Another form of welding is electron beam welding which utilizes a high beam of energy electrons to heat the joint and obtain a weld. The electron beam is converted by the weld joint into heat to create a weld.
- Electron Beam Welding (EBW) is a fusion joining process that produces a weld by impinging a beam of high energy electrons to heat the weld joint.
- Electrons are elementary atomic particles characterized by a negative charge and an extremely small mass.
- An electron beam welding gun functions similarly to a TV picture tube.
- An electron beam welding gun uses a high intensity electron beam to target a weld joint.
- The weld joint converts the electron beam to the heat input required to make a fusion weld.
- The electron beam is always generated in a high vacuum.
- The use of specially designed orifices separated a series of chambers at various levels of vacuum permits welding in medium and non-vacuum conditions.
Electron Beam Welding Benefits
- Single pass welding of thick joints.
- Hermetic seals of components retaining a vacuum.
- Low distortion.
- Low contamination in vacuum.
- Weld zone is narrow.
- Heat affected zone is narrow.
- Dissimilar metal welds of some metals.
- Uses no filler metal.
Electron Beam Welding Limitations
- High equipment cost.
- Work chamber size constraints.
- Time delay when welding in vacuum.
- High weld preparation costs.
- X-rays produced during welding.
- Rapid solidification rates can cause cracking in some materials.
Electron Beam Welding Problems and Discontinuities
- Undercutting. Porosity.
- Cracking.
- Underfill.
- Lack of fusion.
- Shrinkage voids.
- Missed joints.
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