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Ebw1
Ebw1
Metallurgical cleanliness
Advantages
High energy density & low energy input allows less shrinkage & distortion, narrow HAZ High quality, contamination free weld
High conductivity materials can be welded Finish machined and intricate parts can be joined
Highly concentrated beam, less thermal effects on materials to be joined Refractory materials & dissimilar material combination can be effectively joined High aspect ratio welds allow single pass for heavy thickness material
: 125-175kV, 120kW
Hard vacuum, soft vacuum and Non vacuum
WELDING SPEED: Controls heat input, depends on depth and width of weld and thermal conductivity.
Reduced cracking Improved weld properties Narrow Heat Affected zone Aluminium alloys can be welded Blind welding can be done High frequency beam spinning will reduce porosity
WELD QUALITY LOW DISTORTION LOW HEAT INPUT LONG FOCUS WIDE RANGE OF THICKNESS WELDING OF DISSIMILAR MATERIALS HIGH WELDING SPEED ACCURACY OF REPEATABILITY MULTIPLE PENETRATION
Electron optical column and accessories High voltage supply system Ancillary supplies and controls Vacuum systems and vacuum pumps Manipulators
Control of components before processing Control of parameters during processing Control after the operation
Mechanism
Electron Beam d
P1
ax1
Mechanism
Electron Beam
o1 a1 o2
a2
I. II. III.
Gun view
6KW EB Machine
Max Voltage
: 70KV
Power :
45 kW
Acceleration Voltage : 60 kV Beam current : 750 mA Chamber size :1500 X 1200 X 1200 mm X-Y table movement : 700 X 400 mm
Materials
Steels:
With less than 0.4% are easily EB welded without preheat or PWHT High Carbon & Tool steel - more than 0.5%C- weldable
Stainless Steel:
Austenitic Steel-easily weldable Martensitic Steel-cracking problem due to lack of toughness Ferritic Steel- magnetic in nature create beam deflection high cooling rates inhibit carbide precipitation
- easily EB weldable
Beta-alloys
Aerospace application
T I T ANI UM PROPELLANT T ANK
HIGH QUALITY WELDING IS ACHIEVED THROUGH EBW FOR TITANIUM GAS BOTTLE MANUFACTURE
Applications of EBW
Precombustion chamber
Cardiac pacemakers
Gas turbine
Copper/steel weld
Schematic diagram of the joint Cu-Cr-Zr cast connecting piece - OFC expansion strips
15 20 15 180
Expansion strips
EB weld
Expansion strips
58
3 58
3 58
Spacer strips
connecting Piece
Connecting piece
Component description Flexible copper terminal assembly used in 500MW water-cooled generator for transferring the full stator current (16.2kA) from stator winding bus bars to terminal bushings. The assembly remains in side the generator with H2 cooling and subjected to continuous vibration
Connecting pieces
Each assembly consists of: four connecting pieces twelve expansion strips
Connecting pieces
Case study
EBW of flexible copper terminal assemblies for 500MW generators..
Each assembly - 4 connecting pieces & 12 expansion strips. Ag coated connecting pieces - Cu-CrZr sand casting. Expansion strip OFC 2 Cu strips of 0.5X58X265mm & 49 Cu strips of 0.3X60X265mm - diffusion welded together.
Connecting piece
Expansion strips
Half assembly
Mn 0.004
58mm
58mm
58mm
Case study
EBW of flexible copper terminal assemblies for 500MW generators..
Joint No.
EB welding parameters used for joints Accln Beam Focus Heating voltage, kV current, mA current, A current, A 49.9 49.1 48.2 49.2 48.6 49.7 47.3 52.2 344 147 345 110 320 105 324 135 4.08 4.21 4.04 4.19 4.09 4.52 4.14 4.61 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Chemical composition
Cr - 0.70 wt% Zr - 0.07 wt%
Mechanical properties
Ultimate Tensile Strength : 465.87 Mpa Yield Strength Elongation : 324.22 Mpa : 14.42%
Cu expansion strips
Oxygen free deoxidised copper with low residual phosphorous content and high electrical conductivity Copper Phosphorus UTS Elongation : 99.90 wt % : 0.003 wt % : 20-25 kP/mm2 : 32-38 %
Cu Strips
Zr-Cr-Cu alloy
20mm
0.3mm
2 3
1 Strips
100m
200m
Weld
Strip HAZ
WELD
HAZ Strip
200m
200m
Hardness, HV 500ggg
260 240 220 200 180 160 140 120 100 Strip HAZ Weld Zr-Cr-Cu Location
Tests conducted
Radiography test Sound weld metal Occasional depression due to oxide expulsion Electrical conductivity study Ohmic resistance measured Zr-Cr-Cu :15 m Expansion strips :17 m Welded assembly :32 m
Case study
EB welding of AISI 316 Stainless steel
D I
Case study
Microstructure of fractured surface of the tensile specimen
toughness of the
weld metal in EB welded AISI 316
stainless steel in
as welded condition