TWI is active in the development of new capability as well as deployment of established in-chamber EB welding at a range of power levels, including:
High power – welding of thick-section material using a high accelerating potential (up to 175kV) and high beam power (up to 100kW) to penetrate steel up to 300mm thick, while achieving a stable weld keyhole in sections of 200mm or more. Application fields are often in the power sector, nuclear waste encapsulation and for value-adding in primary manufacture.
Medium power (as shown in the video) – the main users of EB welding are the aerospace and automotive sectors. Here weld penetrations are typically between 1 and 20mm. Welds in turbine engine drums, control actuators, heat exchangers, gear clusters and turbochargers are common; many oil and gas industry instrumentation assemblies are also welded/hermetically sealed. The process is beneficial as the resulting welds, having been made with a very localised heat source, which is consistent through the thickness being welded, typically have low distortion and allowing parts to be welded at or very close to final size/geometry.
Low power – EB welding machines may be configured to produce very fine, intense beams with spot sizes at the workpiece as small as 20µm. These beams may be used effectively to create very small welds, cuts, holes and other features.
Welding, as at higher powers, is a keyhole process.