Fabtech AWS Educational Programs

International Electron Beam Welding Conference Session 3

Home > Educational Programs > International Electron Beam Welding (IEBW) Conference Session 3

Tuesday, November 17 – Wednesday, November 18, 2009 • 9:00 AM – 4:15 PM
Chair: Ernest Levert
Member of AWS, FMA, SME, NAM, or PMA: $550
Nonmembers: $685 • Registration Code: W28
Room N231

The American Welding Society, DVS (German Welding Society), and The International Institute of Welding are organizing their first International Electron Beam Welding Conference. This event will be held in conjunction with the Fabtech International & AWS Welding Show. It will include a two-day technical program plus a half-day tutorial sponsored by the Pro-beam foundation. IEBW will bring together scientists, engineers and technical personnel from around the globe involved in the research, development, and application of electron beam welding processes.

In addition, on Monday, November 16th from 9:00 AM to 3:00 PM, a free student tutorial on electron beam welding is being presented by Pro-Beam Foundation (Germany).

Session 1 | Session 2 | Session 3 | Student Tutorial

Conference Program

Keynote Asia: Asia Business Developments - Electron Beam Welding in Japan

9:00 AM – 9:45 AM
Hirosada Irie, The Japan Welding Technology Center
Since the 1970s, considerable research and development in the electron beam welding technology have been carried out in Japan. Owing to the long-term recession of the Japanese economy since the 1990’s collapse of the bubble and the R&D activities of new technologies -- laser technology, FSW -- the R&D activities in electron beam welding technology have scarcely been published. However EBW technology has walked with steady steps in industries. As well known, the feature of EBW is deep penetration and low distortion. Since the bubble collapse, usage of EBW in Japan completely divided two extreme fields; that is, one is the construction of heavy gauge facilities and the other in mass production of small automotive and machine parts. The shipment of EB welders for the latter applications has been still active. In big construction, recently, the development of EBW of high-pressure gas pipe and the development of the welding process of overpack (container) for high level radioactive waste, and others, have been carried out. A brief introduction of electron beam welding technologies in Japan will be presented.

Keynote America: America Business Developments

9:45 AM – 10:15 AM
Don Powers (Retired – PTR-Precision Technologies, Inc.) (USA)

Break

10:15 AM – 10:40 AM

Fabrication and Closure Welding of Containers for Long Term Storage of High Level Nuclear Waste Using Reduced Pressure Electron Beam Welding

10:40 AM – 11:00 AM
Jim Dorsch, Ed Savage, Chris Punshon and Nick Bagshaw, TWI Ltd.
The growing demand for new base-load electricity generation will see an expanding role for nuclear energy as a major component. In consequence, increasing demands will be placed on the safe treatment and storage of high level nuclear waste (HLW). The current proposal for the USA is currently under review, but it is likely that spent fuel will be stored in a geological repository for a period of the order of a million years. The use of multiple-barriers to safely isolate HLW has been proposed, and the use of welding for fabrication and final closure of the containers considered. This paper describes a program of work carried out to examine the potential benefits of employing local vacuum, reduced pressure EB welding for both fabrication and sealing of containers for HLW, taking into account the demanding requirements for reliability, productivity, and concerns related to welding-induced distortion and residual stress.

EB Surface Engineering for High Performance Heat Exchangers

11:00 AM – 11:20 AM
A. L. Buxton, TWI Ltd; R. J. McGlen, Thermacore Europe Ltd.
From aircraft engines to electronic devices, current thermal management systems are limiting product performance. Heat exchanger designs have been constrained by the available production technologies, eg. machining or chemical etching, but a newly developed electron beam manufacturing process (Surfi-Sculpt) offers the potential to bring about a step-change in heat exchanger efficiency.

An electron beam in conjunction with a sophisticated beam deflection system is used to move material around the surface in a controlled manner to rapidly create a wide variety of complex surface structures, many of which are impossible to produce via any other processing route. New heat exchange surfaces and structures have been modelled to understand how different designs of surface feature can influence the flow behavior over a surface, and a parallel set of wind tunnel tests have been used to verify results. Ultimately this will enable the optimization of surface geometries for heat transfer and allow revolutionary changes in heat exchanger design.

This paper describes the background and scope of a new electron beam manufacturing process. The results of both modeling and wind tunnel testing are presented to demonstrate the impact of this technology on heat exchanger design and efficiency.

The Use of Filler Metal Shims to Improve Electron Beam Weldability

11:20-11:40 AM
Daniel Nowak, GE Energy; Gary LaFlamme and John Rugh, PTR-Precision Technologies, Inc.
Electron beam welding is normally considered an autogenous welding process and is typically used to join components with tight-fitting faying surfaces. Welding autogenously using the electron beam is ideal for producing the lowest possible heat input and minimal distortion by virtue of the processes narrow fusion zone. However, there are materials that cannot be fusion welded autogenously, such as 6000 series aluminum alloys. In these cases, a filler material must be used to change the weld metal chemistry to prevent cracking. The normal method for adding filler metal in conventional arc welding processes is to feed wire into the molten weld pool. This wire feeding method is suitable for the relatively shallow and wide welds produced by conventional non-keyhole welding processes, but it does not provide an adequate distribution of filler metal in the narrow, deep, rapidly solidifying welds produced by the EB welding process. To overcome this lack of filler metal distribution problem, it is possible to pre-place shim material between the faying surfaces prior to welding. This provides an even distribution of filler throughout the depth of the weld. However, the electron beam profile needs to be modified to accommodate the wider fusion zone and some of the inconsistencies of a shimmed joint.

This paper presents the use of filler shims in a number of applications in aluminum alloys and 300 series stainless steel. Properties data are also presented for select applications.

Electron-Beam Welding for Big Science

11:40 AM – 12:00 PM
Dr.-Ing. Wilfried Behr, Zentralabteilung Technologie (ZAT)
The ISF (Institut for Welding Engineering and Joining Technology) at the RWTH Aachen (Aachen University) and the ZAT (Central Department of Technology) at the Forschungszentrum Jülich have worked for decades successfully in the development and application research of the joining technology. The FEZ (Excellency Center for Joining Technology) connects the technical authority of the RWTH Aachen and the Forschungszentrum Jülich. The combined use of personnel and machine resources offers a complete joining technology specialized authority unique in Europe. Both for the industrial site in Germany and in the global competition of the engineer-scientific research, this is very useful, since the FEZ can solve questions made of industry and research as a competent development partner.

The ZAT in the Forschungszentrum Jülich transfers the tasks of the non-university research, development and manufacturing for research establishments and major items of scientific equipment cooperating world-wide in the FEZ. Current joining tasks e.g. for the international fusion experiment ITER in Cadarache/F, for the Spallation Neutron Source SNS in Oak Ridge/USA, for the research reactor FRM II in München/D and for FAIR (Facility for antiproton and ion Research) experiment in Darmstadt/D. The section “beam welding technology” of the ZAT can offer the necessary machine equipment and specialized authority to the research partners with its decades of experience in the processing of special metals as ideal development partner. Embedded into the range special joining and inspection technique can the ZAT a comprehensive research and manufacturing service offer, which are necessary to the solution of more complex joining and technical questions. Electron-beam welding is frequent with the solution of these joining technology questions of central importance. Only with the unique characteristics of this process, the almost boundless deflection technology, the outstanding protection of the melt against atmospheric influences by the vacuum and the highly precise power control material can be worked on such as niobium, molybdenum and titanium in addition, copper and aluminum in the necessary quality.

Lunch

12:00 – 1:20 PM
(Hosted by AWS C7B Committee)

Electron BeamWelding of Titanium-Aluminumides with High Niobium Content

1:00 PM – 1:20 PM
Uwe Reisgen, Simon Olschok, Jens Holk, ISF–Welding and Joining Institute, RWTH Aachen University

Electron Beam Welding of Aluminum Alloys for the Automotive and Aircraft Industry

1:20 PM – 1:40 PM
Prof. Dr.-Ing. Stefan Böhm, Christian Börner, Kai Noack, Prof. Dr.-Ing. Klaus Dilger, Institute of Joining and Welding Technique, Technische Universität Braunschweig (Germany)
In an actual project sponsored by the EU, the electron beam is used for the welding of ductile aluminum die cast alloys for crash-optimized lightweight components for the automotive industry and aluminum wrought alloys for helium-proof chassis of aeronautic and aerospace instruments. For welding of ductile aluminum alloys, the challenges are the mechanic-technological joint properties, because ductile aluminum die cast is difficult to cast and so the hydrogen induced porosity is high. For welding of chassis made of aluminum wrought alloys, the shape of the chassis are not symmetrical rotationally, but complicated. The components are made by precision-casting. Here the heat transfer into the material, the welding order, and the start and stop craters are the challenge.

The paper will show how modern electron beam technology is able to fulfill the requirements of the welding tasks using multiple beams and multiple focuses.

Applications of Electron Beam Diagnostics in Characterizing Low and High Voltage Electron Beam Welders

1:40 PM – 2:00 PM
K.W. Lachenberg, T.A. Palmer**, A.T. Teruya*, and J.W. Elmer*, Sciaky Inc., * Lawrence Livermore National Laboratory; **Applied Research Laboratory, Pennsylvania State University (USA)
Over the past two decades, the development of diagnostic tools for characterizing electron beams has been growing in prominence. The Enhanced Modified Faraday Cup (EMFC), developed at Lawrence Livermore National Laboratory (LLNL), provides measurements of the general size and shape of the beam and the power density distribution across its width. This tool has been utilized in a number of common applications, including the characterization of machine performance for high- and low-voltage electron beam welders, the transfer of parameters between welders at remote locations, and as a process control tool. Because of its capability to quantify beam characteristics, the EMFC can also prove to be a useful tool in diagnosing differences in machine performance related to differences in machine construction. By employing the EMFC diagnostic tool, the power density distribution of the beam from a given electron beam gun configuration can be determined. This quantitative information can then be used as a baseline for providing a better understanding of how different features of the electron gun or power supply affect the resulting beam power. The use of the diagnostic tool will provide a better understanding of the operation of these machines and prove instrumental in producing improved designs for the next generation of electron beam guns and power supplies without extensive visual and destructive testing.

Break

2:00 PM – 2:20 PM

Electron Beam Welding – Process, Applications, Equipment and Future Developments

2:20 PM – 2:40 PM
Dr. Schubert, G. PTR-Precision Technologies, Inc. (USA)
This presentation gives a technical overview of unique features of the electron beam welding process. Applications from different types of industries and different materials will be discussed and technical challenges will be highlighted, as well as how they can be solved with the EB process. Weld cross sections of production parts will be shown to demonstrate weld shapes obtainable. In addition, an overview of today’s welding equipment will be provided, ranging from universal chamber welders to flexible and dedicated production welders with short cycle times. Integration of high production welders into fully automated production lines will also be reviewed. A brief outlook will be given into future developments.

New Capabilities for Efficient Application of Electron Beam Welding for the Fabrication of Large-Scale Parts in Series Production

2:40 PM – 3:00 PM
Volker Adam, pro-beam AG & Co. KgaA (Germany)
One domain of the electron beam is the possibility to join finished or near-net-shape machined parts distortion-minimized. This technology was field-tested and applied for more than 50 years for safety-related parts in space, aviation, military and nuclear applications. Simultaneously the technique is predestined for deep penetration welding of wall thicknesses up to 100mm and more. Possibilities in this field have been discussed in the past, but so far, hardly any equipment was available for flexible and economic operations.

Machines and control systems have been continuously developed by pro-beam. As a result, fast and economic machines with chamber volumes up to 600 m3 for welding of large-scale parts with weights above 50 tons are available.

Enormously increasing or fluctuating commodity prices, especially for high-alloyed steels and noble metals, force up the importance of EB-welding in vacuum without filler material. The low energy consumption of modern EB systems, the matured technology, and the high availability of the systems have turned the technology into an economic production method for semi-finished products.

Large-volume cast or forged parts, as well as large-sized sheets can be subdivided into smaller components, faster and better available, and joined economically with high-quality by EB in the vacuum. New applications in the areas of shipbuilding, aviation and offshore wind power as well as for system and machine building are in pre-series or series production.

The paper reflects the current status of the production and will give future prospects of EB welding in the area of large-scale parts. Besides technical aspects, in particular, economic aspects are discussed.

Studies on the Electron Beam Welding Behavior of Different Lightweight Materials

3:00 PM – 3:20 PM
Marco Klemm, SZF Stahlzentrum and Rolf Zenker, TU Bergakademie
For modern lightweight design, it is becoming more and more necessary to produce welding constructions of lightweight materials as well as same-type design and also multi-material design. This makes high demands on the welding technologies itself, but also on additional thermal pre- and post-processes in connection with the welding process.

The electron beam (EB) can meet the requirements for realizing such complex welding tasks. By using high-frequency beam deflection, it is possible to realize multi-spot welding and/or multi-process technologies in connection with welding.

The paper deals with results relating to EB welding of several Al and Mg alloys and different combinations of these materials. EB welding was realized without filler materials to connect components up to 25 mm in
thickness.

The quality of the weld (porosity, sensitivity to cracking), the microstructure and hardness of the welding seam, and the HAZ and the tensile behavior in comparison to the base materials were investigated.

Same-type and related-type welds of lightweight joints have a good quality and mostly very good properties. In case of unrelated-type welds, the welding results depend on the kinds of welding partners used.

Electron Beam Weldability of Aluminum-Based Dissimilar Alloy Joints

3:20 PM – 3:40 PM
Michinori OKUBO, Toshiyuki HASEGAWA, Nihon University, Japan; Nobuyuki ABE, Osaka University, Japan
Aluminum alloy joints of dissimilar composition will give problems due to difference properties. The electron beam machine is 6 kW for high voltage type. Joint configuration is I type and without filler metal. Electron beam welds are produced on dissimilar aluminum alloys of 10 mm in thickness.

Al-Si alloy shave good performance. Main aluminum alloy is extruded Al-Si plate. Combination wrought alloys are Al-Mg, Al-Mg-Si and Al-Zn-Cu alloy plates. Hardness of Al-Si/Al-Mg and Al-Si/Al-Mg-Si weld metals is same level as both alloys. Tensile strength becomes about 200MPa. In case of Al-Si/Al-Zn-Cu joint, joint elongation is the lowest shown, and they are 80% of the base metal. Impact value shows a tendency to decrease. Micro-segregation of Mg, Si and Cu in weld metals is recognized for Al-Si/Al-Mg-Si joint.

Nanostructure aluminum alloy have high strength and good performance. The main alloy is nanostructure aluminum alloy. Combination aluminum-based alloys were extruded Al-Si plate and wrought Al-Mg, Al-Mg-Si and Al-Zn-Cu alloy plates. Dissimilar welding for nanostructure aluminum alloy to various aluminum-based alloys by electron beam welding process can be possible and crack-free. But some porosity is recognized in weld metal. As for hardness of the weld metal, they become 107 to 124HV with each joints. The high energy density processes such as electron beam welding are suitable because the heat-affected zone width is very narrow.

Panel Discussions

3:40 PM – 4:00 PM

Session 1 | Session 2 | Session 3 | Student Tutorial