Turbochargers are employed to pre-pressurize the air going into the diesel engine to higher than atmospheric levels, thus providing more oxygen for the combustion process. The electron beam welding (EBW) and laser beam welding (LBW) processes are high-energy density welding processes that offer several possible advantages, including low welding heat input, high weld depth-to-width ratio, narrow heat-affected zone (HAZ), and reduced distortion. In the majority of laser welding applications, zero gap is the ideal condition to ensure proper fusion between the upper and lower sheets. The material, meanwhile, continues to melt. The high heat intensity of electron beam welding results in a very narrow fusion zone with minimal distortion (Figure 2), so it is possible to weld machined components in the finished condition. Because it is a noncontact process, welding in holes and in tight spaces is possible if the beam width as it comes into focus is considered. EBW: Equipment, Joint Design and Applications | Metallurgy. This allows flexibility in joint design, and parts can be designed with less material. Therefore, these parameters are tightly controlled in the welding process. Welding at atmospheric pressure almost entirely eliminates problems related to the size of a structure being welded. Electrons are the basic particles of atoms that are negatively charged, extremely lightweight and are the transporters of electrical energy. Weld Characteristics and Quality of EBW: Due to high penetration-to-width ratios of EB welds two distinct advantages accrue, viz., relatively thick plates can be welded in a single pass and welding speeds much higher than those attainable in arc welding can be used. As mentioned earlier, a typical high voltage EB machine can obtain a weld penetration of about 2 inches in steel.
As the laser beam advances along the weld joint, the keyhole moves with it through the workpiece. Laser welding energy sources utilize either a continuous wave (CW) or pulsed output of photons. The molten metal from the forward portion of the vapour hole flows around its periphery and solidifies at the rear to form weld metal as the beam moves forward along the weld line. Electron beam welding joint design and procedure. We consulted with the customer to design an electron beam-specific weld joint that optimized virtual leak performance at ultra-high vacuum. The working principle behind electron beam welding is emitting a focused beam of high-velocity electrons into a joint. Further improvements to weld quality can be achieved by using different weld patterns to eliminate undercuts and irregular penetrations. There are two variants or modes of the main process viz., medium vacuum EBW and non-vacuum EBW. Adjustments to these values can significantly enhance the stability of key holes in most welding applications. Some might use a vision system to ensure part positioning, but this will add some cycle time and complexity to the programming for production.
Tacking can be made as intermittent welds, but 100% tacking is more desirable. Laser Technology Specialist. Edge Joint Ex 1 & Ex 2 — Figure 16a & 16b. Electron beam welding (EBW) uses a high-velocity beam of electrons to melt and fuse metals together. Welding of low melting alloys, like aluminum or magnesium, may initially be a challenge as the high beam power concentration easily can overheat the material possibly resulting in porosity in the weld, rough top beads and splatters. The 2-dimensional weld pattern shown in Figure 8, has total weld length of up to 300 inches which introduces a high amount of heat into the plate. This process was sufficiently large to be machined to parent metal diameter and give a smooth bore. Application of electron beam welding. Due to enhanced presence of air in medium vacuum (100 ppm) mode the process is less satisfactory than high vacuum welding for reactive metals. Applications and Materials. Delivery by Fractory. A tight slip fit to an interference fit is recommended for proper welding. For example, keep a distance of minimum 2-3 mm to the raised edge when welding along a high edge. The ability to process in this manner is provided via a combination of features, including optical seam tracking, integrated clamping, and beam oscillation capabilities, in one tool—the Scansonic FSO (Flange Welding Optic). Applications of Electron Beam Welding (EBW): All metals and alloys that can be fusion welded by other processes can, as a rule, be welded by EBW as well.
Electron beam technology had advanced for decades reaching its current highest level. Electron beam welding converts around 85% of the electrical input into usable power. Clean welds since EBW is done in a vacuum environment. This required the use of reactive (like titanium and zirconium) and refractory (like tungsten, molybdenum and tantalum) metals. It is often used in unrestrained parts to prevent opening-up of the seam as full penetration welding progresses. As the electron beam is moved forward, material melts at the front of the beam. Joint design for welding: the pros and cons of groove joints. However, the main necessity for operating under vacuum is to control the electron beam precisely. Let's start with the basics - the key hole. This results in a very concentrated (approx. Fixture Design Considerations.
2M, Recommended Practices for Laser Beam Welding, Cutting, and Allied Processes. Each industry applies its own criteria to reach these goals. Most flanges, however, are designed to enable efficient welding with current resistance welding and laser optic offerings. While each technology has its benefits, in practical terms, many component designs incorporate both EB and laser welds. Keys to laser welding lap and edge joints | Laser Focus World. There is also little weld protrusion on the top or back side of the weld that needs to be machined after welding. In these situations it is advantageous to be able to adjust the weld profile, very often the width at a given penetration, in order to find the right balance between reliable beam-to-joint repeatability in mass production and the lowest possible heat input for a minimum level of part distortion.
The magazine delivers the news, technical articles, and case histories that enable fabricators to do their jobs more efficiently. "Since the heat source in this type of welding process is the energy of light, the weld material's reflectivity should be considered. The work piece is typically manipulated under the beam with the aid of a rotary device or a CNC table and as the key-hole is formed, molten material falls back into the hole, producing a deep, narrow weld. Butt welding requires accuracy and process repeatability but can achieve strong welds with minimal heat input. Typically, edge welding is done with direct fusion between the two materials (FIGURE 1). Other examples include relays, transducers, aneroid capsules, and diaphragms. Electron beam welding joint design.fr. Provide better overall weld properties compared to arc welding. Most Ni-/Co-base alloys that can be joined with conventional arc welding processes can also be successfully joined via EBW and LBW. The process can have minimal spatter to create visually clean welds, especially with the addition of shielding gases.
Weld Joint Design and Preparation for EBW: The joints commonly made by EBW process, as shown in Fig. As a practical matter, this physical behavior makes the process very robust and reliable! There is no tooling above the joint that could interact with the weld beam as it comes into focus. However, scarf edge preparation and fit-up is more difficult to make. These electrons are accelerated using a high voltage, typically in the range of 30kV to 150kV and with the aid of a focus (convergence) coil and a deflection coil, the electrons can be formed into a narrow convergent beam and accurately positioned on the work piece. And now be more broadly applied, opening up opportunities not feasible in the past. Filler wire diameters are generally small with a maximum of about 0-5 mm and the wire is fed into the leading edge of the small weld pool. Usually no added filler material is required or used, and post-weld distortion is minimal. A number of metals can be welded to give a depth-to-width ratio of upto 50. This type of welder typically employs a 2-station dial index with one part in each of the stations. A more advanced design incorporates a drawer style chamber which allows the tooling including parts to be entirely removed from the chamber for easier loading and unloading of assemblies and tooling changes (Figure 13). The width to penetration ratio upto 50, in steel welds, have reportedly been achieved. Use butt welding (butt joint), or blind welding if this is not possible.
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