What is Electron Beam Welding?

Electron beam welding (EBW) is a fusion welding process that uses a high energy electron beam to join metals together, with a wide range of applications in many industries.

 

How Does Electron Beam Welding Work?

An EBW machine consists of an electron gun that produces a focused beam of high-energy, high-speed electrons, with a velocity of between 0.3 and 0.7 times the speed of light. The electron gun is mounted on, or in, an evacuated chamber that contains tooling and fixtures that holds and moves the workpiece. 

The beam passes through the anode and on towards the workpiece, using a focusing lens to focus the beam to achieve sufficient power density to weld the two metals.

You can read our full FAQ on how EBW works.

CVE
Vacuum

EBW takes place in a vacuum chamber. This aids the weld quality, as it tends to pull contamination away from the weld pool. Welding in a vacuum also results in the operator not becoming exposed to the hazardous welding environment.

 

Automated Process

The process can be highly automated with the evacuation time of the chamber being just a few seconds. A typical cycle time in the automotive industry is 40 seconds per component. But time is dependent upon the length and complexity of the weld.

 

Turnkey Solution

Electron beam systems include a chamber, fully automatic vacuum system, work handling, and control system.

CVE
Weld Characteristics

The process is extremely efficient (typically 95%), and the weld quality is exceptional, presenting the following characteristics:

  • Deep penetration
  • High depth-to-width ratio
  • Narrow fusion zone
  • Inert atmosphere vacuum
  • Near parent metal strength
  • Low distortion

 

Electron Beam Welding Animation

 

CVE’s Range of EB Welding Machines

Please find our full range of machine models below.

Machines are built to order and options include custom and precision work handling, vacuum systems tailored to specific process needs and productivity, wire-feed, automatic joint finding, backscattered electron imaging, automatic focus, alignment and stigmator adjustment, high-speed data capture, beam probes and QA reporting. At the heart of the system is CVE’s fully integrated HMI – find out more about our advanced features and options.

If you are not sure which system is right for your application, please get in touch! Our machines are built and manufactured at our Cambridge Headquarters. With 60-years of process know-how in providing turn-key solutions, we can find the right solution for your application.

CVE operates a Quality Management System that complies with the requirements of BS EN ISO 9001:2015 and all CVE welding machines are tested in accordance with BS EN ISO 14744 Parts 1-6: Acceptance Inspection of Electron Beam Welding Machines.

An Introduction to Laser Welding

Laser welding (LW) is a welding process that uses a high-power density laser beam to join two materials together, creating a deep, narrow weld.

 

How Does Laser Welding Work?

LW is a technique that is known for its versatility and high productivity, especially for thin section materials, and for welding at high speeds.

Compared to other welding techniques, such as MIG and TIG, LW has relatively low heat input overall, resulting in low distortion, excellent mechanical properties, and minimal post-weld machining.

CVE has completed a thorough programme of development work over the past few years, developing systems for welding in a protective atmosphere, in a vacuum chamber and with a local vacuum.

CVE
Vacuum

Conventional laser takes place at atmospheric pressure, with additional shielding gas. However, you can laser weld in a vacuum, which significantly increases the depth of the weld.

 

Component size

LW with a shielding gas can accommodate any component size, as there is no vacuum chamber. Furthermore, you can use fibre optic delivery systems. This allows the welding head to be remote from the power source.

 

Automated Process

Machines can be highly automated with high production rates, in addition to there being no waiting time for chamber evacuation. Beam splitting and beam sharing are also possible.

CVE
Weld Characteristics

The process presents the following characteristics:

  • Deep, narrow weld
  • Excellent mechanical properties
  • High speed, high productivity
  • Low distortion
  • Minimal post-weld machining
  • Suitable for thin section materials

 

CVE's Laser Welding Machines

Please find our full range of machine models below.

CVE has completed a thorough programme of development work over the past few years surrounding laser, developing systems for welding in a protective atmosphere, in a vacuum chamber and with a local vacuum.

If you are not sure which system is right for your application, please get in touch! Our machines are built-to-order and manufactured at our Cambridge Headquarters. With 60-years of process know-how in providing turn-key solutions, we find the right solution for your application.

CVE operates a Quality Management System that complies with the requirements of BS EN ISO 9001:2015.

GET IN TOUCH

If you’d like to know more about our products or would like to speak to one of our team, then please get in touch. We look forward to hearing from you!