Transferring Electron Beam Welding Parameters Between DIfferent Machines and Facilities Using Advanced Diagnostics

Transferring electron beam (EB) welding parameters between different welders can be a costly and time consuming process requiring the completion of expensive weld parameter studies. In order to modernize and streamline this process, the LLNL Beam Profiler diagnostic tool, which has been developed and tested at Lawrence Livermore National Laboratory (LLNL) to measure the size, shape, and power density distribution of electron beams, is currently being used to characterize the performance of EB machines at several U.S. Department of Energy facilities. The characterization of these machines involves performing defocus studies on each welder to measure the properties of 1 kW beams made at constant current, voltage, and work distance settings. Using these carefully characterized beams, autogenous welds on 304L stainless steel were then made at LLNL and replicated on the other machines. A key finding from these studies was that the widespread use of work distance values measured from the surface of the part being welded to the top of the EB vacuum chamber are suitable only for machines with a similar upper column design. Otherwise, the focus-lens to part distance must be determined and controlled. A simple method for determining the focus-lens to part distance with the LLNL Beam Profiler diagnostic tool is presented. The ability to transfer EB welds between machines represents a major accomplishment in the development and more widespread use of this diagnostic tool. This work also serves as a basis for the continuing development of procedures and equipment for characterizing electron beams and as a precursor to the development of a modern weld transfer procedure