A Process Model for Electron Beam Welding with Variable Thickness

2013 ◽  
Vol 762 ◽  
pp. 538-543
Author(s):  
Jiang Lin Huang ◽  
Jean Christophe Gebelin ◽  
Richard Turner ◽  
Roger C. Reed
Keyword(s):  
Electron Beam ◽  
Variable Thickness ◽  
Process Model ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Beam Power ◽  
Welding Parameters ◽  
Eb Welding ◽  
Experimental Calibration ◽  
Beam Focusing

A process model for electron beam (EB) welding with a variable thickness weld joint has been developed. Based on theoretical aspects and experimental calibration of electron beam focusing, welding parameters including beam power, focus current, working distance and welding speed were formulated in the heat source model. The model has been applied for the simulation of assembly of components in a gas turbine engine compressor. A series of metallographic weld sections with different welding thickness were investigated to validate the predicted thermal results. The workpieces were scanned both prior to-and after welding, using automated optical metrology (GOM scanning) in order to measure the distortion induced in the welding process. The measured result was compared with predicted displacement. This work demonstrates the attempts to improve the EB welding process modelling by connecting the heat input directly from the actual welding parameters, which could potentially reduce (or even remove) the need for weld bead calibrations from experimental observation.

scholarly journals Development of Welding P92 Pipes Using the Reduced Pressure Electron Beam Welding Process for a Study of Creep Performance

2014 ◽  
Author(s):  
Nick Bagshaw ◽  
Chris Punshon ◽  
John Rothwell
Keyword(s):  
Electron Beam ◽  
Heat Input ◽  
Power Plants ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Welding Parameters ◽  
Pipe Material ◽  
Reduced Pressure ◽  
Type Iv ◽  
Type Iv Cracking

Boiler and steam piping components in power plants are fabricated using creep strength enhanced ferritic (CSEF) steels, which often operate at temperatures above 550°C. Modification of alloy content within these steels has produced better creep performance and higher operating temperatures, which increases the process efficiency of power plants. The improved materials, however, are susceptible to type IV cracking at the welded regions. A better understanding of type IV cracking in these materials is required and is the basis of the Technology Strategy Board (TSB) UK funded VALID (Verified Approaches to Life Management & Improved Design of High Temperature Steels for Advanced Steam Plants) project. In order to study the relationship between creep performance and heat input during welding, several welds with varying amounts of heat input and resultant HAZ widths were produced using the electron beam welding process. The welding parameters were developed with the aid of weld process modeling using the finite element (FE) method, in which the welding parameters were optimized to produce low, medium and high heat input welds. In this paper, the modeling approach and the development of electron beam welds in ASTM A387 grade P92 pipe material are presented. Creep specimens were extracted from the welded pipes and testing is ongoing. The authors acknowledge the VALID project partners, contributors and funding body: Air Liquide, Metrode, Polysoude, E.ON New Build & Technology Ltd, UKE.ON, Doosan, Centrica Energy, SSE, Tenaris, TU Chemnitz, The University of Nottingham, The Open University and UK TSB. Paper published with permission.

scholarly journals Effect of Electron Beam Welding Parameters on Temperature and Stress Field of AISI P20 Tool Steel in Vacuum Roll-cladding Process

2021 ◽  
Author(s):  
lanyu mao ◽  
Zongan Luo ◽  
Yingying Feng ◽  
Xiaoming Zhang
Keyword(s):  
Electron Beam ◽  
Stress Field ◽  
Tool Steel ◽  
Welding Speed ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Welding Current ◽  
Temperature Fields ◽  
Welding Parameters ◽  
Aisi P20

Abstract Vacuum roll-cladding (VRC) is an effective method to produce high quality ultra-heavy AISI P20 plate steel. In the process of VRC, reasonable welding process of electron beam welding (EBW) can significantly avoid welding cracks and reduce the cost. In this paper, the electron beam welding process of AISI P20 tool steel was simulated by using a combined heat source model based on finite element method, and the temperature field and stress field under different welding parameters were studied respectively . The results showed that welding parameters have a greater effect on weld penetration than that of weld width, which making the aspect ratio increases with the increase of welding current, and decrease with the increase of welding speed. The weld morphologies were consistent with those of the modeling and the measured thermal heat curves were good agreement with those of simulated, which was verified the feasibility and effectiveness of temperature fields. The results of stress fields under different welding parameters indicat ed that lower welding speed and higher welding current resulting in lower residual stress at welded joint, which means lower risk of cracking after EBW. The results of this study have been successfully applied to industrial production.

Electron Beam Welding of Ti-24Al-17Nb-0.5Mo Alloy

2005 ◽  
Vol 475-479 ◽  
pp. 821-824
Author(s):  
J.Y. Zou ◽  
Yu You Cui ◽  
Rui Yang
Keyword(s):  
Electron Beam ◽  
Base Metal ◽  
Room Temperature ◽  
Electron Beam Welding ◽  
Welded Joint ◽  
Weld Zone ◽  
Welding Parameters ◽  
Eb Welding ◽  
Phase Combination ◽  
Postweld Heat

Electron beam (EB) welding of Ti-24Al-17Nb-0.5Mo (at.%) alloy and the effects of postweld heat treatments (PWHT) were studied. Through optimizing the welding parameters, defect-free welding joint was obtained. For the as-welded joint, the fusion zone (FZ) consisted of predominant β and occasional α2 within β grains. Microhardness of FZ was higher than that of the base metal (BM) and that of the heat affected zone (HAZ) was between that of BM and FZ. PWHTs greatly modified the microstructures and mechanical properties of the weld zone. PWHTs at both 820oC and 900oC yielded fine acicular laths in FZ leading to severe brittleness of the weld. Appropriate microstructures and phase combination were obtained by PWHT at 1000oC for 2 h, and room-temperature tensile strength reached the value of the base metal after the same thermal cycle.

Numerical Simulation on Electron Beam Welding Temperature Field of Al-Li Alloy

2011 ◽  
Vol 418-420 ◽  
pp. 1640-1646
Author(s):  
Shao Gang Wang ◽  
Kuang Yu ◽  
Li Xing
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Electron Beam ◽  
Heat Source ◽  
Welding Speed ◽  
Electron Beam Welding ◽  
Beam Power ◽  
Welding Parameters ◽  
Welding Temperature ◽  
Weld Width

The numerical simulation of electron beam welding temperature field for 2090 Al-Li alloy sheet of 2 mm thickness is conducted by using the ANSYS software. The combined model of Gauss surface heat source with cylindrical body heat source in linear attenuation is used according to the unique nail-shaped weld of electron beam welding joint, and the distribution cloud image of temperature field and the instantaneous weld thermal cycle curves of Al-Li alloy electron beam welding are obtained through calculation. The effect of welding parameters such as electron beam power and welding speed on the distribution of temperature field and weld width is investigated. Results show that electron beam welding has a very high rate of both temperature ascending and descending, and the rate of temperature ascending is higher than that of descending. With the increase of electron beam power or decrease of welding speed, the temperature of fusion zone elevates, and the weld width increases. The appearance of weld obtained through numerical simulation is greatly consistent with the practical welding.

Development of Electron Beam Welding Technology Using AA6061-T6 Aluminum Alloy for Nuclear Fuel Plate Assembly

2013 ◽  
Author(s):  
Soo-sung Kim ◽  
Don-bae Lee ◽  
Yoon-sang Lee ◽  
Jong-man Park
Keyword(s):  
Aluminum Alloy ◽  
Electron Beam ◽  
Nuclear Fuel ◽  
Cross Sections ◽  
Electron Beam Welding ◽  
Preliminary Investigation ◽  
Welding Process ◽  
Beam Current ◽  
Welding Parameters ◽  
Plate Assembly

This study was carried out to establish the electron beam welding process for a nuclear fuel plate assembly fabrication. A preliminary investigation for plate fuel fabrication was conducted with a consideration of weld performance using AA6061-T6 aluminum alloy made by the EBW (Electron Beam Welding) process. The optimum welding parameters for the fuel plate assembly were obtained in terms of the accelerating voltage, beam current and welding time. The welds made by the optimum parameters showed slightly lower tensile strengths than those of the un-welded specimens. The integrity of the welds by the EBW process was confirmed by the results of the tensile test, an examination of the macro-cross sections and the fracture surfaces of the welded specimens.

Investigation of Electron Beam Welding Characteristics Using AA6061-T6 for Nuclear Plate-Type Fuel Assembly

2014 ◽  
Author(s):  
Soo-sung Kim ◽  
Yong-jin Jeong ◽  
Jong-man Park ◽  
Yoon-sang Lee
Keyword(s):  
Electron Beam ◽  
Fuel Assembly ◽  
Cross Sections ◽  
Electron Beam Welding ◽  
Preliminary Investigation ◽  
Welding Process ◽  
Beam Current ◽  
Welding Parameters ◽  
Type Fuel ◽  
Plate Type

This study was carried out to establish an electron beam welding process for nuclear plate-type fuel assembly fabrication. A preliminary investigation for plate fuel fabrication was conducted with a consideration of the weld performance using AA6061-T6 aluminum alloy made through the EBW (Electron Beam Welding) process. The optimum welding parameters for the plate-type fuel assembly were obtained in terms of the accelerating voltage, beam current and welding time. The welds made by the optimum parameters showed slightly lower tensile strengths than those of the un-welded specimens. The integrity of the welds by the EBW process was confirmed by the results of the tensile test, an examination of the macro-cross sections and the fracture surfaces of the welded specimens.

Point-Cathode Electron Gun Using Electron-Beam Bombardment for Cathode Tip Heating

1990 ◽  
Vol 48 (1) ◽  
pp. 198-199
Author(s):  
Ryo Iiyoshi ◽  
Susumu Maruse ◽  
Hideo Takematsu
Keyword(s):  
Electron Beam ◽  
Tungsten Wire ◽  
Local Heating ◽  
Electron Gun ◽  
Original Position ◽  
Beam Power ◽  
Radius Of Curvature ◽  
High Brightness ◽  
Beam Focusing ◽  
Time Operation

Point cathode electron gun with high brightness and long cathode life has been developed. In this gun, a straightened tungsten wire is used as the point cathode, and the tip is locally heated to higher temperatures by electron beam bombardment. The high brightness operation and some findings on the local heating are presented.Gun construction is shown in Fig.l. Small heater assembly (annular electron gun: 5 keV, 1 mA) is set inside the Wehnelt electrode. The heater provides a disk-shaped bombarding electron beam focusing onto the cathode tip. The cathode is the tungsten wire of 0.1 mm in diameter. The tip temperature is raised to the melting point (3,650 K) at the beam power of 5 W, without any serious problem of secondary electrons for the gun operation. Figure 2 shows the cathode after a long time operation at high temperatures, or high brightnesses. Evaporation occurs at the tip, and the tip part retains a conical shape. The cathode can be used for a long period of time. The tip apex keeps the radius of curvature of 0.4 μm at 3,000 K and 0.3 μm at 3,200 K. The gun provides the stable beam up to the brightness of 6.4×106 A/cm2sr (3,150 K) at the accelerating voltage of 50 kV. At 3.4×l06 A/cm2sr (3,040 K), the tip recedes at a slow rate (26 μm/h), so that the effect can be offset by adjusting the Wehnelt bias voltage. The tip temperature is decreased as the tip moves out from the original position, but it can be kept at constant by increasing the bombarding beam power. This way of operation is possible for 10 h. A stepwise movement of the cathode is enough for the subsequent operation. Higher brightness operations with the rapid receding rates of the tip may be improved by a continuous movement of the wire cathode during the operations. Figure 3 shows the relation between the beam brightness, the tip receding rate by evaporation (αis the half-angle of the tip cone), and the cathode life per unit length, as a function of the cathode temperature. The working life of the point cathode is greatly improved by the local heating.

GRADIENT BOOSTING METHOD APPLICATION TO SUPPORT PROCESS DECISIONS IN THE ELECTRON-BEAM WELDING PROCESS

2020 ◽  
Vol 21 (2) ◽  
pp. 206-214
Author(s):  
V. S. Tynchenko ◽  
◽  
I. A. Golovenok ◽  
V. E. Petrenko ◽  
A. V. Milov ◽  
...  
Keyword(s):  
Electron Beam ◽  
Electron Beam Welding ◽  
Welding Process ◽  
Gradient Boosting ◽  
Boosting Method

scholarly journals Electron beam welding of rectangular copper wires applied in electrical drives

2021 ◽  
Author(s):  
Tamás Tóth ◽  
Jonas Hensel ◽  
Sven Thiemer ◽  
Philipp Sieber ◽  
Klaus Dilger
Keyword(s):  
Electron Beam ◽  
Oxygen Content ◽  
Electron Beam Welding ◽  
Base Material ◽  
Fusion Welding ◽  
Eb Welding ◽  
Technological Parameters ◽  
Low Level ◽  
Residual Oxygen ◽  
Ofe Copper

AbstractThe so-called hairpin winding technology, which is specially tailored to electrical traction components, deploys rectangular plug-in copper wires in the stator. The fusion welding of the adjacent wire ends is associated with challenges due to the high thermal conductivity as well as the porosity formation of the copper. During this study, the electron beam (EB) welding of electrolytic tough pitch (ETP) and oxygen-free electronic grade (OFE) copper connectors was investigated. Subsequently, the specimens underwent X-ray computed tomography (CT) and metallographic examinations to characterize the joints. It was discovered that the residual oxygen content of the base material is responsible for the pore formation. With only a very low level of oxygen content in the copper, a porosity- and spatter-free welding can be reproducibly realized using the robust EB welding technology, especially for copper materials. By optimizing the parameters accordingly, joints exhibiting a low level of porosity were achieved even in the case of the alloy containing a high amount of residual oxygen. Beyond this, detailed analyses in terms of pore distribution were carried out and a good correlation between technological parameters and welding results was determined.

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