Aerospace

Spiral bevel gears are flight critical components used in helicopter drive  systems and aircraft engines. These parts, which rotate at high speeds and operate at high loads, require virtually defect free welds.  NADCAP approved electron beam welding is the process of choice for aerospace gears. 

Description:

Shaft - approx. 7 in.
Gear Diameter - 5 in.

Material(s):

High Strength Steel

Joint Geometry:

radial circumferential weld

Weld Depth:

0.500 in. full penetration

In normal operation, jet engine fan blades are subject to foreign object damage (FOD) and erosion. A cost efective alternative to new replacement parts is to repair the damaged or worn blades. In a typical fan blade repair, the damaged leading edge section is removed and a "patch" is electron beam welded in place. The electron beam welding process,  which is performed in vacuum, is ideal for preventing oxidation and maintaining the material properties of the titanium fan blade. In the final step, the patch is machined and contoured to the original shape.

Description:

First Stage Fan Blade
Repair (up to 3 ft long)

Material(s):

Ti6Al4V

Joint Geometry:

butt weld

Weld Depth:

0.100 - 0.500 in.

EB welding joins finish machined compressor discs into a multistage compressor rotor, or drum. The parallel sided electron beam welds are predictable with minimal uni-directional shrinkage.This allows the joining of these finished components without further machining.

Description:

Compressor Rotor

Material(s):

Titanium, Stainless Steel

Joint Geometry:

radial circumferential welds

Weld Depth:

up to 1 in.