Aerospace Electron Beam Welding Solutions

At Acceleron Inc., we deliver NADCAP and ITAR-certified aerospace electron beam welding for mission-critical components used in aviation, space, and defense systems. Our advanced EB welding technology produces narrow heat-affected zones, low distortion, and high repeatability, ensuring each weld meets the extreme precision demands of aerospace manufacturing.

Our experienced team, in-house tooling capabilities, and two-shift production allow us to support urgent schedules without compromising quality or documentation. Whether you need deep penetration welds on titanium housings or fine assemblies for satellite instruments, Acceleron provides the precision and control your projects require.

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Quality, Certifications, and Inspection

Acceleron’s commitment to aerospace quality is reflected in every weld we perform.

  • NADCAP Certified: Regularly audited to the highest aerospace standards.

  • ITAR Compliant: Secure handling of defense-related data and components.

  • Inspection Capabilities: CMM, X-ray, microscopy, and NDT available in-house.

  • Traceability: Detailed control plans and full documentation for every batch.

  • First Article Inspection (FAI): Ensures dimensional and process conformity for new projects.

Materials and Component Types

Acceleron supports a wide range of aerospace alloys and component geometries. Our experience covers everything from thin-walled housings and pressure vessels to satellite instruments and jet engine components.

Common Aerospace Alloys

  • Titanium alloys (e.g., Ti-6Al-4V)
  • Nickel-based superalloys (e.g., Inconel)
  • Aluminum alloys
  • Stainless steels
  • Specialty materials available upon request

Typical Joint Types and Ranges

  • Butt, lap, and fillet joints
  • Deep penetration welds with narrow HAZ
  • Thickness and penetration limits determined by part geometry and specifications

Our electron beam welding process maintains exceptional cleanliness, minimizing oxidation and contamination that can compromise aerospace components.

How Our Aerospace EB Welding Process Works

Vacuum Chamber and Beam Control

All welding takes place in a high-vacuum environment. This ensures consistent beam stability, clean welds, and elimination of impurities. Beam focus, travel speed, and power are precisely controlled for every project.

Keyhole Welding and Penetration

Electron beam welding operates in keyhole mode to achieve deep, narrow welds that reduce post-processing. This allows us to weld complex shapes with minimal rework and distortion.

Distortion Control and Repeatability

By combining precise fixturing, heat control, and parameter monitoring, we maintain geometric accuracy even on long seams and thin materials. Every job is engineered for consistency and repeatability.

Inspection and Documentation

Each aerospace weld undergoes inspection via coordinate measuring machines (CMM), X-ray imaging, and microscopy. First-article validations and control plans ensure full traceability from start to finish.

Why Choose Acceleron for Aerospace Welding

1. NADCAP & ITAR Compliant: We maintain full compliance with NADCAP and ITAR requirements. Our process documentation, traceability, and security controls align with the strict standards of aerospace and defense industries.

2. In-House Tooling and Fixtures: Our engineers design and manufacture all fixtures and tooling internally to maintain consistent repeatability, alignment, and throughput—critical for complex aerospace parts.

3. Precision Beam Control: We use finely tuned electron beam parameters that produce deep, narrow welds with minimal heat input, achieving excellent dimensional control and joint integrity.

4. Capacity and Speed: With two-shift operations and efficient scheduling, we offer rapid turnaround times while maintaining rigorous quality standards.

5. Audit-Ready Quality Assurance: Each weld is verified through CMM, X-ray, microscopy, and non-destructive testing (NDT). Our first-article approvals, control plans, and traceable documentation are audit-ready.

Old-fashioned values, integrity and unmatched workmanship

  • Large Privately-Owned Facility

    We have 2 buildings with over 45,000 sq ft of combined manufacturing space, and operate two shifts totaling more than 40 employees.

  • Precision & Accuracy

    We operate with precision compliance for mission critical projects; ITAR, NADCAP & MIL STD compliance.

  • Lean Practices

    Our initiatives all work towards increasing efficiency, improving quality and ensuring fast turnaround times for our customers.

Frequently Asked Questions

Q. What aerospace materials do you weld?
A. We commonly weld titanium, Inconel, stainless steel, and aluminum alloys. We also handle specialty materials upon request.

Q. Are you NADCAP and ITAR compliant?
A. Yes, Acceleron is fully compliant and audit-ready, with all required certifications for aerospace and defense applications.

Q. What tolerances can you maintain?
A. Tolerances depend on geometry and thickness but are typically within extremely tight aerospace specifications. Contact us for part-specific guidance.

Q. How do you manage distortion?
A. We design and manufacture custom fixtures, use vacuum heat control, and optimize beam parameters to minimize distortion during welding.

Q. What are your lead times?
A. Lead times vary by project complexity, but with two-shift production, we’re equipped to support expedited aerospace schedules.