CASE STUDY

Electron Beam Welding used on titanium missile case

A Defense Department contractor needed three components of a titanium missile case to be welded together. The main section of the case was stamped sheet metal that was to be fused with a machined top and bottom bolt rim. The weldment featured multiple angles and varying widths.  

Solution: Titanium is commonly used in aerospace applications for its strength-to-weight ratio. It is very useful where high performance is critical. However, titanium is a stubborn metal to machine and weld. It is highly reactive and can begin to lose its strength if it is not welded properly. At the core of this is its sensitivity to high heat. Titanium begins to degrade when exposed to temperatures above 400ºC. EB Welding is typically used on titanium for this reason. The heat input on EB Welding is much lower than traditional welding techniques and can be isolated and digitally controlled in minute increments. This is the result of welding in a vacuum chamber where the gases are evacuated and the electron beam is neither diverted by airborne molecules nor is the metal exposed to peripheral contaminants. This is EB Welding’s advantage over traditional, hand-held welding techniques. 

The computerized accuracy of EB Welding made this the best fusion option in this particular application. The complex angles, irregular thicknesses, along with precise positioning of the bolt patterns are perfect for EB Welding. It fuses metals with meticulous accuracy. In this case, the EB Weld was able to mirror the complex contour of the stamped sheet metal. It aligned the lip of the sheet metal part and butt welded it to the adjacent components while fluctuating both the depth of the weld and the heat needed to fuse the weldment together. The result was a precision weld over uneven surfaces without damaging the peripheral metal by overheating it.

EB Welding can also be used with very large or long components. Roark Welding has the ability to add extensions onto their vacuum chambers. This is especially necessary when you are applying precision welds down the length of very long parts.

If you are dealing with complex, highly sensitive metal parts with tight variances, contact us. For more information, contact us at info@roarkfab.com or call us at 317-852-3163, ext. 901.