ELECTRON- BEAM WELDING IN VACUUM ELA-6, ELA -30V, ELA -60V, ELA -120 ELECTRON-BEAM WELDING EQUIPMENT Single pass welding of metals and of different thickness from 0,1 up to 400 mm in vacuum.
ELECTRON-BEAM WELDING EQUIPMENT of JSC SELMI production, allows single pass welding of metals and of different thickness from 0,1 up to 400 mm in vacuum. The instrument is equipped with: - beam sweep system; - system of beam guidance on the joints of welded parts; - double refraction system; - system, which eliminates defects due to discharges in the gun. Small dimensions and electron gun weight allows installing it on robotic manipulator inside the chamber. Accesssible price and high reliability make it quite competitive on the world market. JSC SELMI has a wide experience and the following technologies, used in manufacturing: - manufacture of ceramics and glass assemblies and parts; - soldering of assemblies in vacuum and in the reducing medium; - high-accuracy mechanical manufacture of parts and assemblies; - using of different electroplating, including precious metals; - sheet-metal stamping; - manufacture of printed circuit boards and assemblies on their basis using soldering with solder wave - manufacture of high-voltage assemblies using compounds; - manufacture of transformers of different type, including turned-core transformers; - manufacture of rubber and plasstic parts; - adjustment and alignment of electron-optical systems. JSC SELMI (Sumy, Ukraine) is an owner of intellectual rights on the electron-beam equipment. Welding unit ELA with vacuum chamber 0,25 m 3 Welding unit ELA with vacuum chamber 1,7 m 3 Technical data of universal welding instruments with vacuum chamber volume 0,25 m 3 and 1,7 m 3 Chamber type 0,25 1,7 Volume, m³ 0,25 1,7 Lenght x width x height, m х m х m 0,6 х 0,6 х 0,7 1,2 х 1,2 х 1,2 Moving along X-axis, mm 300 600 Moving along Y-axis, mm 150 400 Moving speed range, mm/s 0,5 40 0,5 40 Positioning accuracy, mm ± 0,1 ± 0,15 Rotation device: rotation speed, rmp 0,1 15 0,1 15 faceplate diameter, mm 300 600 Maximum part weight, kg 100 500 Complete electron-beam equipment with power, kw 6, 30 30, 60 2
WELDING UNITS FOR ELECTRON-BEAM TECHNOLOGIES Welding units for electron-beam technologies include: Electron-beam equipment; Vacuum chamber of frame type; Vacuum system; Part moving table X, Y; Rotation device with vertical and horisontal axis; Gun displacement device; Drive controllers; Industrial construction computer; Videocamera CCD. Door with X, Y positioners runs out and in with the help of electromechanical drive. Run-in time is 1 min. Sound and light signal system works during the door running in and out for safety. The following service lines go through the door: - control fo drives X, Y and rotation drive; - camber lighting device (two halogen lamps); - water feed. Visual examination system: - glass window with the diameter 200 mm; - CCD camera. Manipulator made on the basis of STAR precision modules (Germany): - positioning accuracy 0,01 mm. Servodrive AC with INDRAMAT control modules. Technical characteristics of electron-beam equipment with the power 6, 30, 60, 120 kw PARAMETERS ELA-6 ELA -30V ELA -60V ELA -120 Maximum beam power, kw 6 30 60 120 Accelerating voltage, kv 60 60 60 120 Range of welding current control, ma 0,1 100 1 500 1 1000 1 1000 Accelerating voltage stability, % ± 0,5 ± 0,5 ± 0,5 ± 0,5 Welding current stability, % ± 0,5 ± 0,5 ± 0,5 ± 0,5 Angle of beam deflection ± 7 ± 7 ± 7 ± 7 Time of welding current increase at the beginning according to the specified program, s 1 8 1 8 1 8 1 8 Time of welding current and focusing altering at the end of welding, s 2 140 2 140 2 140 2 140 Gun vacuum valve response time, s 2 10 10 10 Beam sweep frequency, Hz 800 ± 50 800 ± 50 800 ± 50 800 ± 50 Gun-to-work distance, mm 50 450 100 500 100 500 100 500 Consumed power, kva 10 57 90 220 Cooling water: pressure, Mpa 0,3 0,4 0,3 0,4 0,3 0,4 0,3 0,4 flow rate, l/min 25 25 25 25 Equipment weight, kg 1400 2700 3000 6000 Computer control yes yes yes yes Complete set Overall dimensions, mm ELA-6 ELA -30V ELA -60V ELA -120 Electron gun 205 х 290 х 550 205 х 290 х 550 205 х 290 х 550 205 х 290 х 550 High-voltage source I 857 х 963 х 866 1180 х 1218 х 1340 1064 х 1372 х 1355 1350х1064х1388 High-voltage source II 1294х1270х1388 Voltage control unit 660 х 862 х 1414 660 х 862 х 1502 1034х1572х1480 Control panel 200 х 200 х 100 480 х 150 х 360 480 х 150 х 360 480 х 150 х 360 Power cabinet 650 х 850 х 1600 554 х 570 х 1408 554 х 570 х 1408 554х570х1648 Current limiter I 440 х 690 х 780 440 х 690 х 780 440 х 690 х 780 Current limiter II 440 х 690 х 780 Control unit 650 х 850 х 1600 800 х 1200 х 1230 800 х 1200 х 1230 800х1200х1230 3
SINGLE PASS WELDING OF HOMOGENEOUS AND HETEROGENEOUS METALS OF DIFFERENT THICKNESS IN VACUUM AREAS OF APPLICATION Obtaining of high-strength, vacuum tight welds in: aircraft industry (turbines, fuselage and wings elements, chassis); aerospace equipment (engines, rocket airframes, shuttle bodies); shipbuilding (turbines, ship hulls, screw propellers); power engineering industry (turbines, nuclear reactor usemblies); motor industry and agricultural machinery industry (gears, shafts, wheel bosses). FEATURES high-speed system of weld protection from gun break-down; high weld quality and repeatability of welding process; gun can be installed on a robotic manipulator. STABLE PARAMETERS AND HIGH SPECIFIC POWER OF THE BEAM (7,5 10 6 W/sm 2 ) GUARANTEE WELDING QUALITY, DEEP PENETRATION AT A SINGLE PASS AT HIGH WELDING SPEED, SAVING OF MATERIALS, POWER AND LABOUR Thickness, mm Materials ELA-6 ELA-30V ELA-60V ELA-120 Weld depth-towidth ratio Carbon steels 10 75 100 200 15-20 Austenitic steels and 15 90 120 250 15-20 Titanium and its 20 110 150 300 15-20 Aluminium based 25 150 200 400 30 4
ELCTRON-BEAM EQUIPMENT IS A RESULT OF AN EFFECTIVE TEAM WORK OF PATON ELECTRON WELDING INSTITUTE (Kiev) AND JSC SELMI (Sumy) HIGH QUALITY WELDS AND RELIABLE PERFORMANCE ARE PROVIDED BY THE HIGH VOLTAGE UNIT In the electron guns for welding in vacuum high voltage 60 or 120 kv is applied to a small interval between cathode, venelt and anode. Gun break-down may occure in case of ingress of metal vapours and ions from weldpool into cathode gun area during welding. SPECIAL ELECTRON TUBE IN THE HIGH-VOLTAGE CIRCUIT ENABLES: to prevent spark discharges from transition into arc discharges; to eliminate weld defects caused by gun discharges; to decrease average beam current down to several tens of ma in the load short-circuit mode; to ensure quick response of the stabilizer, high stability, small electron beam pulsations. 5