vacuumelectronbeam technologies ... - deutsche messe ag
TRANSCRIPT
Institute of Joining
and Welding
Vacuum Electron Beam Technologies
(Elektronenstrahltechnologien im Vakuum)
Dr.-Ing. Thomas Krüssel
Institut für Füge- und
Schweißtechnik
Vacuum Electron Beam Technologies
� Electron Beam
� Generation
� How it works
� Different ways of „Hochleistung“
� High Power/
� Highly Productive
� Steps into Future
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 2
Institut für Füge- und
Schweißtechnik
Vacuum Electron Beam Technologies
� Electron Beam
� Generation
� How it works
� Different ways of „Hochleistung“
� High Power/
� Highly Productive/
� Steps into Future
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 3
Institut für Füge- und
Schweißtechnik
Vacuum: Space on Earth
Vacuum:
Condition in a space with gas
pressure below normal
atmosphere (1013 mbar)
Source: http://www.pfeiffer-vacuum.de/
10-5 mbar: 2.400 molecules
10-3 mbar: 240.000 molecules
Atmosphere: 240 billion molecules
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 4
Institut für Füge- und
Schweißtechnik
Why should electrons move?
rest mass of electron: 9.1 . 10-31 kg
elementary charge: 1.6 .10-19 C
Accellerating Voltage
150 kV in Vacuum
velocity:
2 .108 ms-1 = 2/3 speed of light
UB * IB = PB 150kV * 200mA = 150,000V * 0.2 A = 30,000 W = 30kW
30kW * 1.359622 ~ 40.79 PS
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 5
Institut für Füge- und
Schweißtechnik
High precision assembly device
for cathodes
Tape katode BK 1.4; Tungsten,
Thickness 0.1 mm – Emitting Surface 2 mm2
Beam Generator: e.g. PTR-Beam Generator 60 kV
Source: PTR
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 6
Institut für Füge- und
Schweißtechnik
Typical Design of an EB Column
Be
am
Ge
ne
ratio
nM
ag
net O
ptic
s
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 7
Institut für Füge- und
Schweißtechnik
Electron Beam (EB) generation
beam source, cathode,
bias cup and anode
focosing coil
centering coil and
stigmator
component
manipulator
x-y deflection system
sensor plate (BSE)
Source: PTR
Source: pro-beam
Gravings produced by Lessajou figures
of oscillating EB
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 8
Institut für Füge- und
Schweißtechnik
Beam – Materials Interaction
penetration depth
of electrons
=
region of
energy conversion
Source: Schultz, Elektronenstrahlschweißen
Ions
Vapour
Light
BSE
Thermal Radiation
EB
X-Ray
ee
e
e
e
e
e
ee
ee
e
ee
e
e
e
e
Efficiency of energy conversion:
� flat impact and heat conduction welding: 0.6
� in a key whole: 0.9 to 0.95
0
100
150
200
50
W Cu Fe Ti Al
Pen
etr
ati
on
Dep
th[µ
m]
Materials
Penetration depth of
electrons at UA=150 kV
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 9
Institut für Füge- und
Schweißtechnik
Electron Beam Welding
Butt joint before
welding
Melting on the
point of impact of
the electron beam
Formation of a
steam channel
Steam channel and
melting channel
have penetrated
the work piece
Weld seam after
solidification
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 10
Institut für Füge- und
Schweißtechnik
Electron beam as a universal tool
lens
deflector
sensor
plates
e-b
eam
backscattering
electrons
welding
hardeningcontour detection
deposit welding
process control / QAengraving
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 11
Institut für Füge- und
Schweißtechnik
Vacuum Electron Beam Technologies
� Electron Beam
� Generation
� How it works
� Different ways of „Hochleistung“
� High Power/
� Highly Productive
� Steps into Future
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 12
Institut für Füge- und
Schweißtechnik
EB Chamber Machines
Typ S450+120 EB2 eg. usedto weld satelite components
Chamber for RPT by EB + wire feeder
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 13
Institut für Füge- und
Schweißtechnik
Manipulation of Parts by Flexible Clamping Concepts
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 14
Institut für Füge- und
Schweißtechnik
Gas turbine casing
17 t casting as welding-related solutionBy means of the electron beam welding procedure, thick-walled castings can be
repaired or, as a welding-related solution, produced more cost-effectivelyG
Material: G 20 Mo 5
Weight: 17,500 kg
Largest diameter: 5.5 m
3-D welding, carried out at a static
component
Seam length: 4.5 m
Welding depth: 58 mm
Welding time: 33 minutes
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 15
Institut für Füge- und
Schweißtechnik
Cover of a vacuum furnace chamber for the
production of stainless steel
Cover made of the material 1.4571 can be welded by electron beam in the
finished state G
The following welding
operations are to be
carried out:
1.EB welding of the flange
(diameter 3.2 m,
wall thickness 50 mm)
2.EB welding of the pipe
connections (3-D)
(diameter 250 mm,
wall thickness 50 mm)
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 16
Institut für Füge- und
Schweißtechnik
Tripod Design for Welding
Sections with
80 – 100 mm of
wallthickness
S355 NL
Bereich mit Wand-
dicken 20 – 70 mm
S355 NL
To produce a tripod of ~900 t weight (S355) 1.229 m weld seam are necessaryG
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 17
Institut für Füge- und
Schweißtechnik
Manufacturing costs EB and UP in comparison
depending on the procedures and number of items
0
50
100
150
200
250
300
10 20 30 40 50 60 70 80 90 100
Anzahl Tripods pro Jahr
Ko
ste
n p
ro T
rip
od
[T
€]
UPTWIN in DeutschlandUPTWIN in PolenEB und UPEindraht in PolenEB und UPTWIN in PolenEB
EB/UP-Kombination
ab 14m Länge
reine UP-Fertigung
reine EB-Fertigung
Source: pro-beam / IMS Nord
Co
sts
per
trip
od
In Germany
In Poland
One-wire in Poland
Pure UP manufacture
Pure EB manufacture
EB/UP combination from a length of 14 m
Number of tripods per year
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 18
Institut für Füge- und
Schweißtechnik
Vacuum Electron Beam Technologies
� Electron Beam
� Generation
� How it works
� Different ways of „Hochleistung“
� High Power/
� Highly Productive
� Steps into Future
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 19
Institut für Füge- und
Schweißtechnik
Industrial Automotive Series Production
Inconel 713 LC + 42CrMo4
(Shaft finaly grinded before welding)
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 20
Institut für Füge- und
Schweißtechnik
Example of a Process Chain for Welding Gears
semi finished
parts
transport
OK parts
Cle
an
ing
EBW
magnetic
heating
mechanical
joining
US-testing
2 robots
� Requirements
� Many parts in shortest time
� Highest quality
� Absolutely reproducible
� Minimized costs
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 21
Institut für Füge- und
Schweißtechnik
ELO picture versus colour picture
Colour picture
seam
ELO picture
seam
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 22
Institut für Füge- und
Schweißtechnik
Example: Seam detection and positioning with ELO picture
Three different procedures
High precision (subpixel)
Center of device (zoomed)
Single steps for the detection of the seam track
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 23
Institut für Füge- und
Schweißtechnik
Examples of EBW-Machines usable for this kind of production
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 24
Institut für Füge- und
Schweißtechnik
Vacuum Electron Beam Technologies
� Electron Beam
� Generation
� How it works
� Different ways of „Hochleistung“
� High Power/
� Highly Productive/
� Steps into Future
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 25
Institut für Füge- und
Schweißtechnik
EB Deposition Welding, the general idea
Schematic diagram of the structure Depositing welding process (S355 plate / G3Si1)
Structure after machining (S355 plate / G3Si1)Structure after EB welding (S355 plate / G3Si1)
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 26
Institut für Füge- und
Schweißtechnik
Main advantages of EB-deposition welding
• Use of solid and flux cored wire with almost 100% depositionrate
• Minimum heating effects by precisely adjustable (dilution / fusion)
• Experience: no basic material (steel) in 2nd layer of a hardfacing
• Reduced porosity
• Build up structures from reactive materials as e.g. titanium
• No limitation by any powder bed
• Flexible to use for repair and production
Dilution in macrosection
(steel)
Dilution in macrosection
(aluminum)Thin structure
(S355 plate, G3Si1)
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 27
Institut für Füge- und
Schweißtechnik
Repair of Cost Intensive Parts: Roller Shaft
Roller shaft
vacuum chamber
Adjustment for welding
Shuttle machine
Bearing seat after
EB deposition welding
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 28
Institut für Füge- und
Schweißtechnik
Research Project: EB-Repair of Dies
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 29
� Expensive tools
� Special steels
� Complex heat treatment
� Repair of cracks, erosion, etc.
� Re-building of structures
Institut für Füge- und
Schweißtechnik
Rapid Prototyping (Titanium)
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 30
Institut für Füge- und
Schweißtechnik
Direct Manufacturing (all examples from Sciaky Inc.)
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 31
Institut für Füge- und
Schweißtechnik
Examplary Provider of EB Devices/Components
Th. Krüssel | Hannovermesse 2013|
Mobile: +49 1523 3772583 11.04.2013 32
www.steigerwald-eb.de www.pro-beam.de www.ptr-gmbh.de
www.tadadenki.jp/english/index.html www.evobeam.com www.camvaceng.com
www.techmeta.com www.sciaky.com www.wega-konstruktion.de