VacuumElectronBeam Technologies ... - Deutsche Messe AG

Institute of Joining

and Welding

Vacuum Electron Beam Technologies

(Elektronenstrahltechnologien im Vakuum)

Dr.-Ing. Thomas Krüssel

Institut für Füge- und

Schweißtechnik


� Electron Beam

� Generation

� How it works

� Different ways of „Hochleistung“

� High Power/

� Highly Productive

� Steps into Future

Th. Krüssel | Hannovermesse 2013|

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Schweißtechnik


� Electron Beam

� Generation

� How it works


� High Power/

� Highly Productive/



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Schweißtechnik

Vacuum: Space on Earth

Vacuum:

Condition in a space with gas

pressure below normal

atmosphere (1013 mbar)

Source: http://www.pfeiffer-vacuum.de/

10-5 mbar: 2.400 molecules

10-3 mbar: 240.000 molecules

Atmosphere: 240 billion molecules


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Schweißtechnik

Why should electrons move?

rest mass of electron: 9.1 . 10-31 kg

elementary charge: 1.6 .10-19 C

Accellerating Voltage

150 kV in Vacuum

velocity:

2 .108 ms-1 = 2/3 speed of light

UB * IB = PB 150kV * 200mA = 150,000V * 0.2 A = 30,000 W = 30kW

30kW * 1.359622 ~ 40.79 PS


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Schweißtechnik

High precision assembly device

for cathodes

Tape katode BK 1.4; Tungsten,

Thickness 0.1 mm – Emitting Surface 2 mm2

Beam Generator: e.g. PTR-Beam Generator 60 kV

Source: PTR


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Schweißtechnik

Typical Design of an EB Column

Be

am

Ge

ne

ratio

nM

ag

net O

ptic

s


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Schweißtechnik

Electron Beam (EB) generation

beam source, cathode,

bias cup and anode

focosing coil

centering coil and

stigmator

component

manipulator

x-y deflection system

sensor plate (BSE)

Source: PTR

Source: pro-beam

Gravings produced by Lessajou figures

of oscillating EB


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Schweißtechnik

Beam – Materials Interaction

penetration depth

of electrons

=

region of

energy conversion

Source: Schultz, Elektronenstrahlschweißen

Ions

Vapour

Light

BSE

Thermal Radiation

EB

X-Ray

ee

e

e

e

e

e

ee

ee

e

ee

e

e

e

e

Efficiency of energy conversion:

� flat impact and heat conduction welding: 0.6

� in a key whole: 0.9 to 0.95

0

100

150

200

50

W Cu Fe Ti Al

Pen

etr

ati

on

Dep

th[µ

m]

Materials

Penetration depth of

electrons at UA=150 kV


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Schweißtechnik

Electron Beam Welding

Butt joint before

welding

Melting on the

point of impact of

the electron beam

Formation of a

steam channel

Steam channel and

melting channel

have penetrated

the work piece

Weld seam after

solidification


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Schweißtechnik

Electron beam as a universal tool

lens

deflector

sensor

plates

e-b

eam

backscattering

electrons

welding

hardeningcontour detection

deposit welding

process control / QAengraving


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Schweißtechnik


� Electron Beam

� Generation

� How it works


� High Power/




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Schweißtechnik

EB Chamber Machines

Typ S450+120 EB2 eg. usedto weld satelite components

Chamber for RPT by EB + wire feeder


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Schweißtechnik

Manipulation of Parts by Flexible Clamping Concepts


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Schweißtechnik

Gas turbine casing

17 t casting as welding-related solutionBy means of the electron beam welding procedure, thick-walled castings can be

repaired or, as a welding-related solution, produced more cost-effectivelyG

Material: G 20 Mo 5

Weight: 17,500 kg

Largest diameter: 5.5 m

3-D welding, carried out at a static

component

Seam length: 4.5 m

Welding depth: 58 mm

Welding time: 33 minutes


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Schweißtechnik

Cover of a vacuum furnace chamber for the

production of stainless steel

Cover made of the material 1.4571 can be welded by electron beam in the

finished state G

The following welding

operations are to be

carried out:

1.EB welding of the flange

(diameter 3.2 m,

wall thickness 50 mm)

2.EB welding of the pipe

connections (3-D)

(diameter 250 mm,

wall thickness 50 mm)


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Schweißtechnik

Tripod Design for Welding

Sections with

80 – 100 mm of

wallthickness

S355 NL

Bereich mit Wand-

dicken 20 – 70 mm

S355 NL

To produce a tripod of ~900 t weight (S355) 1.229 m weld seam are necessaryG


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Schweißtechnik

Manufacturing costs EB and UP in comparison

depending on the procedures and number of items

0

50

100

150

200

250

300

10 20 30 40 50 60 70 80 90 100

Anzahl Tripods pro Jahr

Ko

ste

n p

ro T

rip

od

[T

€]

UPTWIN in DeutschlandUPTWIN in PolenEB und UPEindraht in PolenEB und UPTWIN in PolenEB

EB/UP-Kombination

ab 14m Länge

reine UP-Fertigung

reine EB-Fertigung

Source: pro-beam / IMS Nord

Co

sts

per

trip

od

In Germany

In Poland

One-wire in Poland

Pure UP manufacture

Pure EB manufacture

EB/UP combination from a length of 14 m

Number of tripods per year


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Schweißtechnik


� Electron Beam

� Generation

� How it works


� High Power/




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Schweißtechnik

Industrial Automotive Series Production

Inconel 713 LC + 42CrMo4

(Shaft finaly grinded before welding)


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Schweißtechnik

Example of a Process Chain for Welding Gears

semi finished

parts

transport

OK parts

Cle

an

ing

EBW

magnetic

heating

mechanical

joining

US-testing

2 robots

� Requirements

� Many parts in shortest time

� Highest quality

� Absolutely reproducible

� Minimized costs


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Schweißtechnik

ELO picture versus colour picture

Colour picture

seam

ELO picture

seam


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Schweißtechnik

Example: Seam detection and positioning with ELO picture

Three different procedures

High precision (subpixel)

Center of device (zoomed)

Single steps for the detection of the seam track


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Schweißtechnik

Examples of EBW-Machines usable for this kind of production


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Schweißtechnik


� Electron Beam

� Generation

� How it works


� High Power/

� Highly Productive/



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Schweißtechnik

EB Deposition Welding, the general idea

Schematic diagram of the structure Depositing welding process (S355 plate / G3Si1)

Structure after machining (S355 plate / G3Si1)Structure after EB welding (S355 plate / G3Si1)


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Schweißtechnik

Main advantages of EB-deposition welding

• Use of solid and flux cored wire with almost 100% depositionrate

• Minimum heating effects by precisely adjustable (dilution / fusion)

• Experience: no basic material (steel) in 2nd layer of a hardfacing

• Reduced porosity

• Build up structures from reactive materials as e.g. titanium

• No limitation by any powder bed

• Flexible to use for repair and production

Dilution in macrosection

(steel)

Dilution in macrosection

(aluminum)Thin structure

(S355 plate, G3Si1)


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Schweißtechnik

Repair of Cost Intensive Parts: Roller Shaft

Roller shaft

vacuum chamber

Adjustment for welding

Shuttle machine

Bearing seat after

EB deposition welding


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Schweißtechnik

Research Project: EB-Repair of Dies


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� Expensive tools

� Special steels

� Complex heat treatment

� Repair of cracks, erosion, etc.

� Re-building of structures


Schweißtechnik

Rapid Prototyping (Titanium)


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Schweißtechnik

Direct Manufacturing (all examples from Sciaky Inc.)


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Schweißtechnik

Examplary Provider of EB Devices/Components


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www.steigerwald-eb.de www.pro-beam.de www.ptr-gmbh.de

www.tadadenki.jp/english/index.html www.evobeam.com www.camvaceng.com

www.techmeta.com www.sciaky.com www.wega-konstruktion.de

VacuumElectronBeam Technologies ... - Deutsche Messe AG

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