Abstract
Using a non-vacuum electron beam, a two-step process chain for plate materials is a feasible possibility. Cutting and welding can be performed in subsequent steps on the same machine for a highly productive process chain. The electron beam is a tool with high energy conversion efficiency, which is largely independent of the type of metal. Its high power density qualifies the non-vacuum electron beam as an outstanding energy source for the well-known NVEB welding as well as for high-speed cutting. Welding is possible with or without filler wire or shielding gas, depending on the application. The NVEB-cutting process employs a co-moving cutting head with a sliding seal for extremely high cutting speeds producing high quality edges. Due to direct removal of fumes and dust, NVEBC with local suction is an exceptionally clean and fast process. The NVEB welding process is possible directly after cutting, without further edge preparation. The potential directions of development of non-vacuum electron beam technologies are discussed. An exemplary two-step process chain using high-strength steel is presented to highlight possible application in industries such as general steel construction, automotive, shipbuilding, railway vehicle or crane construction. An analysis of the mechanical properties of the resulting weld seam is presented.
Highlights
IntroductionThe high efficiency of energy conversion of an electron beam makes it a valuable tool
The electron beam is a tool with high energy conversion efficiency, which is largely independent of the type of metal
The welding process at atmospheric conditions is known as non-vacuum electron beam welding (NVEBW)
Summary
The high efficiency of energy conversion of an electron beam makes it a valuable tool. The electron beam is routinely used for welding in vacuum, in low pressure and under atmospheric conditions [2]. The pressure difference across the process zone from atmospheric condition at the top of the plate and low vacuum at the bottom induces a flow of gas across the melt front that removes the molten material in a highly efficient manner. Further production steps such as marking or labelling and various methods of heat treatment can be performed with such a machine due to the accurate control of beam power and power density This enables the use of the NVEB technology as a tool to allow cutting, welding, marking and heat treatment on the same equipment with high efficiency and productivity [8]. The shown process combination of cutting and welding with NVEB can be utilized for other materials and other industrial applications as well, such as shipbuilding, railway vehicle manufacturing, automotive industry, steel building or electrical industry for materials such as standard and high-strength steels, aluminium and copper or copper alloys
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