Abstract
Material treatment using high-energy beams is an established process. In the field of welding, the most used processes are laser beam and vacuum electron beam welding. This paper describes the possibilities of the Non Vacuum Electron Beam Welding (NV-EBW) process. Fundamental investigations were made: beam power density measurements, Arata beam tests as well as penetration tests for aluminum alloy AlMg3, magnesium alloy AM50 and stainless steel X4CrNi18–10. Due to high achievable welding speeds (<20 m/min) and to the high automation grade, mainly sheet metal and aluminum alloys up to a thickness of 5 mm can be welded economically. Welding tests were made to check the applicability of the process to the welding of tailored blanks in AlMg3 and AlMgSi0.8 as well as to DC04 steel sheet. Furthermore it is possible to weld different materials and tailored blanks (tests were made on Mg alloys AZ31, AZ61, AZ91 and AM50) as well as flanged joints, plain butt joints, lap joints and fillet welds. For welding flanged joints, the process is characterized by a high gap bridging ability. The influence of linear misalignments and of gaps between the plates on the quality of edge welds was also investigated.
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