Electron Beam Welding
of a Titanium
Missile Housing
A leading defense manufacturer approached Roark Welding with a titanium missile housing challenge. The assembly consisted of a stamped, thin-walled titanium shell and two machined bolt flanges that needed to be joined with full-penetration welds—without warping, misalignment, or contamination.
The margin for error was nonexistent. Titanium’s heat sensitivity, along with the precision bolt patterns, made conventional welding methods too risky. The customer required tight tolerances, no post-weld machining, and full mechanical strength.
Why Electron Beam Welding
Titanium presents a unique welding challenge—particularly when different forms of titanium must be joined, like sheet metal and machined components. The missile housing needed three titanium pieces joined together: a thin-walled stamped body, and top and bottom machined bolt rings. Heat sensitivity was a major concern, as titanium’s structural integrity can be compromised above 400°C. Any distortion to the bolt pattern from thermal expansion would make the entire component unusable.
Electron Beam Welding was selected for this application due to its unmatched control, cleanliness, and ability to join complex titanium components in a vacuum environment.
Key advantages included:
- Minimal heat input, protecting the thin shell from distortion
- Deep, narrow welds for full-strength joints
- Vacuum conditions to eliminate oxidation and contamination
- CNC-guided beam path for consistent, repeatable results
The Roark Approach
Using our CNC-controlled electron beam welding system in a high-vacuum chamber, Roark Welding executed deep, narrow welds that kept heat input to an absolute minimum. Our team engineered a weld path that stayed clear of the bolt hole radius while delivering the penetration depth needed to ensure strength and durability. The EB welds created a seamless join between the sheet and machined parts with no risk of porosity, oxidation, or post-weld distortion.
- Aligned and fixtured the components to preserve the bolt hole patterns
- Welded the titanium rings to the shell with precision and minimal thermal exposure
- Avoided the need for any post-weld machining or cleanup
Results
The final product exceeded expectations. The client received fully assembled missile housings that met all dimensional and strength requirements with no distortion to the bolt hole alignment. The precision of our electron beam process ensured each part came off the line consistent and repeatable.
- Zero distortion of the titanium shell
- Perfect alignment of critical bolt hole patterns
- Full weld penetration without porosity or cracking
- No post-weld machining required
- Consistent performance across all units
The success of this project reinforced why mission-critical aerospace and defense components turn to Roark Welding when performance matters most.
Project Summary
- Material: Titanium Alloy
- Components Joined: Stamped Shell + Two Machined Flanges
- Weld Type: Full Penetration, Vacuum EB Weld
- Tolerance Requirements: Bolt Pattern Must Remain True-To-Spec
- Post-Weld Cleanup: None Required
- Production Run: Multiple Assemblies
