Welding technique of aircraft pylon
“Sukhoi civil aircraft”, Komsomolsk-on-Amur, Russia.
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TechnoBeam - high-tech company provides solutions using electron-beam technology -
TechnoBeam - high-tech company provides solutions using electron-beam technology -
TechnoBeam - high-tech company provides solutions using electron-beam technology
Features
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No gas contamination
Because electron beam welding is done in vacuum, there’s no atmospheric gas contamination. This results in the cleanest, highest-quality weld possible. For parts that require post-weld testing such as x-raying, EB welding is your best option.
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Joining dissimilar materials
One of EBW’s greatest advantages is its ability to weld materials with different melting points, such as copper to stainless steel. From a cost and performance perspective EB welding also has the ability to weld high-cost nickel alloys to relatively low-cost stainless steel.
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Excellent for refractory materials
such as titanium, niobium, and tantalum. Since electron beam welding is done in a vacuum chamber, it prevents the exposure to oxygen that can cause these welds to fail. This is particularly an issue with welding titanium – if the welds are exposed to oxygen, it can cause a serious failure called alpha casing.
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High quality and integrity from machine-controlled automation
EBW has high strength with minimal distortion or damage. Also, very little post-weld machining is needed due to its accuracy, making it suitable for welding precision parts. Since the machine is programmable, it is possible to have custom weld-profiles.
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EBW do not damage heat-vulnerable materials
Because of the low heat input of electron beam welding, temperature-sensitive parts can be located in proximity to the weld region.
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Highly efficient
Electron beam welding is about 90 percent efficient – meaning 90 percent of the input power is reaching the part. That’s more important to us as welders rather than you the customer, but it’s another reason to prefer EB welding.
What We Offer
Small Chamber EBW Systems
Volume of chamber is not exceed
10 m3
Electron gun is placed outside the chamber.
Operational pressure is 5×10-4 mbar. The parts to be welded are moved by a high-precision manipulator located inside the chamber
Medium Chamber EBW Systems
Volume of chamber is up to 50 m3. Electron gun is placed inside the chamber. Operational pressure is 5×10-4 mbar. The parts to be welded and the gun are moved inside the chamber by a high-precision manipulator in 3D dimensions and rotation
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Big Chamber EBW Systems
Volume of chamber is more then 50 m3.Accelerating voltage is 60 kV, electron beam current is up to 1000 mA. Operational pressure is 5×10-4 mbar. The parts to be welded and the gun are moved inside the chamber by a high-precision manipulator in 3D dimensions and rotation
Special EBW Systems
3-gun machines for welding of drill bits. Equipment for welding of the thick steel slabs. Machines for the granule metallurgy. Machines for welding of tube plates. High-Voltage power supply. System for stabilization of focus of electron beam
Modernization of Obsolete Equipment
Regular maintenance of your equipment. Repair and modernization of the equipment. Modernization of obsolete equipment.
EB Job Shop Welding Services
Job-shop from prototypes to serial production – your resources will be relieved and your efficiency will be increased.
We help and advise you from producing prototypes to high volumes.
Implemented projects
Big chamber
GKN Aerospace Chem-tronics Inc., USA
chamber - 98 m3
accelerating voltage - 60 kV
power - up to 60 kW
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Medium chamber
Shanghai, aviation institute, China
chamber - 22 m3
accelerating voltage - 60 kV
power - up to 60 kW
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Medium chamber
Harbin Polytechnic Institute, China
chamber - 20 m3
accelerating voltage - 60 kV
power - up to 60 kW
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Medium chamber
Kharkov Institute of Physics and Technology, Ukraine
chamber - 10.5 m3
accelerating voltage - 60 kV
power - up to 60 kW
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Medium chamber
“Zorya-Mashproekt”, Nikolaev, Ukraine
chamber - 40.5 m3
accelerating voltage - 60 kV
power - up to 60 kW
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Small chamber
Vikram Sarabhai Space Center, India
chamber - 3 m3
accelerating voltage - 60 kV
power - up to 30 kW
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Small chamber
Brahmos Aerospace Thiruvananthapuram Ltd., India
chamber - 6 m3
accelerating voltage - 60 kV
power - up to 30 kW
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Special Project
Jigang Group Co., Ltd, China
chamber - 50 m3
accelerating voltage - 60 kV
power - up to 60 kW
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Special Project
Central Iron & Steel Research Institute (CISRI), China
Machines for the degassing, filling and vibration compaction of the granules in the capsules with subsequent hermetic sealing by means electron beam welding
Zoom inMachines for precise electron beam welding of small work pieces
Description of small chamber class machine models CB-112
The EB gun has an independent vacuuming system using a turbomolecular pump.
- Universal production machines for precise EBW of a wide range of small cylindrical and flat work pieces
- CNC+PLC of the machine
- Visualization of workpiece by RASTR system on the basis of the secondary electron emission, magnification x10
- Power source with the electron tube flashless system
- Up to 15kW beam power at 60 kV
- The working chamber has a front pivoting door
- There is manipulation table with 2-axis and rotation inside chamber. Guiding system managed by servodrive with high-precision tolerance
Technical data
| Vacuum chamber inner dimensions L×W×H, mm, up to | 640×640×640 |
| Time it takes to reach vacuum of 5×10-4torr, min | <5 |
| Vacuum in the gun, torr | 2×10-5 |
| The work piece height/length, mm, max | 200 |
| The work piece diameter, mm, max | 150 |
Description of small chamber class machine model KL-134
Small chamber machine with programmable three coordinate axes movement (two axes of linear movement and one axis of rotator) with linear and circular interpolations
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Real-time logging.
- Up to 30kW beam power at 60 kV
- The gun can be mounted on upper or side wall. It has an independent turbomolecular pumping system
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 2020×1100×1200 |
| Time it takes to reach vacuum of 8×10-5torr, min | ≤20 |
| EB gun movement with accuracy ±0.03mm, mm | Y axis-500 |
| EB gun moving speed with positioning accuracy ±0.03mm , mm/s | 0.16-33 |
| Rotary manipulator moving speed with positioning accuracy ±0.03 mm , mm/s | 0.16-33 |
| Lanthanum Hexaboride tablet cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 2940 |
| Beam deflection angle | ±3.5° |
Description of small chamber class machine model KL-200
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Real-time logging.
- Up to 30kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 1800×1200×850 |
| Time it takes to reach vacuum of 4×10-4torr, min | ≤12 |
| Work table movement with accuracy ±0.1mm , mm | X axis - 600; Y axis - 400 |
| Work table moving speed, mm/s | 1-50 |
| Rotary manipulator moving speed with positioning accuracy ±0.03 mm , mm/s | 0.16-33 |
| Rotation speed, rpm | 0.25-30 |
| Loading capacity of rotaty manipulator max, kg | 30 |
| Diameter of faceplate of rotary manipulator, mm | 300 |
Electron beam welding machine with medium size chamber and 7-axis motion system
Description of medium chamber class machine model KL-132
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Multi-axis manipulator, using the Cartesian cantilever
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Concurrent movement of 4-axis dimensions with linear and/or circular interpolations
- Real-time logging.
- Up to 60kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 3200x2400x2400 |
| Time it takes to reach vacuum of 1×10-4torr, min | ≤20 |
| EB gun movement with accuracy ±0.1mm, mm | X axis-2200; Y axis-1040; Z axis-1200 |
| EB gun rotation angle with accuracy 0.1° | ±90° |
| EB gun moving speed with positioning accuracy ±0.025mm , mm/s | 1-33.3 |
| Tungsten tablet cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 2940 |
| Beam deflection angle | ±3.5° |
Description of medium chamber class machine model KL-115
The machine is equipped with two sliding doors and retractable platforms.
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Multi-axis manipulator, using the Cartesian cantilever
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Concurrent movement of 4-axis dimensions with linear and/or circular interpolations
- Real-time logging.
- Up to 60kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 4040x2950x2950 |
| Time it takes to reach vacuum of 1×10-4torr, min | ≤20 |
| EB gun movement with accuracy ±0.1mm, mm | X axis-3000; Y axis-1800; Z axis-2000 |
| EB gun rotation angle with accuracy 0.1° | ±90° |
| EB gun moving speed with positioning accuracy ±0.025mm , mm/s | 1.66-33.3 |
| Lanthanum Hexaboride tablet cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 2000 |
| Beam deflection angle | ±3.5° |
Description of medium chamber class machine model KL-197
The machine is equipped with a manipulator with 4-axis concurrent movement.
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Concurrent movement of 4-axis dimensions with linear and/or circular interpolations
- Real-time logging.
- Up to 60kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 3235×2400×2400 |
| Time it takes to reach vacuum of 2×10-4torr, min | ≤25 |
| EB gun movement with accuracy ±0.1mm, mm | X axis-2000; Y axis-1000; Z axis-1200 |
| EB gun rotation angle with accuracy 0.1° | ±90° |
| EB gun moving speed with positioning accuracy ±0.05mm , mm/s | 1-33.3 |
| Tungsten tablet cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 2200 |
| Beam deflection angle | ±3.5° |
Description of medium chamber class machine model KL-195
The machine is equipped with a manipulator with 4-axis concurrent movement.
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Concurrent movement of 4-axis dimensions with linear and/or circular interpolations
- Real-time logging.
- Up to 60kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 4523×2994×2982 |
| Time it takes to reach vacuum of 2×10-4torr, min | ≤25 |
| EB gun movement with accuracy ±0.1mm, mm | X axis-2000; Y axis-1000; Z axis-1200 |
| EB gun rotation angle with accuracy 0.1° | ±90° |
| EB gun moving speed with positioning accuracy ±0.05mm , mm/s | 1-33.3 |
| Tungsten tablet cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 2200 |
| Beam deflection angle | ±3.5° |
Electron beam welding machine with big size chamber
Description of big chamber class machine model KL-144
For electron beam welding of airplane structures. Vacuum chamber is equipped with two sliding doors. Two rotary manipulators on which the workpieces are clamped.
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The vacuum chamber volume is 100m3
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Multi-axis manipulator, using the Cartesian cantilever
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Concurrent movement of 4-axis dimensions with linear and/or circular interpolations
- Real-time logging.
- Up to 60kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 7000×3500×4000 |
| Time it takes to reach vacuum of 1×10-4torr, min | ≤20 |
| EB gun movement with accuracy ±0.1mm, mm | X axis-5900; Y axis-2340; Z axis-3000 |
| EB gun rotation angle with accuracy 0.1° | ±90° |
| EB gun moving speed with positioning accuracy ±0.025mm , mm/s | 1.6-33.3 |
| Tungsten tablet cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 3500 |
| Beam deflection angle | ±3.5° |
Description of big chamber class machine model KL-118
for electron beam welding with 7-axis motion system. Machine is equipped with three rotatory manipulators: with horizontal rotation axis, with vertical rotation axis and with angled rotation axis.
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Concurrent movement of 4-axis dimensions with linear and/or circular interpolations
- Real-time logging.
- Up to 60kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 3800×3600×4800 |
| Time it takes to reach vacuum of 1×10-4torr, min | ≤25 |
| EB gun movement with accuracy ±0.1mm, mm | X axis-2800; Y axis-2500; Z axis-3700 |
| EB gun moving speed with positioning accuracy ±0.025mm , mm/s | 1.66-33.3 |
| Lanthanum Hexaboride tablet cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 4500 |
| Beam deflection angle | ±3.5° |
Special electron beam welding systems
Description of 3-gun machines for welding of drill bits model KL-137
3-gun machines for welding of drill bits.The vacuum chamber consists of two sections. The upper chamber has three nozzles for the installation of three electronic guns equipped with turbomolecular pumps. The lower chamber has a manipulator for fixing the drill. The three legs of the drill bit are attached using a dedicated holder.
- The machine is designed for electron-beam welding of drills up to 17.5" in diameter with simultaneous execution of three welds, which increases the productivity of the process and accuracy of the drill.
- CNC+PLC of the machine
- Three, two or even one gun can be used for repair pf drills if necessary
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Real-time logging.
- Up to 20kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 800×650×1275 |
| Time it takes to reach vacuum of 5×10-4torr, min | ≤2 |
| Movement with accuracy ±0.1mm, mm | X axis-740 |
| Manipulator moving speed with positioning accuracy ±0.025mm , mm/s | 1.66-33.3 |
| Lanthanum Hexaboride cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 3140 |
Description of big chamber class machine model KL-114
Special EBW system for powder (granular) metallurgy. The equipment is used to produce nickel-based blanks for high-temperature components for aircraft turbine engines using the method of granular metallurgy.
- Design of the water-cooled vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- Vibration compaction of the granules in a capsule using vibrodrive mod
- Real time automatic seam tracking and observation system
- There is a heater inside the chamber that keeps the necessary temperature of the working area
- Real-time logging.
- Up to 1.2kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 940×940×1065 |
| Time it takes to reach vacuum of 2×10-5torr, min | ≤2 |
| Working temperature, °C | 500-600 |
| Vibration amplitude, mm | 2 |
| Vibration frequency, Hz | 10-50 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 3250 |
Description of big chamber class machine model KL-169
For EBW of thick steel slabs. Several plates with a maximum size of 4.2 x 2.3 x 0.9 m are contour-welded with an electron beam to a depth of 50 mm
- Design of the vacuum chamber has a double wall, giving greater vacuum hermeticity with less overall weight
- CNC+PLC of the machine
- The high rigidity of the design ensures that the motion system is high precision and repeatability
- Real time automatic seam tracking and observation system
- Unique high voltage control regulator with vacuum tube prevents arc formation and enables welding without ruptures and defects
- Concurrent movement of 4-axis dimensions with linear and/or circular interpolations
- Real-time logging.
- Up to 60kW beam power at 60 kV
Technical data
| Vacuum chamber inner dimensions L×W×H, mm | 5680×5250×2550 |
| Time it takes to reach vacuum of 3×10-4torr, min | ≤20 |
| EB gun movement with accuracy ±0.1mm, mm | X axis-4350; Y axis-1475; Z axis-460 |
| EB gun moving speed with positioning accuracy ±0.025mm , mm/s | 1.6-33.3 |
| Tungsten tablet cathode life, hours, | 40 |
| Consumption of cooling water at temprature ≤20°C, dm3/hour | 3500 |
Modernization of Obsolete Equipment
Samples of modernization project of ELU-20M EBW system.
| Before | After |
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Technobeam’s contract welding job shop offers a wide range of affordable industrial EB welding services for customers in a wide variety of industries worldwide.
We have the ability to weld large assemblies up to xx meters long and up to hx meters in diameter, as well as tiny parts that can fit in the palm of your hand. Whether you need prototype part development or fabrication services for high-volume production, Technobeam has the right solution to meet your needs. Most importantly, Technobeam's custom EB welding services are competitively priced and based on years of scientific research into welding processes, as well as a tremendous amount of experience.
Our high quality machinery and skilled production teams ensure that your products are delivered on time and in top quality. In case of bottlenecks, we take over your production in our job-shops.
Our exclusive Additive Manufacturing solution, which utilizes our state-of-the-art EB technology, is the only commercially-available, large-scale, fully-programmable means of achieving near-net shape parts. This unique process can be provided as a service to produce functional prototypes and production parts at a fraction of the cost and time of traditional manufacturing methods.
Electron Beam Welding for aircraft industry. EBW of titanium aircraft profiles
Electron Beam Welding for aircraft industry. EBW of large aluminum beams and thin-walled profiles.
Electron Beam Welding. EBW turbine's blade repair by insert pieces.
Electron Beam Welding of aircraft industry. EBW of parts of aircraft engines.
Electron Beam Welding. Repair of hydraulic cylinders.
Projects
Countries
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Clients
Media from implemented projects
Application
Aerospace
- Precision Aerospace Gear Welding
- Ti, Ti-allloys Turbine Blade Repair Welding
- Compressor Rotor Welding
Power Generation
- Combustion Chamber Cover Welding
- Steam Turbine Diaphragm Welding
- Gas Turbine Fuel Nozzle Assembly Welding
Automotive
- Transmission Component Welding
- Turbocharger Impeller Welding
- Planet Carrier Welding
Electronics
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- Cooling Plate Welding for Semiconductor Fab Systems
- Heat Sink Welding
- Hermetically Sealed Electronics Package Welding
Oil & Gas
- Impeller Body with Integral Machined Blades Welding
- Bi-metal materials Welding
- Complex parts Welding
About us
Established in 2010, Beamtechnology s.r.o. is the most trusted provider of advanced welding systems and job shop welding services in the fabrication market. Our wide selection of electron beam welders, electron beam additive manufacturing solutions makes us the most versatile welding solutions supplier on the market. Beamtechnology s.r.o. is at the forefront of electron beam welding technology and pioneers of metal additive manufacturing processes, also referred to as 3D printing. We are dedicated to world-class engineering, as well as extensive research and development. When you talk to Beamtechnology s.r.o. about your requirements, you're dealing with the best in the business.