Competitive solutions for joining technology

Transcription

1 Competitive solutions for joining technology DVS-up to date: Electron beam welding Research... Technology... Education...

2 Content Competitive solutions for joining technology Electron beam welding Overview 3 Research 7 Research Association on Welding and Allied Processes of DVS Expert Committee 6, Beam Processes Technology 10 Technical Committee Working Group V 9.1, Electron Beam Welding IIW - International Institute of Welding Commission IV, Power Beam Processes Education 13 Education Committee Expert Group 4.7, Laser and Electron Beam Welding Technical Committee Working Group V 9.3, Training for Beam Welding DVS courses Events International Electron Beam Welding Conference (2009, 2011) oder Contact: Dipl.-Ing. Christoph Eßer-Ayertey Tel.: 0211/ Fax: christoph.esser@dvs-hg.de Publisher: DVS Deutscher Verband für Schweißen und verwandte Verfahren e.v. Aachener Str Düsseldorf Credits for illustrations: FEZ; Fügetechnisches Exzellenzzentrum ISF der RWTH Aachen ZAT des Forschungszentrum Jülich pro-beam PTR-Präzisionstechnik GmbH Steigerwald Strahltechnik GmbH Focus GmbH 2

3 Overview The electron beam - A proven tool for the future The electron beam can be used in the most diverse ways as a tool in research and development as well as in large technical applications. From the electron microscope for the representation of the microcosmos, the exposure of food to radiation and as a tool in radiotherapy right up to the single-layer welding of thick-walled components with wall thicknesses up to over 200 mm, the electron beam can always be utilised profitably with unique properties. Since it was first used in welding technology in the 50s of the last century, the electron beam has faced up to constantly new challenges and market situations until today. In welding technology, it is predominantly used in vacuum chambers and is capable of welding nearly all metallically conductive joining members. However, applications in atmosphere are also possible and technically established. Particularly microjoining, the processing of special materials such as high-purity refractory metals and the single-layer welding of the thickest cross-sections will be domains of the electron beam in future too. Its unique manipulability, the high available beam power in combination with the very good energy input into the workpiece and the very high energy-related efficiency are constantly opening up new application fields to the electron beam. Aerospace, energy plant engineering and heavy mechanical engineering are just a few sectors in which the advantages of the electron beam are recognised anew time and again and where this is then a yardstick for further developments and innovations as a bearer of technology. The competitive situation has become more diverse. New laser beam types achieve good efficiencies and deep-penetration welding effects in almost comparable dimensions. The requirements on modern beam welding technology have become much more stringent. In future, the electron beam will have to be able to process thicknesses from just a few nanometres right up to weld depths over 100 mm. Another factor relates to materials science requirements for which the vacuum in the electron beam welding process serves as the ideal shielding atmosphere. In future as well, the limitless deflection possibilities and its unique beam quality will make the electron beam a joining tool which will offer the very highest quality but will be able to shine in mass fabrication too. Not only a wide variety of development steps such as the beam jump technique and electron-optical observation possibilities but also the application of the electron beam in the large chamber in cycle and lock machines as well as in atmosphere are generating new stimuli and fabrication possibilities with the electron beam. DVS and, in particular, DVS Working Group V 9.1 as the expert body in Germany have set themselves the tasks of accompanying the development of the electron beam with instructions, technical bulletins and standards and of thus making its application accessible to a wide circle of specialists in welding technology. 3 Jülich, February 2009 Dr.-Ing. Wilfried Behr, Forschungszentrum Jülich GmbH Chairman of AG V 9.1, Electron Beam Welding 3

4 Overview Advantages of the electron beam The electron beam offers diverse application possibilities. These include not only the joining of metallic materials by means of welding but also, just as much, the treatment and hardening of surfaces or electron beam drilling as well. - steel plate with a thickness of 200 mm can be welded in one passage with a feed of 1.25 mm/s (13.3 minutes for a weld length of one metre) The main areas of application are: Three-pool technique for the welding of a switch wheel Single-layer deep-penetration weld in steel Welding Electron beam (EB) welding in a vacuum offers a number of advantages since the high power density of the electron beam permits welds which are narrower than the average, heat-affected zones with tight limits and without any temper colours, great welding depths and high welding speeds. The exact reproducibility of the welds gives the user the guarantee of a constant quality. It is also possible to carry out simultaneous welding at several points on a suitable workpiece. In this respect, the quick deflection system guides the beam from one welding position to the next within fractions of a second and the beam continues the welding there before the vapour cavity collapses at this point. The workpiece can also be preheated parallel to the welding. Deep-penetration welding - particularly slender, deep welds - almost all material combinations possible 4 Maximum productivity due to multipool technique - up to ten welds produced simultaneously - minimised distortion due to low energy per unit length - welding time shortened by two thirds - no need for expensive clamping technology or tackwelds High welding speed - in the case of thin foils, up to 60 m/min (1,000 mm/s) - typical welding speeds between 10 mm/s and 100 mm/s for weld-penetration depths between 20 mm and 2 mm Deep-penetration weld: Material combination: bronze/steel (30 mm) 4

5 Overview Drilling When a laser beam is utilised as a drilling tool, it needs several energy pulses per hole in order to penetrate into the depth of the material to be drilled. In contrast, one hole can be produced per one beam pulse with the electron beam. For processing purposes, the workpiece is inserted into a vacuum chamber in this case and is perforated with short, very bundled electron pulses with a high power. The strengths are to be found wherever conventional methods reach their limits or become extremely slow. possible to alter not only the type, distribution and quantity proportions of phases but also residual stress conditions of materials. In the case of electron beam hardening and annealing, energy is transferred to the material surface on an area of up to 100 x 100 mm and is processed in a track shape. 3 Strengths of EB drilling - high economic viability with a high number of holes - fabrication of sieves with very small hole diameters, very high numbers of holes or with very deep boreholes Hardening, annealing and optimisation of material properties A thermal treatment with the electron beam may influence the structure and certain material properties of peripheral layers of metallic materials. Due to targeted heating, it is Spinning head for the production of glass fibres (EB drilling) High reproducibility Welding of materials afflicted by oxide coats (Mg or Al) High-quality welded joints Precision welding Material combinations Heavy plate application Welding of reactive materials (titanium or niobium) Examples of applications in welding technology 5

6 Overview Areas of application of electron beam welding The installation types for electron beam welding extend from large-chamber installations with chamber sizes over 55 m3 right down to small installations for microsystems technology. For special tasks, custom-built installations are also designed according to the requirements. The great advantages of production installations such as continuous installations, lock cycle installations etc. are to be found in the fact that the machine-bound non-productive times are minimised by the specialisation and that the economic advantages of the electron beam technology are thus exploited to the full. 3 The main area of application of chamber machines is the individual processing of larger workpieces with complex weld geometries, Steigerwald Strahltechnik GmbH Custom-built machine for the welding of truck axles, PTR-Präzisionstechnik GmbH Small installation for microsystems technology, Focus GmbH Large-chamber installation, pro-beam 6

7 The Research Association on Welding and Allied Processes of DVS Research The core activity of the Research Association on Welding and Allied Processes of DVS is the cooperative industrial research (IGF) in which companies, corporate bodies and research institutes from the various fields of joining technology actively take part. The Research Association is divided into 13 expert committees (FAs) with specific subject-related main focal points. The companies agree upon the need for cooperative research and define main focal points for pioneering research which the research institutes involved convert into concrete research projects without delay. The cooperative industrial research achieves optimum closeness to the application and permits the direct utilisation and implementation of the results. The collaboration of industry means that know-how is transferred at an early stage and that the research work and the utilisation of the results are parallelised. IGF research projects may be promoted from funds of the Federal Ministry of Economic Affairs and Technology (BMWi) via the Otto von Guericke Federation of Industrial Research Associations (AiF). 3 Further information at: 7

8 Research Expert Committee 6 Beam Processes FA 6 Strahlverfahren Chairman of the expert committee: Dr.-Ing. Ronald Holtz LASAG AG, Thun/Schweiz Vice-Chairman: Dr.-Ing. Johannes Weiser BBW Lasertechnik GmbH, Prutting Secretary: Dipl.-Ing. Christoph Eßer-Ayertey Tel.: Fax: christoph.esser@dvs-hg.de Website: Fundamental principles of the research planning The research work of FA 6 is closely coordinated with the work of AG V 9.1, Electron Beam Welding, and AG V 9.2, Laser Welding and Allied Laser Processes. If necessary, a joint colloquium is staged every year in order to guarantee the lively exchange of information between research institutes and industrial companies. The tasks of the Beam Processes expert committee are to evaluate newly developed and refined beam welding processes taking account of aspects relating to application technology and to accelerate the transfer of process innovations to small and mediumsized enterprises by means of supporting research activities. In this respect, special emphasis is placed not only on the development of processes but also on their simulation. The experience gathered in recent years shows that improvements in the handling, aids for simplification and process or application-specific optimisation measures for installation components, e.g. improved beam manipulation and output systems or processing lenses, frequently very quickly already lead to results which can be implemented in small and medium-sized enterprises (SMEs). One important way of helping SMEs is to indicate sensible process and application limits within the framework of projects. Apart from the process technology, consideration must be given to the particular behaviour of the materials during the processing by means of beam technology with little heat at high cooling rates. For this purpose, the peculiarities of the socalled short-time metallurgy are taken into account, as are the mechanical-technological material properties caused by this. Even at an early development stage, new developments in the electron beam technology as well as material developments should already be accompanied by fundamental and technological investigations. Research fields The possibilities of joining material combinations should be investigated to a greater extent in future since there is high potential for requirements in nearly all branches of industry and production innovations may be expected from this. The research activities should continue to focus on combinations or couplings of beam processes with each other or with conventional joining technologies and thus on the extension of the areas of application of the beam technology. In this respect, the beam technology processes are regarded as main processes which are overlapped by supporting tools, e.g. the arc. The simulation of the processes and of the material behaviour is an additional essential area of research. Thus, exceptionally high significance is still attached to work in order to improve the process monitoring and management and thus to the improvement in the productionrelevant assurance of the reproducibility and process reliability of beam processes since these frequently constitute one of the most important criteria for the application of beam technology in industry. 3 8

9 Research Ongoing/concluded research projects Ongoing research projects Design and control of the weld sag in the case of beam welding DVS no.: / IGF no.: N Start: End: Prof. Dr. habil. Thomas Graf, Universität Stuttgart Institut für Strahlwerkzeuge, IFSW, Stuttgart Qualification and optimisation of out-of-position joining with the electron beam DVS no.: / IGF no.: N Start: End: Univ.-Prof. Dr.-Ing. U. Reisgen, RWTH Aachen Institut für Schweißtechnik und Fügetechnik Influence of the degree of forming (work hardening) on the weldability and brazability of coated sheets with Rp >= 800 N/mm2 DVS no.: / IGF no.: N Start: End: Dipl.-Ing. Franz Zech, SLV München, Niederlassung der GSI mbh Concluded research projects Investigations into the joining of dissimilar metallic material combinations using beam welding technology DVS no.: / AiF no.: N Univ.-Prof. Dr.-Ing. U. Reisgen, RWTH Aachen Institut für Schweißtechnik und Fügetechnik Development of a measuring procedure for the diagnostics of the electron beam in atmosphere DVS no.: / AiF no.: N Univ.-Prof. Dr.-Ing. U. Reisgen, RWTH Aachen Institut für Schweißtechnik und Fügetechnik Qualification of electron beam processes in order to improve the wear and corrosion resistance of light metal materials (magnesium alloys) DVS no.: / AiF no.: B Prof. Dr.-Ing. habil. B. Wielage, TU Chemnitz Lehrstuhl für Verbundwerkstoffe, Prof. Dr.-Ing. V. Wesling, TU Clausthal Institut für Schweißtechnik und Trennende Fertigungsverfahren Weld configuration and material reactions during the electron beam welding of Al materials in atmosphere DVS no.: / AiF no.: N Prof. Dr.-Ing. V. Wesling, TU Clausthal Institut für Schweißtechnik und Trennende Fertigungsverfahren, Univ.-Prof. Dr.-Ing. U. Reisgen, RWTH Aachen Institut für Schweißtechnik und Fügetechnik Electron beam welding with filler material using free-programmable deflection technology DVS no.: / AiF no.: B Dr.-Ing. M. Ströfer, SLV Halle GmbH Comparative investigations into the influence of highproductivity beam welding on the metallurgical properties of aluminium and magnesium alloys DVS no.: / AiF no.: N Prof. Dr.-Ing. V. Wesling, TU Clausthal Institut für Schweißtechnik und Trennende Fertigungsverfahren, Univ.-Prof. Dr.-Ing. U. Reisgen, RWTH Aachen Institut für Schweißtechnik und Fügetechnik Stress crack corrosion on beam welds in the case of unalloyed and low-alloyed structural steels DVS no.: / AiF no.: B Prof. Dr.-Ing. habil. K.-J. Matthes, TU Chemnitz Institut für Fertigungstechnik/Schweißtechnik 3 9

10 Technology Technical Committee (AfT) of DVS The technical-scientific cooperative work of DVS is predominantly determined by the activities of its Technical Committee (AfT) with its working bodies oriented to specific subjects. Specialists from the economic and scientific fields, from authorities and from other areas collaborate in them. The Technical Committee promotes the active exchange of experience amongst experts, describes the state of the art by elaborating and contributing to the preparation of a set of technical rules (DVS technical bulletins, technical codes, guidelines and standards) and is actively involved in the technical development of welding and the allied processes such as brazing/soldering, thermal spraying, adhesive bonding, mechanical joining and plastics joining. Joint committees with the Standards Committee for Welding Technology of DIN also exist for this purpose. 3 Further information at: Joint Committee DVS / DIN AG V 9.1 / NA AA, Electron Beam Welding Chairman: Dr.-Ing. Wilfried Behr Forschungszentrum Jülich GmbH Vice-Chairman: Kurt Leeb Steigerwald Strahltechnik GmbH Secretary: Dipl.-Ing. Christoph Eßer-Ayertey Tel / FAX: 0211 / christoph.esser@dvs-hg.de Website: In the joint DIN/DVS committee, Electron Beam Welding, more than 30 specialists from industry and from research and development facilities elaborate DVS technical bulletins, technical codes and guidelines, national and international standards and other sets of rules. In this respect, the activities of the experts concentrate on indications, rules and regulations for the application of electron beam welding taking particular account of its unique properties. The potential for material processing with the electron beam in high and fine vacuums as well as in atmosphere is indicated taking the latest state of the art into consideration. Additional working fields are the continuous updating of terms for electron beam welding, the elaboration of rules for the acceptance testing of electron beam processing machines and the quality assurance in the electron beam technology sector. 3 10

11 Technology Essential work results DVS technical bulletins and technical codes DVS 3209, Efficiencies in the case of electron beam and laser welding Published in: June 2007 DVS 3212, Peripheral coat hardening with the electron beam Published in: July 2007 DVS 3220, Fundamental principles for the utilisation of electron beam welding in atmosphere Technological and design-related indications Published in: July 2007 DVS 3202, Controllers of electron beam welding installations Published in: April 2004 Standards (selection) DIN ( ) Welding - Electron beam process for material treatment - Terms for processes and equipment DIN EN ( ) Welding - Recommendations for welding of metallic materials - Part 7: Electron beam welding; German version EN :2004 DIN EN ISO Teil 1-2 ( bis ) Welding - Electrons and laser beam welded joints; guidance on quality levels for imperfections (ISO :1996); German version EN ISO :1996, (ISO :2001); German version EN ISO :2001 DVS 3201, Fundamental principles for the designing of components for electron beam welding in fine and high vacuums Published in: October 2001 DVS 3213, Recommendations for the cleaning of weld grooves for electron beam welding Published in: October 1998 DVS 3205, Protection against X-rays from electron beam machines for material processing Published in: February 1993 DVS 3204, Electron beam weldability of metallic materials Published in: June 1988 DVS 2803, Electron beam welding in microtechnology (overview) Published in: December DIN EN ISO Teil 1-6 ( bis ) Welding - Acceptance inspection of electron beam welding machines DIN EN ISO ( ) Specification and qualification of welding procedures for metallic materials - Welding procedure specification - Part 3: Electron beam welding (ISO :2004); German version EN ISO :2004 DIN EN ISO ( ) Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 11: Electron and laser beam welding (ISO :2002); German version EN ISO : Specialist books Series of Specialist Books on Welding Technology, Volume 93 Electron beam welding Published in: 2000 Welding Technology Research Reports, Volume 27 Contribution to the electron beam welding of thick plates in the vertical beam position with a modified weld geometry Published in: 1989 The specified publications can be purchased via DVS Media GmbH: DVS Media GmbH Aachener Straße 172 D Düsseldorf Tel.: 0211 / media@dvs-hg.de 11

12 Technology 1. International Electron Beam Welding Conference (IEBW) The American Welding Society (AWS), DVS and the International Institute of Welding (IIW) are organising the first International Electron Beam Welding Conference in Chicago/ USA on November 17 and 18, The conference will be held in conjunction with the Fabtech International and AWS Welding Show. It will encompass not only the twoday technical programme but also a half-day tutorial which will be sponsored by the pro-beam foundation. The event will receive further support from the Japan Welding Society. The staging of the conference in a two-year rhythm is to be continued. In 2011, the conference will take place in Germany. Subjects: tor (aerospace, motor vehicles and transport, shipbuilding and rail traffic) technology, electrotechnology and medical technology nology, petrochemistry and chemical plant engineering technology 3 Student and tutorial sponsor: Endorsing sponsor: You can obtain further information from the Internet at or from DVS, Aachener Straße 172, Düsseldorf, Christoph Eßer-Ayertey, telephone: 0211 / , christoph.esser@dvs-hg.de. 12

13 Education Education Committee (AfB) Personnel qualification in DVS The Education Committee (AfB) of DVS elaborates and structures the range of training and further education offered by DVS in the fields of joining, cutting and coating. It follows tendencies and trends as well as concrete developments in the education sector and evaluates their effects on society in general and on the areas of joining, cutting and coating in particular. AfB is oriented to the latest state of the art and to the needs of the German economy. Due to the close network of DVS, the structures of the society are used optimally, the latest findings are exchanged across bodies and there is feedback about the current needs. DVS thus offers the expert world of joining technology, members and interested people a comprehensive range of competitive solutions for joining technology. 3 Further information at: Working Group V 9.3, Training for Beam Welding Expert Group 4.7, Laser and Electron Beam Welding Chairman: Dipl.-Ing. Klaus G. Hänsel Vice-Chairman: Dipl.-Phys. Henry Orlick Secretary: Dipl.-Ing. Christoph Eßer-Ayertey Tel.: Fax: christoph.esser@dvs-hg.de Website: In close cooperation with the Education Committee (AfB), Expert Group 4.7, Laser and Electron Beam Welding, Working Group V 9.3 is geared to the needs of the economy when it elaborates the training guidelines of DVS. Another main focal point is to represent the German interests in the corresponding bodies of EWF (European Federation for Welding, Joining and Cutting) and IIW (International Institute of Welding). The working group is very interested in suggestions in order to ensure that the DVS training guidelines for beam welding can be prepared close to practice. In 2009, the first DVS 1199 guideline, DVS course relating to training and further education for electron beam welding in the stages for engineers, technologists and specialists will probably emerge from the work of AG V 9.3. This course will offer fundamental training in electron beam welding technology, the prerequisite for people in monitoring, operations planning and scheduling, design, training, machine operation, maintenance, technical sales and customer support. The educational measures of DVS are taken in courses, e.g. according to DVS, DVS -EWF or DVS -IIW/ EWF guidelines, at educational facilities authorised by DVS ( 3 DVS information brochures As a new service, DVS is offering its members and all the interested people bundled technical information about various subject areas in joining technology with the portfolio of services from DVS. The information brochures prepared in two languages (German/English) include not only detailed explanations about the respective main focal points including a description of the development potential but also valuable explanations about the activities and available work results of DVS in the fields of research, technology and education. The brochures which have been published until now are available to you for downloading. Printed copies can be requested by (aft@dvs-hg.de). 13