Electron Beam Welding

We are the Industry Leader for Electron Beam Welding

When your application requires an ultra-precise, clean, and strong weld, electron beam welding is your ideal choice. it is capable of achieving deep penetrations with minimal heat-affected zones and shrinkage vs other welding technologies, and excels in joining hard-to-weld or dissimilar metals. With hundreds of clients around the globe, we have delivered custom solutions to innumerable projects – all with highly demanding timelines.

  • Fast, High Quality Results

    We do everything in-house with superior quality control practices for the highest level of speed and accuracy.

  • Customer-Centric Approach

    Our entire team is dedicated to unmatched quality of service from start to finish.

  • Lean Practices

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

  • Large Privately-Owned Facility

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

Our Capabilities

EB Dept

  • 15 state-of-the-art EBW machines, up to 25KW power and up to 8 axis CNC motion and beam controls
  • Chamber sizes ranging from 23” W x 24” H x 28” L up to 60” W x 72” H x 108” L
  • Controls have been standardized for greater flexibility
  • Welding can be performed on parts ranging from a few thousandths up to several inches
  • Our largest machine is 60”W x 72”H x 108”L
    • 25kW up to 2.5” depth of penetration
    • CNC and manual control capabilities
    • 2 ton overhead crane

Maintenance Dept

  • Equipment upgrades – Our state-of-the-art equipment is essential to our success. That’s why we continuously invest, year after year, upgrading and standardizing. We want to make sure our customers have the best, most reliable welding service possible.
  • Preventative maintenance – Using Lean Principles we have put together an extensive PM program which has considerably increased our equipment reliability. This has resulted in improved “beam on” times ensuring we meet or exceed our promised delivery dates.

Quality Assurance – Nadcap Certified

  • Final inspection – Utilizing our “Best Practices” model, all in-process parts are inspected by the weld technician. All parts are then reviewed by a separate inspector. This redundancy is our way of ensuring that only the highest level of workmanship arrives at your door.
  • Met Lab – Pratt certified LCS Met lab provides us the opportunity to cross-section and verify that our welds meet the specification requirements the same day. Please note, that all initial qualifications do require us to send samples out to an independent lab.

Machine Shop

  • We have all the necessary CNC equipment to support our tooling and fixture commitments, new builds, modifications & repairs as needed.
  • We have Toolmakers on staff who can conceive, design, model and manufacture the most complex tools and fixtures needed to support our services.
  • Modifying customer details – there are occasions that component details do not fit together as intended, rather than sending parts back to our customer for re-work, we can modify them in-house, potentially saving days of lost schedule time.

How an Electron Beam Weld is Made

Formation of an Electron Beam

Electrons are generated in a vacuum enclosure by heating the cathode, a negatively charged emitter, to its thermionic emission temperature causing electrons to “boil off” the cathode. As the temperature is increased, more electrons are emitted from the cathode until a maximum emission level is reached. This cloud of electrons is shaped into a beam by an electrostatic field created by a negatively charged bias cup and a positively charged anode. The combination of all three of these components constitute an electron beam gun.


Control of the Electron Beam

Since electrons are charged particles, their direction of travel can be controlled by electromagnetic fields. When the accelerated beam of electrons emerge from the aperture in the anode, it begins to diverge because of mutual repulsion. An electromagnetic coil is used to re-focus the beam of electrons, allowing the beam to be focused at any location beyond the plane of the focus coil. Deflection coils can be added to manipulate the beam to move in predetermined patterns. These parameters can be adjusted to optimize process stability and to accommodate joint fit-up, shrinkage, or cosmetic appearance.


Weld Formation

The high energy density of the focused beam vaporizes some of the material on which it impinges. A keyhole forms. As the beam traverses over the base metal, the material melts at the leading edge of the keyhole, flows around the keyhole, and solidifies at the trailing edge. The formation of the keyhole provides high power density EBW with the unique capability to produce deep, narrow welds and narrow heat-affected zones resulting in minimized distortion of weldments. This type of energy transfer is referred to as keyhole mode welding.

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