Details
| Original language | English |
|---|---|
| Pages (from-to) | 272-281 |
| Number of pages | 10 |
| Journal | Welding and Cutting |
| Issue number | 4 |
| Publication status | Published - 2022 |
Abstract
The electron beam welding process in the atmosphere is characterised by a high process speed as well as an energy input that is independent of the material, surface properties and angle of incidence with minimal distortion. In addition, the atmospheric process offers the advantage over the vacuum process that the process is not bound to a vacuum work chamber and the beam offers good gap bridge ability due to the higher scattering in the atmosphere and enables reliable melting of the welding wire. In contrast, systems with voltages of up to 175 kV are operated to accelerate the electrons. The resulting kinetic energy is largely converted into heat when the electrons hit the work piece surface. The deceleration of the electrons also causes X-rays to be emitted. This results in high demands on X-ray protection. A reduction of the acceleration voltage minimises the necessary radiation protection and improves the flashover safety in the generator, even when processing easily vaporisable materials. At the same time, the potential of a narrower design of the beam generator, which results in a significant weight reduction compared to conventional electron beam technology and thus enables robotic use, is very high. In the triode system with 60 kV acceleration voltage, the electron velocity is sufficient to provide the necessary energy density at the joint (soldering and welding with filler material). In the investigations on which the article is based, a process window was worked out for the joining of aluminium in the thin sheet range, process-related proper-ties were identified and compared with those of high-voltage technology. For this purpose, metallographic and mechanical investigations were carried out and the previously determined parameter windows were transferred to the joining of aluminium alloys susceptible to hot cracking in I-joining.
Keywords
- aluminium, aluminium alloys, electron beam welding, material questions
ASJC Scopus subject areas
- Engineering(all)
- Mechanics of Materials
- Engineering(all)
- Mechanical Engineering
- Materials Science(all)
- Metals and Alloys
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In: Welding and Cutting, No. 4, 2022, p. 272-281.
Research output: Contribution to journal › Article › Transfer › peer review
}
TY - JOUR
T1 - Electron beam welding and brazing in atmosphere with reduced accelerating voltage on aluminium alloys susceptible to hot cracking
AU - Senger, Aleksej
AU - Klimov, Georgii
AU - Beniyasch, Alexander
AU - Hassel, Thomas
AU - Olschok, Simon
N1 - Funding Information: The IGF Project number 19.435 N/DVS number 06.114 of the research association ”Forschungsvereinigung Schweißen und verwandte Verfahren e. V. des DVS, Aachener Str. 172, 40223 Düsseldorf” was, on the basis of a resolution of the German Bundestag, promoted by the German Ministry of Economic Affairs and Energy via the Federation of Industrial Research As-sociations (AiF) within the framework of the programme for the promotion of joint industrial research (IGF).
PY - 2022
Y1 - 2022
N2 - The electron beam welding process in the atmosphere is characterised by a high process speed as well as an energy input that is independent of the material, surface properties and angle of incidence with minimal distortion. In addition, the atmospheric process offers the advantage over the vacuum process that the process is not bound to a vacuum work chamber and the beam offers good gap bridge ability due to the higher scattering in the atmosphere and enables reliable melting of the welding wire. In contrast, systems with voltages of up to 175 kV are operated to accelerate the electrons. The resulting kinetic energy is largely converted into heat when the electrons hit the work piece surface. The deceleration of the electrons also causes X-rays to be emitted. This results in high demands on X-ray protection. A reduction of the acceleration voltage minimises the necessary radiation protection and improves the flashover safety in the generator, even when processing easily vaporisable materials. At the same time, the potential of a narrower design of the beam generator, which results in a significant weight reduction compared to conventional electron beam technology and thus enables robotic use, is very high. In the triode system with 60 kV acceleration voltage, the electron velocity is sufficient to provide the necessary energy density at the joint (soldering and welding with filler material). In the investigations on which the article is based, a process window was worked out for the joining of aluminium in the thin sheet range, process-related proper-ties were identified and compared with those of high-voltage technology. For this purpose, metallographic and mechanical investigations were carried out and the previously determined parameter windows were transferred to the joining of aluminium alloys susceptible to hot cracking in I-joining.
AB - The electron beam welding process in the atmosphere is characterised by a high process speed as well as an energy input that is independent of the material, surface properties and angle of incidence with minimal distortion. In addition, the atmospheric process offers the advantage over the vacuum process that the process is not bound to a vacuum work chamber and the beam offers good gap bridge ability due to the higher scattering in the atmosphere and enables reliable melting of the welding wire. In contrast, systems with voltages of up to 175 kV are operated to accelerate the electrons. The resulting kinetic energy is largely converted into heat when the electrons hit the work piece surface. The deceleration of the electrons also causes X-rays to be emitted. This results in high demands on X-ray protection. A reduction of the acceleration voltage minimises the necessary radiation protection and improves the flashover safety in the generator, even when processing easily vaporisable materials. At the same time, the potential of a narrower design of the beam generator, which results in a significant weight reduction compared to conventional electron beam technology and thus enables robotic use, is very high. In the triode system with 60 kV acceleration voltage, the electron velocity is sufficient to provide the necessary energy density at the joint (soldering and welding with filler material). In the investigations on which the article is based, a process window was worked out for the joining of aluminium in the thin sheet range, process-related proper-ties were identified and compared with those of high-voltage technology. For this purpose, metallographic and mechanical investigations were carried out and the previously determined parameter windows were transferred to the joining of aluminium alloys susceptible to hot cracking in I-joining.
KW - aluminium
KW - aluminium alloys
KW - electron beam welding
KW - material questions
UR - http://www.scopus.com/inward/record.url?scp=85144525035&partnerID=8YFLogxK
U2 - 10.53192/WAC202204272
DO - 10.53192/WAC202204272
M3 - Article
AN - SCOPUS:85144525035
SP - 272
EP - 281
JO - Welding and Cutting
JF - Welding and Cutting
SN - 1612-3433
IS - 4
ER -