EB Weld System Speeds Welding Process
Allied Signal Aerospace had a need to significantly reduce its average Electron Beam (EB) welding process time for turbine engine components. The system was required to weld numerous parts in one pump-down. Sciaky built a system that offered an automatic manipulator to load parts into the weld positioner. The welding system also featured a movable electron beam gun with a tilt axis.
The system is unique because the in-chamber parts manipulator automatically loads and unloads up to 10 different parts to the weld positioner. This differs from traditional EB welding practices that typically weld one part per weld chamber pump-down cycle.
Working with a senior process engineer at Allied Signal, the Sciaky concept of multiple-part processing was developed. In the past, concepts have been limited to numerous small parts of the same kind. The Allied Signal concept utilizes a universal pallet that can accommodate a variety of different parts. The pallet features a matrix of fixturing hold-down positions that can be easily changed.
Sciaky's advances in EB gun design and system control architecture also reduce processing time. The EB gun features a TV-video optic package that allows the operator to see a magnified view of the weld joint exactly where the beam will strike. This improves programming and verification of the joint location. In addition, a reflected electron scanner views the weld joint to provide a more exact validation of the joint location.
A Versa Module European (VME)-based control system that is installed features a multi-tasking operator interface that permits various activities to occur at the same time. While parts are being welded, programs can be modified, new sequences programmed, etc. A higher level of control with its man-machine interface (MMI), using a SUN Sparc workstation, allows multiple channels for data collection and facilitates statistical process control, further reducing the weld process.
Electron Beam
EB Gun
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