<abstract xmlns="http://www.w3.org/1999/xhtml"> This contribution deals with the issue of electron beam welding of high-accurate gear wheels composed of a spur gearing and fluted shaft joined with a face weld for automotive industry. Both parts made of the high-strength low-alloy steel are welded in the condition after final machining and heat treatment, performed by case hardening, whereas it is required that the run-out in the critical point of weldment after welding, i. e. after the final operation, would be 0.04 mm max.. In case of common welding procedure, cracks were formed in the weld, initiated by spiking in the weld root. Crack formation was prevented by the use of an interlocking joint with a rounded recess and suitable welding parameters, eliminating crack initiation by spiking in the weld root. Minimisation of the welding distortions was achieved by the application of tack welding with simultaneous splitting of one beam into two parts in the opposite sections of circumferential face weld attained on the principle of a new system of controlled deflection with digital scanning of the beam. This welding procedure assured that the weldment temperature after welding would not be higher than 400 °C. Thus, this procedure allowed achieving the final run-outs in the critical point of gearwheels within the maximum range up to 0.04 mm, which is acceptable for the given application. Accurate optical measurements did not reveal any changes in the teeth dimensions.</abstract>

This contribution deals with the issue of electron beam welding of high-accurate gear wheels composed of a spur gearing and fluted shaft joined with a face weld for automotive industry. Both parts made of the high-strength low-alloy steel are welded in the condition after final machining and heat treatment, performed by case hardening, whereas it is required that the run-out in the critical point of weldment after welding, i. e. after the final operation, would be 0.04 mm max.. In case of common welding procedure, cracks were formed in the weld, initiated by spiking in the weld root. Crack formation was prevented by the use of an interlocking joint with a rounded recess and suitable welding parameters, eliminating crack initiation by spiking in the weld root. Minimisation of the welding distortions was achieved by the application of tack welding with simultaneous splitting of one beam into two parts in the opposite sections of circumferential face weld attained on the principle of a new system of controlled deflection with digital scanning of the beam. This welding procedure assured that the weldment temperature after welding would not be higher than 400 °C. Thus, this procedure allowed achieving the final run-outs in the critical point of gearwheels within the maximum range up to 0.04 mm, which is acceptable for the given application. Accurate optical measurements did not reveal any changes in the teeth dimensions.

Electron Beam Welding of Gear Wheels by Splitted Beam

PRVÁ ZVÁRAČSKÁ, a. s. Bratislava, (First Welding Company Inc.)

Slovak University of Technology in Bratislava, Faculty of Materials Science and Technology in Trnava, Institute of Production Technologies, Department of Welding and Foundry, ul. Jána Bottu 25, 917 24 Trnava

Research Papers Faculty of Materials Science and Technology Slovak University of Technology

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.

{"article-title":"Electron Beam Welding of Gear Wheels by Splitted Beam"}

This contribution deals with the issue of electron beam welding of high-accurate gear wheels composed of a spur gearing and fluted shaft joined with a face...

Electron Beam Welding of Gear Wheels by Splitted Beam

Published Online: Nov 25, 2014

Page range: 35 - 41

DOI: https://doi.org/10.2478/rput-2014-0025

Keywords
electron beam welding, beam deflection system

© by Daniel Dřímal

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.

Electron Beam Welding of Gear Wheels by Splitted Beam

Published Online: Nov 25, 2014

Page range: 35 - 41

DOI: https://doi.org/10.2478/rput-2014-0025

Keywordselectron beam welding, beam deflection system

© by Daniel Dřímal

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.

Keywords
electron beam welding, beam deflection system