First current is flow between welding electrode and base plate.

This
establishes an arc between electrode and base plate which heat the
flux or filler wire. This heat leads to melt the filler metal and deposits
into the weld cavity.
Now the cooled copper shoe comes into action and start solidified this
filler metal into weld cavity. This will made to avoid flowing out the
weld metal.
As the filler metal solidified into weld cavity, the current flow through
it. It will generate heat due to electric resistance. This heat is further
use to continuous melting down the filler metal into weld Cavity.
The filler metal continuously provide through roller arrangement as
shown in figure.
During welding both the copper shoe and feed mechanism moving
upward unlit the whole cavity is formed.
This will create a strong joint in single pass. The single or multi-pass
weld is used according to plate thickness.
It is used in heavy industries where plate
thickness up to 80mm to be joint. This process
is used to joint large casting and forging to
produce very large and composite
structure. Welding of thick walled large
diameter pipes, pressure vessels, storage tanks
and ships etc.
 Cooling rate is very low so there is no problem of cold
cracking.
There is no problem of slag inclusion or porosity
in electroslag welding.
The process is semi-automatic and faster.
Heavier section can be welded in single pass.
High productivity can be achieved.
Low cost for joint preparation.

Too high heat input to base.

High temperature of welding needs cooling arrangement.
Introduction

i. Electron Beam Welding is a

fusion welding process in which
a beam of high-velocity
electrons is applied to the
material to be joined.
ii. The work-piece melt as the
kinetic energy of the electrons
is transformed into heat upon
impact.
iii. The EBW process is well-
positioned to provide industries
with highest quality welds and
machine designs that have
proven to be adaptable to
specific welding tasks and
production environments. Fig.1: Key hole penetration in EBW
Electron Beam?

i. In an electron beam welder

electrons are “boiled off” as
current passes through
filament which is in a
vacuum enclosure.

ii. An electrostatic field,

generated by a negatively
charged filament and bias
cup and a positively
charged anode, accelerates
the electrons to about 50%
to 80% of the speed of light
and shapes them into a
Beam.
Fig 2:Electron beam source for EB disposal
 How does the Process Work?
i. The electron beam gun has a tungsten
filament which is heated, freeing
electrons.

ii. The electrons are accelerated from the

source with high voltage potential
between a cathode and anode.

iii. The stream of electrons then pass

through a hole in the anode. The beam is
directed by magnetic forces of focusing
and deflecting coils.

iv. This beam is directed out of the gun

column and strikes the work piece. The
potential energy of the electrons is
transferred to heat upon impact of the
work piece and cuts a perfect hole at the
weld joint. Molten metal fills in behind
the beam, creating a deep finished weld.
Steps Used in EBW process

Joint preparation.

Cleaning of work piece.

Fixturing of work piece.

De-magnetization of work piece.

Setting up work piece in chamber.

Pump down air form chamber.

Carry welding process.

v. Compared with arc welding
processes, EBW improves joint
strength 15 per cent to 25 per
cent.

vi. It has a narrow heat-affected

zone(HAZ), which results in
lighter-weight products.

vii. Geometric shapes and dimensions

are highly stable, particularly
when it is used as a finish
operation.

viii. It eliminates oxide and tungsten

inclusion sand removes impurities.

ix. The weld metal has a fine

crystalline structure.
Field of Application

Industrial areas

• Automotive industries
• Aircraft and space industries
• Mechanical engineering
• Tool construction
• Nuclear power industries
• Power plants
• Fine mechanics and electrical
• Industries
• Job shop