Real-Time Adaptive Control for Conduction Mode EB Welding of Niobium SRF Cavities

The proposed project is intended to develop and demonstrate advanced weld process monitoring to improve the quality and reduce scrap and repairs of high value conduction mode welds. Conduction mode welding of niobium superconducting radio frequency components is an enabling technique developed over several decades. Producing these critical welds currently requires very tight tolerance joint preparation otherwise variations in material thickness and fitup can lead to weld defects such as ôblow throughö that can either result in scrapping of a component or costly repairs and schedule delays. The electron beam welding operations are often performed on complex assemblies that represent cost in excess of $350K for total materials and fabrication steps. It is being proposed to apply Sciakyĺs IRISS® electron beam additive manufacturing melt pool control software to the conduction mode EB welding process. Utilizing active melt pool control automatic adjustments shall be made to compensate for typical material and joint variations reducing or eliminating the potential for ôblow throughö defects. An array of samples will be welded using the adapted control software to demonstrate improved control of conduction mode EB welding for niobium superconducting radio frequency applications. Future efforts may include adapting the control software to other types of electron beam welding for different applications. Additionally, this technology can be adapted onto an Electron Beam Welder purchased by Michigan State University after completion of this project.