narrow welds. Due to the extremely small weld width, the deformation is also very small. Electron beam is used to weld parts requiring very small welds, because the electron beam can be accurately controlled and deflected by the electric field. The weld depth that can be reached is between 0,3 mm and 300mm (aluminum) and 150mm (steel). The high energy density enables the electron beam to weld all the gold mold holes and doorways. The size is correct, including some fusible metals, and welding different materials to achieve mixed combinations, such as steel and bronze

electron beam welding equipment is often used in the mass production of transmission parts in the automotive industry (mainly in Japan and Germany). In addition to simple and inexpensive processing tasks, other components from aerospace, railway transportation and food industry can also be welded by electron beam

more information about the effect of deep welding. When electrons hit the raw material, they will slow down and release their kinetic energy (most of which is converted to heat energy)

deep melting can weld a very narrow weld with a depth of more than 100mm (as shown in the figure, the depth welding of aluminum (150mm)). It can reach a depth to width ratio of 50:1. The process parameters of electron beam can be accurately controlled. All parameters can be measured and controlled as electrical units

the measurement of electrical parameters is simpler than that of optical fiber and optical parameters. The combination of innovative control methods and CNC control system opens up more new possibilities for material processing

in view of the accuracy and adjustability, all applications of electron beams benefit a lot:

through simple and reliable measurement, the adjustment parameters of all beams can be accurately recorded and easy to reproduce. The feedback in the whole closed-loop control is feasible, so the adjustment of the electron beam in the processing position can be realized manually or automatically, and it is also easy to operate manually. Allowable gap during welding: the maximum allowable gap is 5% of the welding depth, but the maximum is 0.3 mm. The deviation shall be confirmed for each application

larger gaps require welding accessories. These two situations are usually undesirable from a technical and commercial point of view. Design: electron beam technology is designed for design engineers. When dealing with connection problems, it brings very high natural temperature. After putting it into the prepared water with pH of 8, hardness of 100mg/l and effective chlorine of 2mg/l, you can enter the cost-saving production through the optimization of materials. Because welding with electron beam ensures not only low deformation and high precision

in addition, the application of multi beam electron beam can also overcome the limitations of other welding processes:

during welding, if the workpiece is not allowed to be too hot, or the required weld depth is very large, and must be guaranteed within a very small tolerance range, then the electron beam has an advantage over the laser body. Because many workpieces can be connected by separate parts, it is possible for cheap materials to replace expensive materials. A good welding design can avoid costly chip processing and pickling at other positions of the weldment

materials: the extremely high energy density enables electron beam welding of all materials, including highly molten metals, and the production of mixtures through the welding of different materials, such as steel and bronze (the figure shows the typical deep welding of bronze and steel (20mm))

using electron beam technology, bobbin company can reliably weld die-casting aluminum parts. The remaining part of the separation medium locked in the material as a gas will slowly disperse, so as to avoid the worrying explosive expansion of the gas

in many cases, the formation of hot cracks in high-strength nickel alloys can be controlled by appropriate heat of displacement. Multi weld pool technology: using the multi weld pool technology of bobbin, up to 60 welds can be welded at the same time. The welding of the axial weld on the pinion is realized by the three weld pool technology (the pinion is welded by the three weld pool technology)

this method reduces the deformation and shortens the welding time by 2/3. In addition, expensive tooling technology and spot welding can be discarded. In this case, the error of radial and axial concentricity is less than 1/500. (end)