Real-Time Adaptive Control Technology for Electron Beam Welding Systems
As one of the leading innovators in electron beam (EB) welding and metal additive manufacturing for over half a century, Sciaky has assisted in the development of numerous groundbreaking technologies.
Highlighted in this case study is a novel weld process monitoring system that we engineered to improve weld quality and reduce scrap / repairs for high-value conduction mode welds – specifically in cutting-edge particle accelerator applications.
A More Reliable and Repeatable Electron Beam Welding Process
Sciaky’s solution is real-time adaptive control technology. Working alongside leading researchers and equipment developers, we have fine-tuned our adaptive control system for the conduction mode EB welding process of niobium superconducting radio frequency (SRF) cavities. By leveraging our proprietary IRISS® (Interlayer Real-time Imaging & Sensing System) platform, Sciaky has substantially enhanced the quality, reliability, and cost-efficiency of fabricating these critical high-cost components used in particle accelerators.
Optimized for SRF Cavities in Particle Accelerators
Considering the high price and extremely sensitive nature of particle accelerator equipment, SRF cavities demand exceptional weld quality, consistency, and process control. These components are typically fabricated from high-purity niobium (high RRR value), a notoriously difficult-to-weld metal with a current cost of over $350 per pound. Each cavity can cost over $500,000 and typically requires 6 - 12 months to fabricate.
EB weld defects, particularly "blow-throughs" caused by over-penetration, result in substantial rework or complete part loss. In the case of these complex SRF cavities, costs can exceed $350,000 per defect / lost part, simultaneously contributing to project delays which cost additional time and money.
Sciaky’s adaptive control solution addresses this challenge through real-time in-situ monitoring combined with dynamic parameter adjustment – a truly novel approach for conduction mode EB welding of niobium materials.
Traditional EB Welding vs. Sciaky’s Adaptive Approach
Traditional EB welding processes for SRF cavities typically relied on pre-programmed weld parameters, which are sensitive to manufacturing tolerances such as wall thickness and joint alignment. Even the slightest of deviations can lead to weld failures, particularly in the final fabrication stages when the potential cost of a weld defect is highest.
Sciaky’s innovative EB welding control technology takes a real-time adaptive approach with image-tracking:
- A high-resolution optical camera tuned specifically to the weld zone.
- A machine learning algorithm that interprets melt pool geometry in real-time.
- Closed-loop control that dynamically adjusts beam power, focus, and positioning.
- Fuzzy logic systems to enable nuanced, rule-based decision-making during the weld process.
This novel approach facilitates a significant improvement in overall weld quality and reliability by minimizing the risk of blow-through while enhancing the repeatability of critical weld profiles.
Learn more about Sciaky’s innovative electron beam (EB) welding systems.
Validation and Partnership with Michigan State University
Sciaky has teamed with Michigan State University’s SRF fabrication group and the U.S. Department of Energy to refine this new technology and prove its effectiveness. The collaboration includes design, material preparation, and real-world testing of the adaptive system using representative geometries.
Initial results show promise in enabling adaptive responses to geometrical variations such as material thickness changes and joint misalignments. Benchmarking trials demonstrated that Sciaky’s IRISS®-driven control loop effectively prevents blow-throughs in situations where conventional methods would fail.
This information is based upon work supported by the U.S. Department of Energy, Office of Science under prime grant no. DE-SC0024798, which was issued to Sciaky with MSU as its subcontractor.
Innovation in Additive Manufacturing – Established in 1939
Sciaky is backed by more than eight decades of innovation and manufacturing excellence. We’ve continuously embraced the rise of 3D metal printing across industries through the refinement of our innovative additive manufacturing processes.
