A process chain using a non-vacuum electron beam as a universal tool for material processing

A process chain using a non-vacuum electron beam as a universal tool for material processing T. Hassel, N. Murray, A. Beniyash VIII. International Conference - Beam technologies and laser application St. Petersburg 2015 01.12.2015

Structure of the Institute of Materials Science Director: Chief engineer: Prof. Dr.-Ing. Hans Jürgen Maier Dr.-Ing. Florian Nürnberger Biomedical Engineering and Lightweight Construction Dipl.-Ing. Christian Klose Light metal technologies Alloy development Casting technology Forming technology Absorbable implants Brazing and Surface Technology Dr.-Ing. habil. Kai Möhwald Soldering, PVD, electroplating Thermal spraying Simulation, diagnostics, micro-systems Coating services Technology of Materials Dr.-Ing. Florian Nürnberger Steel metallurgy Heat treatment and simulation Microstructural analysis Mechanical testing Underwater Technology Center Hanover Dr.-Ing. Thomas Hassel Cutting and Welding technology Electron beam technology Water jet technology Corrosion and environmental testing Non-Destructive Testing Dr.-Ing. Wilfried Reimche Ultrasonic and electromagnetic testing procedures Vibration control and damage diagnostics Radiography and thermography Shared Facilities Dr.-Ing. Florian Nürnberger Machine workshop Training workshop Analytical techniques and failure analysis Metallography Slide 2 Garbsen 49. AWT-Sitzung 05.10.2015

UWTH - Underwater Technology Centre Hanover Main research topics Non-vacuum electron beam technology Non-vacuum electron beam welding Non-vacuum electron beam cutting Welding technology Electric arc welding in air and under water Analysis of welding processes with ANALYSATOR HANNOVER Cutting technology Dry ice laser blasting for surface stripping Thermal cutting processes for dismantling of nuclear facilities Water jet technology Pure-water blasting technology Injected-abrasive water jet technology (WAIS) Suspended-abrasive water jet technology (WASS) Corrosion and environmental testing Electrochemistry in corrosion science Underwater stick electrode welding NVEB welding equipment Water jet cutting Plasma cutting Slide 3 Garbsen 49. AWT-Sitzung 05.10.2015

What is the idea? Slide 4 Garbsen 49. AWT-Sitzung 05.10.2015

What is the idea? One machine concept Slide 5 Garbsen 49. AWT-Sitzung 05.10.2015

~70 cm ~ 70 cm Non-vacuum EB welding X-Ray protection Max. beam power: Max. beam current: High voltage: 24.5 kw 140 ma 175 kv Slide 8 Garbsen 49. AWT-Sitzung 05.10.2015

Non-vacuum EB welding Advantages of the NVEB process High power (24.5 kw) High power density ( ca. 10 6 W/cm²) High velocity (up to 20 m/min) Low tolerances Very energy efficient Energy conversion almost independent of Material Surface properties Applications: Welding Cutting Marking Thermal Treatment Slide 9 Garbsen 49. AWT-Sitzung 05.10.2015

Process chain using NVEB technology Cutting Heat treatment (e.g. pre-heating) 1 chain of process steps 1 NVEB machine Welding Marking Heat treatment Surface hardening Remelting Slide 10 Garbsen 49. AWT-Sitzung 05.10.2015

NVEB Welding - High welding speed - High plug efficiency (~ 40-50 %) - High process tolerances - Short cycle times work-piece (atmosphere) welding Slide 11 Garbsen 49. AWT-Sitzung 05.10.2015

Applications NVEBW Copper, 6mm, 4 m/min Electrical industry Wishbone, Mild steel, 8m/min Automotive industry Dash board support Aluminium, 8-12 m/min Automotive industry Mild steel, 30 mm Wind energy converters Slide 12 Garbsen 49. AWT-Sitzung 05.10.2015

Good tolerance acceptance Specimen: D36 steel 15 mm Welded with NVEB 1 st pass:1.5 m/min, 140 ma 2 nd pass: 1 m/min, 65 ma, G3Si filler wire 264 321 351 232 Weld edge preparation with plasma arc cutting Micro section with HV0,2 Mechanical testing Rm: 581 MPa Rp0,2: 386 MPa e: 11% Charpy: 64-83 J (-20ºC) Slide 13 Garbsen 49. AWT-Sitzung 05.10.2015

Welding of high-strength steel S1100QL Lap joint, 5 mm 3 m/min, 85 ma S1300QL NVEB welded 3 m/min, 135 ma 5mm Comparison of Plasma welds with NVEB welds S1300QL Plasma welded 0.8 m/min 5mm Material Thickness (mm) Welding speed (m/min) Rm (MPa) Rp 0,2 (MPa) Filler wire Position of failure S960QL 6 3 1190 1037 - Base metal NVEBW S1100QL 6 3 1310 1250 - HAZ NVEBW S1100QL 6 2,5 1485 1420 X90 HAZ NVEBW S1300QL 6 3 1315 1300 - HAZ NVEBW S1300QL 6 2,5 1440 1385 X90 HAZ NVEBW S1100QL 6 0,6 1265 1207 X90 HAZ Plasma+MIG S1300QL 6 0,8 1235 1160 X90 HAZ Plasma+MIG Slide 14 Garbsen 49. AWT-Sitzung 05.10.2015

Process chain using NVEB technology Cutting Heat treatment (e.g. pre-heating) 1 chain of process steps 1 NVEB machine Welding Marking Heat treatment Surface hardening Remelting Slide 15 Garbsen 49. AWT-Sitzung 05.10.2015

NVEB Cutting variants Favourable flow pattern for complete extraction of fumes and smoke from the cutting process Conventional thermal cutting process (co-axial gas jet) NVEB Cutting with local suction Beam generator Cutting gas Atmospheric air Fumes / smoke Molten material / slag Slide 16 Garbsen 49. AWT-Sitzung 05.10.2015

NVEB cutting with local suction Working prototype with sliding seal for versatile NVEB Cutting tasks First experimental set-up Slide 17 Garbsen 49. AWT-Sitzung 05.10.2015

NVEBC - Examples 3 mm aluminium 2.5 mm stainless steel 6 mm copper Material Thickness Power Cutting speed Stainless steel, 1.4301 3 mm 24.5 kw 19 m/min Mild steel, DC01 3 mm 24.5 kw 18.5 m/min Aluminium 3 mm 14 kw 20 m/min Copper 6 mm 24.5 kw 10.5 m/min Slide 18 Garbsen 49. AWT-Sitzung 05.10.2015

Thick plates top Macrosection Mild steel GL-D36 15 mm 1.5 m/min 21 kw bottom Stainless steel, thickness: 30 mm 600 mm/min, 24.5 kw Slide 20 Garbsen 49. AWT-Sitzung 05.10.2015

Low heat input 1.4301 stainless steel 2.5 mm, 17 m/min Thickness of HAZ: 20 45 µm Slide 21 Garbsen 49. AWT-Sitzung 05.10.2015

Low heat input Cu, thickness 6 mm 24.5 kw 9 m/min Slide 22 Garbsen 49. AWT-Sitzung 05.10.2015

Movable cutting head Cutting head with sliding seal for efficient removal of molten metal Zinc-coated steel Cutting head Aluminium and copper Slide 23 Garbsen 49. AWT-Sitzung 05.10.2015

Movable cutting head Copper, 6 mm, 5 m/min, 16 kw Some smoke during process start No fume discharge during cutting process Copper, 2 mm, 5 m/min, 7 kw Slide 24 Garbsen 49. AWT-Sitzung 05.10.2015

NVEBC as preparation step for NVEBW NVEBC can be used as weld preparation for NVEBW First step towards process chain Welding specimen Stainless steel (1.4301), 3 mm cut with NVEBC, welded with NVEBW Slide 26 Garbsen 49. AWT-Sitzung 05.10.2015

Process chain using NVEB technology Cutting Heat treatment (e.g. pre-heating) 1 chain of process steps 1 NVEB machine Welding Marking Heat treatment Surface hardening Remelting Slide 27 Garbsen 49. AWT-Sitzung 05.10.2015

Heat treatment Large working distance -> controllable heating of surface Pre-heating Post-heating Surface hardening Surface remelting Slide 28 Garbsen 49. AWT-Sitzung 05.10.2015

Marking with NVEB Quality control, counterfeit protection, decoration Low current -> marking by surface alteration Imprint e.g. Company logos Serial numbers Welding parameters Slide 29 Garbsen 49. AWT-Sitzung 05.10.2015

Process chain using NVEB technology Cutting Heat treatment (e.g. pre-heating) 1 chain of process steps 1 NVEB machine Welding Marking Heat treatment Surface hardening Remelting Slide 30 Garbsen 49. AWT-Sitzung 05.10.2015

Process chain High strength steel for crane building, S1100QL Slide 31 Garbsen 49. AWT-Sitzung 05.10.2015

Conclusion NVEB-processes offer High power and high power density High plug-efficiency Energy conversion independent of material High speed cutting and welding High quality Low heat input One machine one whole process chain To be proofed in the next projects with industry! Slide 32 Garbsen 49. AWT-Sitzung 05.10.2015

Thank you For your Attention EB-Technologies Group, Institute of Materials Science, LUH Prof. Dr.-Ing. Hans Jürgen Maier Dr.-Ing. Th. Hassel N. Murray A. Beniyash G. Klimov M. Mlinaric Ch. Rolffs Slide 33 Garbsen 49. AWT-Sitzung 05.10.2015