A fusion welding process using a high volume of electrons at very high velocity, collimated to a sharp focus and used to impart energy into a work piece creating heat and a highly controllable, defined fusion (weld).
EBTEC offers our customers a partnership in component fabrication by solving their complex joining needs with Electron Beam Welding.
EBTEC maintains and operates 13 electron beam welding machines, ranging in output power from 2.5kw to 25kw. (The higher the “kw” the deeper the penetration capabilities). All of EBTEC’s Electron Beam Welding equipment operates at full vacuum ensuring the utmost in weld quality with complete remediation of oxygen, and other foreign atmospheric contamination. Many of our electron beam machines have CNC controls that allow for precise and consistent weld repeatability on complex weld paths.
We respect that your valuable assets are in our facility for electron beam welding and that you trust us with their care. Weld quality, weld costs, and professional services are core to our philosophy. Whether an application is in development, or a prototype, a single part flow, or high volume, a highly experienced operator with years of professional training is caring for your assets as we perform our services.
EBTEC maintains AS9100 / ISO9000 certification and NADCAP welding certification.
Process CG EB Welding per P8TF10, P8TF7, P8TF5, P8TF1, AWS D17.1. S-312
Process EE Laser Machining, Drilling/ Cutting per EE01 (Laser Drilling) per P17TF2, ANSI-Z136.1, S- 422; EE02 (Laser Cutting) per P17TF2, P1TF78, P1TF10, ANSI-Z136.1, S-422
TIG welding to P8TF3 – CF01
RR9000: SABRe Certificate# 109110, RPS 657, RPS 709
WBS52, WBS53, 91547-P6063, 91547-P6203, 91547-P6206, AMS 2681, EMS52571, EMS52572, FI-1191, FI-1165, FI-1288,P6203, P6206, PNCP52574 Type I, PNCP52574 Type II, WBS5071 Type I & III.
Note: Some approvals may be part specific.
NADCAP Non conventional machining
Electron Beam (EB) Welding is often chosen over convention methods and has many advantages. It can used for joining ferrous metals, light metals, precious metals, and other alloys to themselves or to other, dissimilar materials. Our Electron Beam Welding services offer you and your components the following advantages:
- Low Heat input with narrow fusion zones into welded component reducing weld distortion
- Versatility: weld depths from .002″ depth to 3.00″ depth of penetration
- Compatibility with dissimilar alloys that are not possible with convention methods
- A vacuum environment: cleanest weld process and weld profiles possible.
- Multi-axis EB control
- High ratio of depth-to-width
- Maximum penetration with minimal distortion
- Exceptional weld strength
- Ability to weld components up to 10′ in diameter
- High precision and repeatability with virtually 0% scrap
Benefits of EB Welding
- Receive the maximum amount of weld penetration with the least amount of heat input, resulting in reducing distortion
- EB Welding often reduces the need for secondary operations
- Repeatability is achieved through electrical control systems
- A cleaner, stronger, and homogeneous weld is produced in a vacuum
- The electron beam machine’s vacuum environment eliminates atmospheric contaminants in the weld
- Exotic alloys and dissimilar materials can be welded
- Extreme precision due to CNC programming and magnification of operator viewing
- Electron Beam Welding frequently yields a 0% scrap rate
- The electron beam process can be used for salvage and repair of new and used components
Limitations of EB Welding
- Evacuation time – creation of vacuum environment – EBTEC remediates this with high pump down speeds and greater part densities with tooling into each cycle
- High Capital Costs – with 13 electron beam machines on premise, EBTEC mitigates that Capital Expense to place equipment within your facility
- Work Chamber size restraints – with 13 machines varying from 1 cubic-foot to 1404 cubic-feet, EBTEC has a machine that fits your specific needs.
An Electron Beam Welding system is composed of an electron beam gun, a power supply, control system, motion equipment, and vacuum-welding chamber. Fusion of base metals eliminates the need for filler metals (Autogenous welds). The vacuum requirement for operation of the electron beam equipment eliminates the need for shielding gases and fluxes. The electron beam gun has a tungsten filament, which is heated, freeing electrons. The electrons are accelerated from the source with high-voltage potential between a cathode and anode. The stream of electrons passes through a hole in the anode. The beam is directed by magnetic forces of focusing and deflecting coils. This beam is directed out of the gun column and strikes the workpiece.
The potential energy of the electrons is transferred to heat upon impact of the workpiece and cuts a perfect hole at the weld joint. Molten metal fills in behind the beam, creating a deep, finished weld. The electron beam stream and workpiece are manipulated by means of precise, computer-driven controls, within a vacuum welding chamber, therefore eliminating oxidation or contamination.
Hamilton Standard 308
Hamilton Standard 603
Hamilton Standard 379
Hamilton Standard 194
Hamilton Standard 177
Cambridge Vacuum Engr (CVE)
High Volume Gear Machine
Japax LXR100 – Wire
Japax LDM100 – Wire
Surfi-Sculpt™ is a patented process of TWI and a high energy beam process that can modify surface characteristics of any metal to exact tolerances, lending itself to virtually any market. Surfi-Sculpt™ is not a deposition process; this high energy beam process creates detailed protrusions and intrusions on any ferrous or nonferrous metal, allowing for an infinite number of textures or patterns, with a depth of penetration of .001′ to .150′.