150 KV RANGE

With high accelerating voltages and beam powers our range of 150 kV electron
beam welders are used extensively within the aerospace, power generation, nuclear
and specialised industries.

Photograph courtesy of BMW/Rolls-Royce GmbH

Our 150 kV range include both standard and bespoke designs. A selection of machines
is shown below.

XW150.30

This machine includes a comprehensive tooling package including dual run-out platform, CNC controlled X-Y table, rotary tilt table, rotary pancake table, roller support manipulator and horizontal beam column support. Chamber size 5000 x 3000 x 3000 mm (16 x 10 x 10 ft) nominal internal dimensions with a 150 kV electron beam column and 30 kW power supply.

150 kV Electron Beam Column

At the heart of our 150 kV range of electron beam welders is the electron beam column designed for powers up to 30 kW
The design has been optimized to provide:

• Long filament life
• Ease of access for maintenance
• kV maintained for critical and long duration welds
• Low cost filaments can be replaced without:
  • Venting the chamber
  • Disturbing the mechanical alignment of the beam column
  • Disturbing the optics

Manipulators & work handling We have a comprehensive range of standard and bespoke systems to manipulate the piece part under the electron beam including: X-Y tables Rotary manipulators with or without a tailstock Rotary tilt, 0-900, manual or motorised Multi-station carousel Run out platforms

CNC controlled XY table with 0-900 motorised tilt 1000 mm diameter stainless steel faceplate for a 500 kg maximum load

XW150.7.5 Chamber size 1400 x 1100 x 1000 mm (55 x 44 x 40”) 7.5 kW switch mode power supply Fully automatic high vacuum system for operation in the 10-4 mbar range X-Y table, rotary tilt table & run-out platform PC/CNC control of beam parameters & work handling Conventional optics & CCTV

XW150.15 Chamber size 2000 x 1900 x 1600 mm (7 x 6 x 5 ft) 15 kW power supply X-Y table, rotary tilt table 0-900 & run-out platform PC/CNC control of beam parameters & work handling

We also have the capability to design and build special systems for particular components and offers a project management service for the customers process needs.

Computer control system HMI Operator interface Either desk mounted PC with CD-RW, colour monitor, keyboard, mouse or touch screen QA Data logging option CNC controls Dynamic change function Conventional optics and or CCTV with colour monitor

Frequently Asked Questions

Q: Why use high voltage up to 150 kV?
A: High voltage machines have an extremely long beam throw with gun to work distances up to 1.5 m.
A low angle of beam divergence gives good depth of focus and the higher the accelerating voltage the higher the velocity of the beam and the greater the depth to width ratio of the weld

Q: Can 150 kV systems be used at lower voltage?
A: Yes, our 150 kV systems can typically be used in the range of 60 to 150 kV.

Q: Why is the electron beam column externally mounted?
A: With the beam column outside the chamber the metal vapour from the process
is deposited on the chamber and not in the column making it easier to maintain kV
during welding.

Q: Why not move the electron beam column for welding?
A: We sometimes use motorised movement for positional control of the beam column however moving the column can give problems with maintenance of dynamic vacuum seals.

Q: Are there any special issues regarding health and safety and 150 kV systems?
A: All electron beam welding machines supplied by us comply with the most stringent health and safety legislation. The outside of the chamber is clad with lead and covered with painted panels. Periodic X-ray checks need to be made and this service can be provided by our after sales division as part of a preventative maintenance schedule.