Electron-beam welding

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Illustration of keyhole electron beam welding: 1) object, 2) electron beam, 3) keyhole, 4) weld. Keyhole welding scheme.png
Illustration of keyhole electron beam welding: 1) object, 2) electron beam, 3) keyhole, 4) weld.

Electron-beam welding (EBW) is a fusion welding process in which a beam of high-velocity electrons is applied to two materials to be joined. The workpieces melt and flow together as the kinetic energy of the electrons is transformed into heat upon impact. EBW is often performed under vacuum conditions to prevent dissipation of the electron beam.

Contents

History

Electron-beam welding was developed by the German physicist Karl-Heinz Steigerwald  [ de ] in 1949, [1] who was at the time working on various electron-beam applications. Steigerwald conceived and developed the first practical electron-beam welding machine, which began operation in 1958. [2] American inventor James T. Russell was also credited with designing and building the first electron-beam welder. [3] [4] [5]

Electron-beam welder Svarecka v DI.jpg
Electron-beam welder
Deep narrow weld Deep narow weld.jpg
Deep narrow weld

Physics

Electrons are elementary particles possessing a mass m = 9.1 · 10−31 kg and a negative electrical charge e = 1.6 · 10−19 C. They exist either bound to an atomic nucleus, as conduction electrons in the atomic lattice of metals, or as free electrons in vacuum.

Free electrons in vacuum can be accelerated, with their paths controlled by electric and magnetic fields. In this way beams of electrons carrying high kinetic energy can be formed. Upon collision with atoms in solids their kinetic energy transforms into heat. EBW provides excellent welding conditions because it involves:

Beam effectiveness depends on many factors. The most important are the physical properties of the materials to be welded, especially the ease with which they can be melted or vaporize under low-pressure conditions. EBW can be so intense that material can boil way, which must be taken into account. At lower values of surface power density (in the range of about 103 W/mm2) the loss of material by evaporation is negligible for most metals, which is favorable for welding. At higher power, the material affected by the beam can quickly evaporate; switching from welding to machining.

Beam formation

Cathode

Tungsten Filament Cathodes: a) Ribbon b) Hairpin Katody 2.jpg
Tungsten Filament Cathodes: a) Ribbon b) Hairpin

Conduction electrons (those not bound to the nucleus of atoms) move in a crystal lattice of metals with velocities distributed according to Gauss's law and depending on temperature. They cannot leave the metal unless their kinetic energy (in eV) is higher than the potential barrier at the metal surface. The number of electrons fulfilling this condition increases exponentially with increasing metal temperature, following Richardson's rule.

As a source of electrons for electron-beam welders, the material must fulfill certain requirements:

  • To achieve high power density, the emission current density [A/mm2], hence the working temperature, should be as high as possible,
  • To keep evaporation in vacuum low, the material must have a low enough vapour pressure at the working temperature.
  • The emitter must be mechanically stable, not chemically sensitive to gases present in the vacuum atmosphere (like oxygen and water vapour), easily available, etc.

These and other conditions limit the choice of material for the emitter to metals with high melting points, practically to only tantalum and tungsten. Tungsten cathodes allow emission current densities about 100 mA/mm2, but only a small portion of the emitted electrons takes part in beam formation, depending on the electric field produced by the anode and control electrode voltages. The most frequently used cathode is made of a tungsten strip, about 0.05 mm thick, shaped as shown in Figure 1a. The appropriate width of the strip depends on the highest required value of emission current. For the lower range of beam power, up to about 2 kW, the width w=0.5 mm is appropriate.

Acceleration

Beam generator Beam generator.jpg
Beam generator

Electrons emitted from the cathode are low energy, only a few eV. To give them the required speed, they are accelerated by an electric field applied between the emitter and the anode. The accelerating field must also direct the electrons to form a narrow converging “bundle” around an axis. This can be achieved by an electric field in the proximity of the cathode which has a radial addition and an axial component, forcing the electrons in the direction of the axis. Due to this effect, the electron beam converges to some diameter in a plane close to the anode.

For practical applications the power of the electron beam must be controllable. This can be accomplished by another electric field produced by another cathode negatively charged with respect to the first.

At least this part of electron gun must be evacuated to high vacuum, to prevent "burning" the cathode and the emergence of electrical discharges.

Focusing

After leaving the anode, the divergent electron beam does not have a power density sufficient for welding metals and has to be focused. This can be accomplished by a magnetic field produced by electric current in a cylindrical coil.

Magnetic lens Magnetic lens.jpg
Magnetic lens

The focusing effect of a rotationally symmetrical magnetic field on the trajectory of electrons is the result of the complicated influence of a magnetic field on a moving electron. This effect is a force proportional to the induction B of the field and electron velocity v. The vector product of the radial component of induction Br and axial component of velocity va is a force perpendicular to those vectors, causing the electron to move around the axis. An additional effect of this motion in the same magnetic field is another force F oriented radially to the axis, which is responsible for the focusing effect of the magnetic lens. The resulting trajectory of electrons in the magnetic lens is a curve similar to a helix. In this context variations of focal length (exciting current) cause a slight rotation of the beam cross-section.

Beam deflection system

Correction and deflection coils Deflection & correction coils.jpg
Correction and deflection coils

The beam spot must be precisely positioned with respect to the joint to be welded. This is commonly accomplished mechanically by moving the workpiece with respect to the electron gun, but sometimes it is preferable to deflect the beam instead. A system of four coils positioned symmetrically around the gun axis behind the focusing lens, producing a magnetic field perpendicular to the gun axis, is typically used for this purpose.

Penetration

Electron penetration

When electrons from the beam impact the surface of a solid, some of them are reflected (backscattered), while others penetrate the surface, where they collide with the solid. In non-elastic collisions they lose their kinetic energy. Electrons can "travel" only a small distance below the surface before they transform their kinetic energy into heat. This distance is proportional to their initial energy and inversely proportional to the density of the solid. Under typical conditions the "travel distance" is on the order of hundredths of a millimeter.

Beam penetration

By increasing the number of electrons (the beam current) the power of the beam can be increased to any desired value. By focusing the beam onto a small diameter, planar power density values as high as 104 up to 107 W/mm2 can be reached. Because electrons transfer their energy into heat in a thin layer of the solid, the power density in this volume can be high. The volume density can reach values of the order 105 – 107 W/mm3. Consequently, the temperature in this volume increases rapidly, by 108 – 109 K/s.

Results

Various forms of melted zone Various forms of melted zone.jpg
Various forms of melted zone

The results of the beam application depend on several factors:

  1. Beam power – The power of the beam [W] is the product of the accelerating voltage [kV] and beam current [mA], which are easily measured and must be precisely controlled. The power is controlled by the beam current at constant voltage, usually the highest accessible.
  2. Power density (beam focusing) – The power density at the spot of incidence depends on factors like the size of the cathode electron source, the optical quality of the accelerating electric lens and the focusing magnetic lens, alignment of the beam, the value of the accelerating voltage, and the focal length. All these factors (except the focal length) are a function of the design.
  3. Welding speed – The welding equipment enables adjustment of the relative speed of motion of the workpiece with respect to the beam in wide enough limits, e.g., between 2 and 50 mm/s.
  4. Material properties – Depending on conditions, the extent of evaporation may vary, from negligible to complete. At values of surface power density of around 103 W/mm2 the loss of material by evaporation is negligible for most metals, which is favorable for welding.
  5. Geometry (shape and dimensions) of the joint

The final effect depends on the particular combination of these parameters.

Welding process

Welded membranes Welded membranes.jpg
Welded membranes

Weldability

For welding thin-walled parts, appropriate welding aids are generally needed. Their construction must provide perfect contact of the parts and prevent movement during welding. Usually they have to be designed individually for a given workpiece.

Not all materials can be welded by an electron beam in a vacuum. This technology cannot be applied to materials with high vapour pressure at the melting temperature, which affects zinc, cadmium, magnesium, and practically all non-metals.

Another limitation may be the change of material properties induced by the welding process, such as a high speed of cooling. [2]

Titanium-to-aluminium joints Dewarka.jpg
Titanium-to-aluminium joints

Joining dissimilar materials

Some metal components cannot be welded, i.e. to melt part of both in the vicinity of the joint, if the materials have different properties. It is still possible to realize joints meeting high demands for mechanical compactness and that are perfectly vacuum-tight. The principal approach is to melt the one with the lower melting point, while the other remains solid. The advantage of electron-beam welding is its ability to localize heating to a precise point and to control exactly the energy needed for the process. Higher-vacuum substantially contributes to a positive result. A general rule for construction of joints made this way is that the part with the lower melting point should be directly accessible by the beam.

Local vacuum

Local vacuum systems allow workpieces to be welded without requiring the workpiece to be enclosed within the work chamber. Instead, a vacuum is established by sealing the chamber to one section of the workpiece, welding that section, and moving the chamber or the workpiece (continuously or in discrete steps) to additional sections and repeating the process until the weld is complete. [6] Using arc welding on pressure vessels requires 100 or more separate welds/cycles with additional processing for each cycle. Materials up to 200mm thick can be welded in a single pass. Shrinkage is minimal (heat treatment is advisable). Welds avoid oxide or nitride contamination. The material retains strength better. The weld has fewer flaws/voids, less NDE required and it's been around for decades.

Challenges

Cracks in weld Cracks in weld.jpg
Cracks in weld

If the material melted by the beam shrinks during cooling after solidification, cracking, deformation and changes of shape may occur.

The butt weld of two plates may result in bending of the weldment because more material has been melted at the head than at the root of the weld, although this effect is not as substantial as in arc welding.

Cracks may appear in the weld. If both parts are rigid, weld shrinkage can produce high stress which may crack a brittle material (even if only after remelting by welding).

Equipment

Electron-beam welder Electron beam welder.jpg
Electron-beam welder

Many welder types have been designed, differing in construction, working space volume, workpiece manipulators, and beam power. Electron-beam generators (electron guns) designed for welding applications can supply beams with power ranging from a few watts up to some one hundred kilowatts. "Micro-welds" of tiny components can be realized, as well as deep welds up to 300 mm or more. Vacuum working chamber volumes range from a few liters to hundreds of cubic meters.

The major EBW components are:

Electron gun

Emitter

The electron gun generates, accelerates, and focuses the beam. Free electrons are gained by thermo-emission from a hot metal strap (or wire).

Accelerator

They are then accelerated and formed into a narrow beam by an electric field produced by three electrodes: the electron emitting strap, the cathode connected to the negative pole of the high (accelerating) voltage power supply (30 - 200 kV) and the anode. The third (Wehnelt or control) electrode is charged negatively with respect to the cathode. Its negative potential controls the portion of emitted electrons entering into the accelerating field, i.e., the electron-beam current. After passing the anode opening, the electrons move with constant speed in a slightly divergent cone.

Focuser

For technological applications the divergent beam has to be focused, which is realized by the magnetic field of a coil, the magnetic focusing lens.

The beam must be oriented to the optical axes of the accelerating electrical lens and the magnetic focusing lens. This can be done by applying a magnetic field of some specific radial direction and strength perpendicular to the optical axis before the focusing lens. This is usually realized by a simple correction system consisting of two pairs of coils. Adjusting the currents in these coils produces the correct field.

Deflector

After passing the focusing lens, the beam can be applied for welding, either directly or after deflection by a deflection system. A deflection system This consists of two pairs of coils, one each for the X and Y directions. These can be used for "static" or "dynamic" deflection. Static deflection is useful for exact positioning of the beam. Dynamic deflection is realized by supplying the deflection coils with currents controlled by a computer. The beam can then be redirected to meet the needs of applications beyond welding such as surface hardening, annealing, exact beam positioning, imaging, and engraving. Resolution of 0.1 mm can be achieved.

Working chamber

Welding typically takes place in a working vacuum chamber in a high or low vacuum environment, although welders can also operate without a chamber.

Working chamber volumes range from a few liters up to hundreds of cubic meters.

Workpiece manipulator

Electron-beam welding can never be "hand-manipulated", even if not realized in vacuum, because of the presence of strong X-radiation. The relative motion of the beam and the workpiece is most often achieved by rotating or moving the workpiece or the beam.

Power supply

Electron-beam equipment must be provided with an appropriate power supply. The accelerating voltage ranges from 30-200 kV, typically 60-150 kV. Technical challenges and equipment costs are an increasing function of the operating voltage.

The high-voltage equipment must also supply low voltage currnet, above 5 V, for the cathode heating, and negative voltage up to about 1000 V for the control electrode.

The electron gun needs low-voltage supplies for the correction system, the focusing lens, and the deflection system.

Control and monitoring

Electronics control the workpiece manipulator, monitor the welding process, and adjust the various voltages needed for a specific application.

Applications

Reactor pressure vessels

Such systems have been applied to welding reactor pressure vessels for small modular reactors, with enormous savings in time and costs over arc welding. [6] Using arc welding on pressure vessels requires 100 or more separate welds/cycles with additional processing for each cycle. Materials up to 200mm thick can be welded in a single pass. Shrinkage is minimal (heat treatment is advisable). Welds avoid oxide or nitride contamination. The material retains strength better. The weld has fewer flaws/voids. Less NDE is required. [7]

Wind turbine

An offshore wind turbine can require 6,000 arc-on hours of welding. Local vacuum EBM can replace this at far lower cost and time, with improved quality. [7]

See also

Related Research Articles

<span class="mw-page-title-main">Cathode-ray tube</span> Vacuum tube often used to display images

A cathode-ray tube (CRT) is a vacuum tube containing one or more electron guns, which emit electron beams that are manipulated to display images on a phosphorescent screen. The images may represent electrical waveforms on an oscilloscope, a frame of video on an analog television set (TV), digital raster graphics on a computer monitor, or other phenomena like radar targets. A CRT in a TV is commonly called a picture tube. CRTs have also been used as memory devices, in which case the screen is not intended to be visible to an observer. The term cathode ray was used to describe electron beams when they were first discovered, before it was understood that what was emitted from the cathode was a beam of electrons.

<span class="mw-page-title-main">Electric current</span> Flow of electric charge

An electric current is a flow of charged particles, such as electrons or ions, moving through an electrical conductor or space. It is defined as the net rate of flow of electric charge through a surface. The moving particles are called charge carriers, which may be one of several types of particles, depending on the conductor. In electric circuits the charge carriers are often electrons moving through a wire. In semiconductors they can be electrons or holes. In an electrolyte the charge carriers are ions, while in plasma, an ionized gas, they are ions and electrons.

<span class="mw-page-title-main">Cathode ray</span> Beam of electrons observed in vacuum tubes

Cathode rays or electron beams (e-beam) are streams of electrons observed in discharge tubes. If an evacuated glass tube is equipped with two electrodes and a voltage is applied, glass behind the positive electrode is observed to glow, due to electrons emitted from the cathode. They were first observed in 1859 by German physicist Julius Plücker and Johann Wilhelm Hittorf, and were named in 1876 by Eugen Goldstein Kathodenstrahlen, or cathode rays. In 1897, British physicist J. J. Thomson showed that cathode rays were composed of a previously unknown negatively charged particle, which was later named the electron. Cathode-ray tubes (CRTs) use a focused beam of electrons deflected by electric or magnetic fields to render an image on a screen.

<span class="mw-page-title-main">Cathode</span> Electrode where reduction takes place

A cathode is the electrode from which a conventional current leaves a polarized electrical device. This definition can be recalled by using the mnemonic CCD for Cathode Current Departs. A conventional current describes the direction in which positive charges move. Electrons have a negative electrical charge, so the movement of electrons is opposite to that of the conventional current flow. Consequently, the mnemonic cathode current departs also means that electrons flow into the device's cathode from the external circuit. For example, the end of a household battery marked with a + (plus) is the cathode.

<span class="mw-page-title-main">Vacuum tube</span> Device that controls current between electrodes

A vacuum tube, electron tube, valve, or tube, is a device that controls electric current flow in a high vacuum between electrodes to which an electric potential difference has been applied.

<span class="mw-page-title-main">Transmission electron microscopy</span> Imaging and diffraction using electrons that pass through samples

Transmission electron microscopy (TEM) is a microscopy technique in which a beam of electrons is transmitted through a specimen to form an image. The specimen is most often an ultrathin section less than 100 nm thick or a suspension on a grid. An image is formed from the interaction of the electrons with the sample as the beam is transmitted through the specimen. The image is then magnified and focused onto an imaging device, such as a fluorescent screen, a layer of photographic film, or a detector such as a scintillator attached to a charge-coupled device or a direct electron detector.

<span class="mw-page-title-main">Electron gun</span> Electrical component producing a narrow electron beam

An electron gun is an electrical component in some vacuum tubes that produces a narrow, collimated electron beam that has a precise kinetic energy.

<span class="mw-page-title-main">Induction heating</span> Process of heating an electrically conducting object by electromagnetic induction

Induction heating is the process of heating electrically conductive materials, namely metals or semi-conductors, by electromagnetic induction, through heat transfer passing through an inductor that creates an electromagnetic field within the coil to heat up and possibly melt steel, copper, brass, graphite, gold, silver, aluminum, or carbide.

Since the mid-20th century, electron-beam technology has provided the basis for a variety of novel and specialized applications in semiconductor manufacturing, microelectromechanical systems, nanoelectromechanical systems, and microscopy.

<span class="mw-page-title-main">Neutron generator</span> Source of neutrons from linear particle accelerators

Neutron generators are neutron source devices which contain compact linear particle accelerators and that produce neutrons by fusing isotopes of hydrogen together. The fusion reactions take place in these devices by accelerating either deuterium, tritium, or a mixture of these two isotopes into a metal hydride target which also contains deuterium, tritium or a mixture of these isotopes. Fusion of deuterium atoms results in the formation of a helium-3 ion and a neutron with a kinetic energy of approximately 2.5 MeV. Fusion of a deuterium and a tritium atom results in the formation of a helium-4 ion and a neutron with a kinetic energy of approximately 14.1 MeV. Neutron generators have applications in medicine, security, and materials analysis.

<span class="mw-page-title-main">X-ray tube</span> Vacuum tube that converts electrical input power into X-rays

An X-ray tube is a vacuum tube that converts electrical input power into X-rays. The availability of this controllable source of X-rays created the field of radiography, the imaging of partly opaque objects with penetrating radiation. In contrast to other sources of ionizing radiation, X-rays are only produced as long as the X-ray tube is energized. X-ray tubes are also used in CT scanners, airport luggage scanners, X-ray crystallography, material and structure analysis, and for industrial inspection.

Ultra-high vacuum is the vacuum regime characterised by pressures lower than about 1×10−6 pascals. UHV conditions are created by pumping the gas out of a UHV chamber. At these low pressures the mean free path of a gas molecule is greater than approximately 40 km, so the gas is in free molecular flow, and gas molecules will collide with the chamber walls many times before colliding with each other. Almost all molecular interactions therefore take place on various surfaces in the chamber.

A vacuum arc can arise when the surfaces of metal electrodes in contact with a good vacuum begin to emit electrons either through heating or in an electric field that is sufficient to cause field electron emission. Once initiated, a vacuum arc can persist, since the freed particles gain kinetic energy from the electric field, heating the metal surfaces through high-speed particle collisions. This process can create an incandescent cathode spot, which frees more particles, thereby sustaining the arc. At sufficiently high currents an incandescent anode spot may also be formed.

<span class="mw-page-title-main">Crookes tube</span> Early type of cathode ray tube

A Crookes tube is an early experimental electrical discharge tube, with partial vacuum, invented by English physicist William Crookes and others around 1869-1875, in which cathode rays, streams of electrons, were discovered.

<span class="mw-page-title-main">Teltron tube</span>

A teltron tube (named for Teltron Inc., which is now owned by 3B Scientific Ltd.) is a type of cathode ray tube used to demonstrate the properties of electrons. There were several different types made by Teltron including a diode, a triode, a Maltese Cross tube, a simple deflection tube with a fluorescent screen, and one which could be used to measure the charge-to-mass ratio of an electron. The latter two contained an electron gun with deflecting plates. The beams can be bent by applying voltages to various electrodes in the tube or by holding a magnet close by. The electron beams are visible as fine bluish lines. This is accomplished by filling the tube with low pressure helium (He) or Hydrogen (H2) gas. A few of the electrons in the beam collide with the helium atoms, causing them to fluoresce and emit light.

<span class="mw-page-title-main">Electrodynamic tether</span> Long conducting wires which can act as electrical motors or generators

Electrodynamic tethers (EDTs) are long conducting wires, such as one deployed from a tether satellite, which can operate on electromagnetic principles as generators, by converting their kinetic energy to electrical energy, or as motors, converting electrical energy to kinetic energy. Electric potential is generated across a conductive tether by its motion through a planet's magnetic field.

The inductive output tube (IOT) or klystrode is a variety of linear-beam vacuum tube, similar to a klystron, used as a power amplifier for high frequency radio waves. It evolved in the 1980s to meet increasing efficiency requirements for high-power RF amplifiers in radio transmitters. The primary commercial use of IOTs is in UHF television transmitters, where they have mostly replaced klystrons because of their higher efficiencies and smaller size. IOTs are also used in particle accelerators. They are capable of producing power output up to about 30 kW continuous and 7 MW pulsed and gains of 20–23 dB at frequencies up to about a gigahertz.

Electron-beam processing or electron irradiation (EBI) is a process that involves using electrons, usually of high energy, to treat an object for a variety of purposes. This may take place under elevated temperatures and nitrogen atmosphere. Possible uses for electron irradiation include sterilization, alteration of gemstone colors, and cross-linking of polymers.

Electron-beam machining (EBM) is a process where high-velocity electrons concentrated into a narrow beam that are directed towards the work piece, creating heat and vaporizing the material. EBM can be used for very precise cutting or boring of a wide variety of metals. Surface finish is better and kerf width is narrower than those for other thermal cutting processes.

<span class="mw-page-title-main">Deflection yoke</span> Part of a cathode ray tube which moves the electron beam around

A deflection yoke is a kind of magnetic lens, used in cathode ray tubes to scan the electron beam both vertically and horizontally over the whole screen.

References

  1. "Research paper: Electron beam welding – Techniques and trends – Review". Archived from the original on 2017-04-13.
  2. 1 2 Schultz, Helmut (1993). Electron beam welding. Cambridge, England: Woodhead Publishing/The Welding Institute. ISBN   1-85573-050-2.
  3. Brier Dudley (2004-11-29). "Scientist's invention was let go for a song". The Seattle Times. Retrieved 2014-07-24.
  4. "INVENTOR AND PHYSICIST JAMES RUSSELL '53 WILL RECEIVE VOLLUM AWARD AT REED'S CONVOCATION" (Press release). Reed College public affairs office. 2000. Retrieved 2014-07-24.
  5. "Inventor of the Week - James T. Russell - The Compact Disc". MIT. December 1999. Archived from the original on April 17, 2003.
  6. 1 2 "British company pioneers new nuclear welding technique : Corporate - World Nuclear News". World Nuclear News. 19 February 2024. Retrieved 2024-02-20.
  7. 1 2 Taylor, Jordan (February 23, 2024). "What Is Electron Beam Welding?". X.