PWI
National Academy of Sciences of Ukraine
E.O. Paton Electric Welding Institute

 

POWER ELECTRON BEAM WELDING UNITS

Since 1961 E.O.Paton Electric Welding Institute has developed not less than 10 types and has provided manufacturing more than 600 complete sets of the power electron beam welding units : gun with power supply and control system. The developed units not only meet the stringent requirements of ISO 14744 on time stability of power parameters of the electron beam (the limit deviations of U acc and I beam is less than +/-1%), but also provide the possibility of:
- pulse modulation of beam current;
- short-time transition from welding to a sharply-focused low-power probing of the welding zone for its real-time secondary electron imaging and, simultaneously, automatic guiding of the beam to the butt being welded;
- prevention of arc discharges in the welding gun and the resulting defects in the welds.

Up to 6 kW power sources use generators based on high-frequency transistor converters. called "switching". Due to a low stored energy of' up to I - 2 J/kW development of spark discharges into arc discharges is essentially impeded, when using such sources, thus preventing the operation of current protection of the power source.

General view of 60 kV, 6 kW power unit with high-frequency generator of accelerating voltage is given on the left in the photo.

In higher power sources of 60kV ,60kW (left) and 120kV,120kW (right) an electron tube is used as linear control element, which essentially improve the power source dynamic characteristics.

 

Some dynamic characteristics of high-voltage power sources at pulsed load.
PARAMETERS
Switch - mode type
Control tube is applied
ELA-60/1,2
ELA- 60/6
ELA-120/6
ELA-120/18
ELA-60/15
ELA-60/30
ELA-60/60
ELA-120/60
ELA-120/120
Beam power, max, kW
1,2
6
6
18
15
30
60
60
120
Accelerating voltage, kV
60
60
120
120
60
60
60
120
120
Range of welding current, mA
0,1…20
0,1…100
0,1…50
0,1…150
0,1…250
0,1…500
0,1…1000
0,1…500
0,1…1000
Stability of accelerating voltage and welding current, %
± 0,5
± 0,5
± 0,5
± 0,5
± 0,5
± 0,5
± 0,5
± 0,5
± 0,5
Angle of beam deflection
± 7°
± 7°
± 7°
± 7°
± 7°
± 7°
± 7°
± 7°
± 7°
Distance from gun to the workpiece, mm
100…300
100…300
100…300
100…300
100…300
100...300
100…300
100…300
100…300
Cooling water:
 - pressure, Mpa
 - expenditure, l/min
0,3…0,4
5
0,3…0,4
5
0,3…0,4
5
0,3…0,4
5
0,3…0,4
10
0,3…0,4
15
0,3…0,4
25
0,3…0,4
25
0,3…0,4
35
Equipment weight, kg
 - electron gun
 - gun radiating protection
 - power source
55

185
55

460
60
130
735
60
130
735
55

2500
55

2750
55

3000
60

5000
60

6000
Compatibility with computer control system and secondary electron emission system RASTR
yes
yes
yes
yes
yes
yes
yes
yes
yes
Power line 50/60 Hz
380/220
±10 %,
1, 5 kVA
380/220
±10 %,
7 kVA
380/220
±10 %,
7 kVA
380/220
±10 %,
21 kVA
380/220
±1 0 %,
20 kVA
380/220
± 10 %,
35 kVA
380/220
±10 %,
70 kVA
380/220
±10 %,
70 kVA
380/220
±10 %,
135 kVA
Maximal thickness of materials penetration, mm
- steel
- titanium alloys
- aluminum based alloys

3
3,5
5

12
15
30

15
20
35

60
100
140

50
80
120

75
110
150

100
150
200

130
220
240

250
400
450

 

Rated by PING
  Prof. Oleg K. Nazarenko
E.O. Paton Welding Institute
11 Bozhenko St., Kyiv 03680, UKRAINE
Tel/Fax: (380 44) 525-4319
E-mail: nazarenko@technobeam.com.ua
1999– 2008 PWI

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