Electron Beam Welding Services

Electron beam welding (EBW) is a fusion welding process that uses a focused, high-energy beam of electrons to join metals. Typically performed in a vacuum chamber, the kinetic energy of the electrons create heat upon impact, melting the materials and creating a deep, narrow weld with minimal distortion and a small heat-affected zone (HAZ). EB welding does not typically require the use of filler wire.

The process uses an electron gun to produce a stream of electrons, which are accelerated using a high voltage and then focused with magnetic lenses into a fine point of around 0.1mm in diameter. The electron beam is directed to where the workpieces are to be fused, melting the material with a ‘keyhole’ effect that can provide deep penetration into the parts. As the beam passes, the molten metal solidifies and creates the weld. Precise control of the power and focus of the beam allows for the penetration depth to be adjusted according to your requirements.

Electron beam (EB) welding needs to take place in a vacuum in order to prevent the electrons from being scattered by air molecules. The inert vacuum environment also leads to a cleaner final weld. This makes EB welding different from other ‘shielded’ welding processes, such as laser welding, which uses a focused beam and a shielding gas in the open air.

Press Releases

Find out more about electron beam welding at TWI:

TWI Technology Delivers First-Ever Autonomous Space-Made Weld

An electron beam welding gun designed and manufactured at TWI has created the first-ever autonomous weld in space.

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Ensure Your Electron Beam Quality with BeamAssure

Check and track the quality of your electron beam to avoid costly rework or the need to scrap parts.

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TWI Completes ‘EBOBend’ Electron Beam Trials

Exploring new electron beam welding capabilities.

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Core Research Programme (CRP) and Joint Industry Projects (JIP)

Core Research

Each year the TWI Core Research Programme (CRP) addresses challenges on behalf of our Industrial Members as well as developing specific technologies and processes. Each of the projects under the CRP is focussed on engineering, materials or manufacturing technologies.

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Joint Industry Projects

TWI also conducts Joint Industry Projects (JIPs) that bring together groups of Industrial Members to share the cost of research activities in areas of mutual industrial interest, gaining exclusive access to the outcomes. These projects cover a broad range of topics.

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Key Advantages

Electron beam welding offers a number of key advantages:

High Quality Welds: EB welding produces narrow and precise welds with good penetration, excellent strength, and very little distortion due to the localised heat input
Repeatability: Because it is automated, EB welding is a highly repeatable and reliable process
Versatile: The process can join a wide range of metals, including dissimilar metals with different melting points, and including high-strength alloys and parts with complex shapes
No Post-Weld Machining: Because the process is highly precise, it rarely requires post-weld machining

Electron Beam Welding at TWI

TWI has been active and innovative in EB technology research and development since the 1960s. Our expertise includes the deployment of established electron beam (EB) processing and technology at a range of power levels, as well as the development of new capabilities for the benefit of our Industrial Members.

As a precision welding process that delivers high-quality, repeatable joints, often without the need for filler material, EB welding has found a range of different applications across industry.

We are responsive to industry needs and provide electron beam consultancy services to all industry sectors, including aerospace, automotive, defence, electronics packaging, medical, oil and gas, power, space and engineering and fabrication.

Support for industry includes advice on component design, process selection and quality issues, troubleshooting, feasibility and pre-production trials, application, and prototype equipment development, helping our Industrial Members to benefit from the high weld quality available with EB welding.

Expertise

We focus on the following five main themes of expertise:

Equipment

EB welding systems can be expensive as electron beam welders require a vacuum to operate but we can help you assess the right system for your needs. Our facilities have electron beam welding machines with a range of accelerating voltage and power (from 60kV, 4kW up to 175kV, 100kW) and vacuum chamber sizes (from less than 1m³ up to more than 36m³). This enables processing of both small and large components with the capability of welding in excess of 200mm steel sections.

As well as commercially-available electron beam equipment, our facilities include a number of unique and bespoke solutions. We are able to provide support with the development of our Industrial Members’ own equipment, while also offering the opportunity to use our equipment as an extension of your own capabilities.

Track Record

We have a strong track record in the development of EB welding and processing, including:

1960s – Early 30kV EBW machine at TWI
1970s – High power electron guns (75kW)
1980s – Charged particle collection innovation and patent
1990s – Reduced Pressure EB
2000s – EB Surfi-Sculpt^® - first demonstration
2010s – Novel radio-frequency-excited plasma electron beam source
2020s – Design and manufacture of the electron beam welding gun that created the first-ever autonomous weld in space

For further information on how we can support you and solve your electron beam welding challenges, please email contactus@twi.co.uk.

For more information please email:

contactus@twi.co.uk