A world leading engine maker wanted tiny welds performed in extremely thin titanium tubes, with very high weld integrity. Several process options were possible but electron beam welding appeared to be the most suitable.
End caps machined in a common titanium alloy needed to be joined to a small diameter tube, of half a millimetre wall thickness and similar metallurgical specification. The job also required micro-focus X-ray analysis of the results to verify the weld integrity in the fusion zone.
TWI used a low power EB welding machine to perform the weld autogenously and developed EB parameters to give the optimum integrity and appearance to these delicate welds.
TWI supported this client's project for approximately four years. After developing the welding procedures batches of components were routinely supplied to the client as requested.
The electron beam solution produced high intensity low heat input welding with a very narrow heat affected zone. The microfocus x-rays show a high integrity weld. The welding process takes place in a vacuum so there can be no entrainment of gas in the joint and consequent embrittlement.
TWI can develop special welding procedures for clients with difficult problems. The developed welding solution can then either be used by a sub contractor or reproduced at TWI in limited numbers.
To learn more about TWI's precision electron beam welding capabilities contact us.