Three Parts,
One Precision Solution:
EB Welding in Aerospace Fabrication
An aerospace manufacturer approached CF Roark Precision Welding & Engineering with a complex challenge: to weld together three intricate components into a fully functional, structurally sound combustion chamber assembly for high-temperature aerospace applications.
The project required extreme precision, material purity, and vacuum-grade electron beam welding (EB welding) expertise to ensure the part could withstand the rigors of high-altitude, high-pressure operation. With our deep expertise in aerospace welding, tight-tolerance fabrication, and electron beam joining, Roark was uniquely equipped to execute this mission-critical solution.
Client Requirements & Technical Challenges
The client provided three separate parts that needed to be joined into a monolithic combustion chamber structure. The part had several design constraints and performance requirements:
- High-Temperature Tolerance: The chamber would be exposed to extreme thermal cycles and required welds that could maintain structural integrity without introducing distortion.
- Full-Penetration Welds: Joints had to be fully fused without the use of filler materials.
- Clean Weld Environment: Welds had to meet high standards of metallurgical cleanliness, ruling out conventional welding methods.
- Precise Fit-Up: Given the tight tolerances of the components, there was minimal room for thermal warping or post-weld corrections.
Traditional fusion welding methods (TIG, MIG, laser) couldn’t offer the precision or purity required. That’s why the client turned to Roark and our electron beam welding capabilities.
Roark’s Solution: High-Precision Electron Beam Welding
CF Roark employed its state-of-the-art electron beam welding chamber to fuse the three parts with extreme accuracy. EB welding allowed us to:
- Perform deep, narrow welds with minimal heat-affected zone
- Maintain vacuum conditions to prevent oxidation and contamination
- Avoid filler materials while achieving high-strength, metallurgically sound joints
- Produce clean, cosmetically consistent welds that passed 100% non-destructive testing (NDT)
The beam was programmed to follow custom weld paths for two major seams—joining the body to the flange and the nozzle—and a third weld path to seal a precision-fitted plug. The combination of beam control, vacuum environment, and strict process monitoring allowed us to complete all welds in a single setup with perfect alignment and minimal distortion.
Welding Procedure Highlights
- Weld 1: Circular seam between cylindrical body and precision-machined flange
- Weld 2: Tapered joint connecting the body to the exhaust nozzle
- Weld 3: Plug weld to seal a thermally sensitive cavity
Each weld was digitally controlled and monitored to ensure heat input, beam focus, and vacuum levels remained within tight parameters. The entire process was completed in a controlled cleanroom environment at our Indianapolis EB welding facility.
Outcome & Benefits
The final combustion chamber passed all dimensional, functional, and visual inspection criteria:
- All welds passed NDT including X-ray and dye penetrant testing
- No post-weld rework required, preserving component integrity
- Delivered on time and in alignment with the client’s production schedule
- Approved for follow-on production work by the client’s engineering and quality teams
Why Electron Beam Welding Was the Best Fit
This project highlights why electron beam welding is essential for aerospace assemblies that require:
- Welding of dissimilar or exotic alloys with precision
- Minimal heat distortion on tight-tolerance parts
- Full penetration joints without the risk of porosity or contamination
- Superior metallurgical quality due to vacuum conditions
About CF Roark’s EB Welding Capabilities
Roark offers industry-leading electron beam welding services for the aerospace, defense, and energy sectors. With a dedicated team of engineers, certified technicians, and quality professionals, we deliver:
- Full penetration EB welds with ±0.002” positional accuracy
- Weld chamber capacity up to 60” in diameter
- Multi-axis fixturing for complex geometries
- Full traceability and documentation for critical components