Electron Beam Welding(EBW)

Electron Beam Welding (EBW)

With the acquisition of KTI, Inc, Advance Welding now specializes in Nadcap and FAA certified electron beam welding and laser welding. All of KTI’s key skilled personnel, machinery, and capabilities for electron beam welding and laser welding came across in the acquisition. We provide welded components for ground turbine engines, power generation equipment, sensor components, missile components and turbo machinery. Various capabilities include tooling, fixturing, designing, etching, inspection, research and development. The acquisition of KTI expands Advance Welding’s ability to serve the aerospace, automotive, electronic, military, medical, commercial and industrial industries. Advance Welding provides electron beam welding services that can accommodate large and small components. We achieve superior control over depth of penetration, weld dimensions, and other properties. Electron beam welding can join together metals that are difficult or impossible to weld with conventional welding processes. EB welding produces welds that are deeper, narrower, and less tapered than conventional welding processes. Our electron beam welding facilities include chambers measuring up to 90” diameter x 192” long, with a 28” diameter x 96” long chamber extension, yielding a maximum overall length of 288”.  The largest chamber is serviced by a 3 ton crane.  Typical applications include aft flange replacement of Low Pressure Turbine Case for commercial aviation end use. The smallest chamber measures 12” cubed and features fast cycle time for cost effective welding of small parts and high volume production. There are three additional EB welding chambers of various intermediate sizes, so that chamber selection can be optimized for part size and weld penetration requirements to maximize efficiency. To better meet the needs of our clients, we have developed strategic alliances with other complementary service shops. These include machining, alternative weld processes, and non-destructive testing. Advance Welding can handle full project and supply chain management for a wide range of components. In addition, our well-equipped facility possesses a limited variety of machining capabilities that complement our welding services. Advance Welding has engineering staff who can offer expertise and assistance in weld joint design and material selection. Advance Welding is now an industry leader in Electron Beam welding technology.

Examples of Our Work

Electron Beam Welding of Long Stainless Steel Vacuum Chamber Part for Nuclear Physics Lab Electron Beam Welding of Steel Diaphragm for the Utility Industry Electron Beam Welding of a Distance Tube Assembly for the GBT & Power Generation Industry Laser and Electron Beam Welding of Stainless Steel Assembly for the Commercial Industry

Advance Welding’s metal joining expertise includes welding on common and specialty metals that include:

  • Carbon and Alloy Steels (Ex.: A36, 1018, 1020)
  • Heat Treatable Alloy Steels (Ex.: 4130, 4140)
  • Stainless Steel (Ex.: 304, 316, 410)
  • Precipitation Hardenable Stainless Steel (Ex.: 13-8Mo, 15-5PH, 17-4PH)
  • Nickel and Nickel-Based Alloys (Ex.: Monel 400, Inconel 625, Hastelloy X)
  • Precipitation Hardening Nickel & Nickel-Based Alloys (Ex.: Monel K500, Rene 41, Inconel 718)
  • Non-Heat Treatable Aluminum Alloys (Ex.: 5052, 5083, 5086)
  • Heat Treatable Aluminum Alloys (Ex.: 355, 356, 6061)
  • Magnesium Alloys (Ex.: AZ31B, AZ91A)
  • Titanium Alloys (Ex.: Grade 2, 6Al4V)
  • Copper Alloys
  • Cobalt-Based Alloys (Overlay, Hardfacing)

Advance Welding has significant experience welding on these types of components:

  • Combustion Cases
  • Combustion Liners
  • High-Pressure Turbine (HPT) Cases
  • Low-Pressure Turbine (LPT) Cases
  • Aviation Ground Support Equipment
  • Aviation Bearing Seal Assemblies
  • Aviation Engine Handling Fixtures and Tooling
  • NAVSEA Ship Components
  • Ground-Based Turbine Components
  • Aircraft Engine Components
Electron Beam & Laser Welding Capabilities Industry Focus
  • Aerospace
  • Automotive
  • Biomedical
  • Computer & Communications
  • Electronics
  • Industrial
  • Medical
  • Military, Defense, and Homeland Security
  • Oil & Gas Power Generation
  • Sensors
  • Gear Manufacturers
Electron Beam & Laser Welding Application
  • Aircraft Engine Components
  • Airframe Components
  • Automotive Components
  • Ground-Based Turbine Components
We can handle a large range of applications
  • Machine Builders
  • Fabrication Shops
  • Paper & Pulp
  • Temperature, Vibration, and Pressure Sensors
  • High Purity
  • Higher Welding Speeds
  • Minimal Distortion
  • Low Heat Input
  • Minimal Need for Secondary Operations
  • Precise Control Over Weld Penetration
  • Repeatable Process Control
Can Join:
  • Copper and Non-Ferrous Alloys
  • Dissimilar Metals & Alloys
  • Materials w/ Different Conductivities
  • Nickel Alloys
  • Stainless Steel Alloys
  • Super & High-Temperature Alloys

Electron Beam Welding Equipment

Hamilton Standard SW-5
  • 192″ x 90″ Dia.
  • CNC Controlled
  • 5 Ton Capacity
Hamilton Standard W-2
  • 132″ x 62″ x 62″
  • 1 Ton Capacity
Hamilton Standard W-2
  • 62″ x 62″ x 62″
  • CNC Controlled
Hamilton Standard W-2
  • 78″ x 36″ x 36″
Leybold Hereaus W-3
  • 108″ x 56″ x 66″
  • 12″ x 12″ x 12″
Production Volume Min 1 Part Prototype to Production Multi-Shift Operation Max 100,000+ Parts Per Year Part Weight Max 5 Ton Capacity Certifications
  • Boeing
  • G.E.
  • Honeywell
  • Lockheed Martin
  • Pratt & Whitney
  • Rolls Royce

Additional Services Provided

  • Multi-Component Assemblies
  • Weld Development
  • Weld Joint Design
  • Material Selection
  • Sectioning
  • Etching
  • Microscopic
Helium Leak Testing (10 -9 cc/sec.) Machining
  • Custom Fixturing and Tooling
Research and Development Stress Relieving