Institute of Joining and Welding Vacuum Electron Beam Technologies (Elektronenstrahltechnologien im Vakuum)

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1 Institute of Joining and Welding Vacuum Electron Beam Technologies (Elektronenstrahltechnologien im Vakuum) Dr.-Ing. Thomas Krüssel

2 Vacuum Electron Beam Technologies Electron Beam Generation How it works Different ways of Hochleistung High Power/ Highly Productive Steps into Future Th. Krüssel Hannovermesse

3 Vacuum Electron Beam Technologies Electron Beam Generation How it works Different ways of Hochleistung High Power/ Highly Productive/ Steps into Future Th. Krüssel Hannovermesse

4 Vacuum: Space on Earth Vacuum: Condition in a space with gas pressure below normal atmosphere (1013 mbar) 10-5 mbar: molecules 10-3 mbar: molecules Atmosphere: 240 billion molecules Source: Th. Krüssel Hannovermesse

5 Why should electrons move? Accellerating Voltage 150 kv in Vacuum rest mass of electron: kg elementary charge: C velocity: ms -1 = 2/3 speed of light U B * I B = P B 150kV * 200mA = 150,000V * 0.2 A = 30,000 W = 30kW 30kW * ~ PS Th. Krüssel Hannovermesse

6 Beam Generator: e.g. PTR-Beam Generator 60 kv Tape katode BK 1.4; Tungsten, Thickness 0.1 mm Emitting Surface 2 mm 2 High precision assembly device for cathodes Source: PTR Th. Krüssel Hannovermesse

7 Typical Design of an EB Column Beam Generation Magnet Optics Th. Krüssel Hannovermesse

8 Electron Beam (EB) generation beam source, cathode, bias cup and anode centering coil and stigmator focosing coil x-y deflection system sensor plate (BSE) component Gravings produced by Lessajou figures of oscillating EB Source: PTR manipulator Source: pro-beam Th. Krüssel Hannovermesse

9 Beam Materials Interaction penetration depth of electrons = region of energy conversion Light Thermal Radiation X-Ray EB e e e e e e e e e e e ee e e e Ions Vapour BSE Penetration Depth [µm] Penetration depth of electrons at U A =150 kv W Cu Fe Ti Al Materials Efficiency of energy conversion: flat impact and heat conduction welding: 0.6 in a key whole: 0.9 to 0.95 Source: Schultz, Elektronenstrahlschweißen Th. Krüssel Hannovermesse

10 Electron Beam Welding Butt joint before welding Melting on the point of impact of the electron beam Formation of a steam channel Steam channel and melting channel have penetrated the work piece Weld seam after solidification Th. Krüssel Hannovermesse

11 Electron beam as a universal tool e-beam lens welding contour detection deflector sensor plates backscattering electrons deposit welding hardening process control / QA Th. Krüssel Hannovermesse engraving

12 Vacuum Electron Beam Technologies Electron Beam Generation How it works Different ways of Hochleistung High Power/ Highly Productive Steps into Future Th. Krüssel Hannovermesse

13 EB Chamber Machines Typ S EB2 eg. used to weld satelite components Chamber for RPT by EB + wire feeder Th. Krüssel Hannovermesse

14 Manipulation of Parts by Flexible Clamping Concepts Th. Krüssel Hannovermesse

15 Gas turbine casing 17 t casting as welding-related solution By means of the electron beam welding procedure, thick-walled castings can be repaired or, as a welding-related solution, produced more cost-effectively 3-D welding, carried out at a static component Material: G 20 Mo 5 Weight: 17,500 kg Largest diameter: 5.5 m Seam length: Welding depth: Welding time: 4.5 m 58 mm 33 minutes Th. Krüssel Hannovermesse

16 Cover of a vacuum furnace chamber for the production of stainless steel Cover made of the material can be welded by electron beam in the finished state The following welding operations are to be carried out: 1.EB welding of the flange (diameter 3.2 m, wall thickness 50 mm) 2.EB welding of the pipe connections (3-D) (diameter 250 mm, wall thickness 50 mm) Th. Krüssel Hannovermesse

17 Tripod Design for Welding To produce a tripod of ~900 t weight (S355) m weld seam are necessary Sections with mm of wallthickness S355 NL Bereich mit Wanddicken mm S355 NL Th. Krüssel Hannovermesse

18 Costs per tripod Manufacturing costs EB and UP in comparison depending on the procedures and number of items Kosten pro Tripod [T ] EB/UP-Kombination ab 14m Länge Pure UP manufacture reine UP-Fertigung reine EB-Fertigung Anzahl Tripods pro Jahr UPTWIN in Deutschland UPTWIN in Polen In Poland EB und UPEindraht in Polen EB und UPTWIN in Polen EB Pure EB manufacture EB/UP combination from a length of 14 m Number of tripods per year In Germany One-wire in Poland Source: pro-beam / IMS Nord Th. Krüssel Hannovermesse

19 Vacuum Electron Beam Technologies Electron Beam Generation How it works Different ways of Hochleistung High Power/ Highly Productive Steps into Future Th. Krüssel Hannovermesse

20 Industrial Automotive Series Production Inconel 713 LC + 42CrMo4 (Shaft finaly grinded before welding) Th. Krüssel Hannovermesse

21 Example of a Process Chain for Welding Gears semi finished parts Cleaning EBW Requirements Many parts in shortest time Highest quality Absolutely reproducible Minimized costs mechanical joining magnetic heating US-testing 2 robots transport OK parts Th. Krüssel Hannovermesse

22 ELO picture versus colour picture seam seam Colour picture ELO picture Th. Krüssel Hannovermesse

23 Example: Seam detection and positioning with ELO picture Single steps for the detection of the seam track High precision (subpixel) Three different procedures Center of device (zoomed) Th. Krüssel Hannovermesse

24 Examples of EBW-Machines usable for this kind of production Th. Krüssel Hannovermesse

25 Vacuum Electron Beam Technologies Electron Beam Generation How it works Different ways of Hochleistung High Power/ Highly Productive/ Steps into Future Th. Krüssel Hannovermesse

26 EB Deposition Welding, the general idea Schematic diagram of the structure Depositing welding process (S355 plate / G3Si1) Structure after EB welding (S355 plate / G3Si1) Structure after machining (S355 plate / G3Si1) Th. Krüssel Hannovermesse

27 Main advantages of EB-deposition welding Use of solid and flux cored wire with almost 100% depositionrate Minimum heating effects by precisely adjustable (dilution / fusion) Experience: no basic material (steel) in 2nd layer of a hardfacing Reduced porosity Build up structures from reactive materials as e.g. titanium No limitation by any powder bed Flexible to use for repair and production Dilution in macrosection (steel) Dilution in macrosection (aluminum) Thin structure (S355 plate, G3Si1) Th. Krüssel Hannovermesse

28 Repair of Cost Intensive Parts: Roller Shaft Shuttle machine Roller shaft vacuum chamber Th. Krüssel Hannovermesse Adjustment for welding Bearing seat after EB deposition welding

29 Research Project: EB-Repair of Dies Expensive tools Special steels Complex heat treatment Repair of cracks, erosion, etc. Re-building of structures Th. Krüssel Hannovermesse

30 Rapid Prototyping (Titanium) Th. Krüssel Hannovermesse

31 Direct Manufacturing (all examples from Sciaky Inc.) Th. Krüssel Hannovermesse

32 Examplary Provider of EB Devices/Components Th. Krüssel Hannovermesse

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