Modernisation of the 4m³ electron beam welding machine K40
Electron beam welding plays a key role in the scientific development of materials, joining processes and special components, as electron beams can be used to carry out soldering and welding processes as well as material modifications and stress tests under vacuum. Electron beam processes are irreplaceable for the development or modification of high-performance materials and for the realisation of unique scientific apparatus. Almost all areas of research require special equipment, sometimes made of materials that are difficult or impossible to join, such as refractory metals (particularly "resistant" corrosion-resistant metals with a high melting point such as niobium, tantalum, titanium, tungsten), so-called non-ferrous metals, diamond, sapphire, glass and ceramic components; also as mixed joints. Such demanding joining tasks can often only be realised under vacuum using electron beam welding. The large chamber electron beam welding machine K 40 is used for this purpose at ZEA-1, particularly for large components, and its control and pump systems have now been modernised with STEF funding.
Accompanied by an expert from TÜV-Rheinland, an initial process test was carried out and the machine's suitability for the process was verified. The electron beam welding machine can now process complex structures with up to 15 kW beam power in a future-proof manner using the latest control technology based on SINUMERIK. The first challenge, a proton beam window for neutron systems, was mastered with flying colours.
In order to push the limits of what is achievable, joining processes must be continuously analysed and scientifically processed. The test parameters are of great importance for the welding result. Only through precise knowledge of beam parameters such as the beam diameter and the power density distribution can a statement be made about the weld seam being formed and the weld pool dynamics. Measurements of the beam parameters in the process allow effects to be investigated and enable reflection on process parameters and thus on the solution of material science and joining technology problems. This expertise has been retained on campus thanks to the funding provided.
With its extensive application experience and modern machine technology, ZEA-1 is thus once again available to all partners in Jülich, in national and international development co-operations and with its own development work in the field of electron beam material processing for new innovative tasks.