THERMAL ANALYSIS OF ELECTRON BEAM

WELDING

Presented By
D. Sai Teja 16N31A2114

B. Akhil Kumar 16N31A2102

Guided By
Assoc.Prof. Mrs.Smitha

Department Of Aeronautical Engineering

 INTRODUCTION
• EBW is a fusion process that produces coalescence of materials with heat obtained
by impinging a beam comprised of high energy electrons onto joint to be welded.
For EBW, electrons are raised to high energy state by being accelerated to
velocities in range of 30 to 70 percent of speed of light. It works on the principle
that when a high-velocity beam of electron that has Kinetic energy strikes the two
metal pieces, the kinetic energy of the electron transformed into heat. The intensity
of heat produced is so much that it melts the two metal pieces and fuses them
together.
 ZIRCONIUM
• The material used for testing is zirconium (Zr).Zirconium is a very strong,
malleable, ductile, lustrous silver-gray metal. Its chemical and physical properties
are similar to those of titanium. Zirconium is extremely resistant to heat and
corrosion. Zirconium is lighter than steel and its hardness is similar to copper.
When it is finely divided, the metal can spontaneously ignite in air, especially at
high temperatures. Zirconium powder is black and is regarded as very dangerous
fire hazard. Zirconium does not dissolve in acids and alkalis.
 MATHEMATICAL CALCULATION

• The mathematical formulation is done by using the below formula to find the
depth of penetration when the welding is done with a specified power, speed.

• b= (P/ (K*Tm))*(1/3.33)*(1/ ((V*w)/αa) 0.625

• Where, b=penetration depth

• w=fusion width
• αa=thermal diffusivity
• V=welding velocity
• Tm=melting temperature
• K=thermal conductivity
• P=beam power
 THERMAL ANALYSIS
• Initially the product is designed in “CATIA” and imported into
“ANSYS R15” for analysis.
• Later the thermal analysis is done on the surface of point of
application of heat source and the temperature distribution is
determined around that point.