Cambridge Vacuum Engineering (CVE), known for its expertise in electron beam and laser welding, has announced the successful conclusion of a Knowledge Transfer Partnership (KTP) with Cranfield University. This collaborative effort has addressed the optical contamination challenges associated with Laser in Vacuum welding, clearing the way for its widespread industrial utilization.
Cambridge Vacuum Engineering (CVE), operating as Aquasium Technology Ltd, is an entity specializing in the design and construction of process solutions. With over six decades of expertise, CVE operates in manufacturing electron beam (EB) systems tailored for various industrial sectors, including aerospace, nuclear, automotive, oil and gas, and sensors.
Notably, approximately 95% of CVE’s systems are exported, with key markets in the USA, China, India, and Europe.
With headquarters in Waterbeach, CVE has regional offices in Beijing, China, and Massachusetts, USA, along with a global network of agents. The company’s dedication to innovation and collaboration has solidified its position as a leader in the electron beam and laser welding domain.
CVE’s portfolio of EB welding equipment encompasses systems ranging from 50-200kV, featuring beam powers of up to 100kW. The company’s commitment to meeting diverse customer requirements is underscored by its team of skilled designers and engineers, enabling the creation of bespoke manufacturing equipment.
Cranfield University, a specialized postgraduate institution, is one of the global leaders in education and transformative research within the realms of technology and management. The university has garnered acclaim in the most recent Research Excellence Framework, with 88% of its research rated as world-leading or internationally excellent.
Cranfield’s focus revolves around key themes such as aerospace, defense and security, energy and sustainability, environment and agrifood, manufacturing and materials, transport systems, and water.
The Cranfield School of Management, an integral part of the university, holds a distinguished position as a world leader in management education and research. Cranfield boasts the remarkable feat of being a six-time recipient of the prestigious Queen’s Anniversary Prize—an exclusive national honor recognizing educational institutions for their contributions in the public interest.
Laser in Vacuum welding, a cutting-edge joining technique, has demonstrated the capability to achieve weld depths two to three times greater than conventional laser welding methods. However, the impediment of optics contamination has hindered its broad adoption across various industries.
CVE and Cranfield University, with a shared commitment to fostering innovation, collaborated on a two-year research initiative, supported by Innovate UK funding, to unravel solutions to this persistent challenge.
The project involved setting up test systems at both CVE and Cranfield, allowing comprehensive exploration of different aspects of the Laser in Vacuum process and the trial of various concepts and solutions.
By leveraging a first-principles, physics-based approach, the teams developed a unique optics protection system that effectively operates with minimal particulate generation. The system ensures cleanliness levels comparable to electron beam welding, enhancing the quality of welded parts.
Several trials were conducted with customers, validating the capabilities of Laser in Vacuum welding across diverse applications, materials, and joint configurations. The project received the highest grade of ‘Outstanding’ from Innovate UK.
Innovate UK, the United Kingdom’s national innovation agency, fosters economic growth by assisting businesses in cultivating and actualizing new ideas. This includes leveraging the country’s outstanding research base to connect businesses with partners, customers, and investors, facilitating the transformation of innovative concepts into commercially successful products, services, and overall business expansion.
Max Nentwich, KTP Project Lead and Head Laser Development Engineer at CVE, emphasized the breakthrough’s importance in the commercialization of Laser in Vacuum welding. Addressing the optics contamination issue unlocks the full potential of this welding technique, enabling it to reach full industrial maturity. Nentwich expressed pride in leading such a meaningful project and highlighted its immediate implications for industry, delivering enhanced productivity, efficiency, and quality.
CVE’s optical protection system ensures the cleanliness of welded parts comparable to electron beam welding, with long-lasting consumable windows that last up to three hours of welding at low power (3kW) without significant weld degradation.
Steve Horrex, Sales Director at CVE, congratulated Max Nentwich and the Cranfield team for completing the project with exceptional results. The impressive grade from Innovate UK validates the future impact of the project, and CVE looks forward to bringing the results to market for commercial benefits across various sectors.
Wojciech Suder, Senior Lecturer at Cranfield University, commended the collaboration for efficiently developing the technology and converting a lab idea into a commercial system in just over two years. He anticipates the technology revolutionizing thick section and specialized welding applications.
Jody Chatterjee, Knowledge Transfer Advisor at Innovate UK (KTN), praised the innovative and productive KTP project, recognizing the excellent contributions of Max Nentwich. KTP projects, which span various industries and sectors, play a crucial role in facilitating knowledge transfer and fostering collaboration.
Laser in Vacuum welding, complementing electron beam and standard laser welding techniques, offers a technology-agnostic approach. CVE, equipped with all three welding types, provides customers with bespoke solutions optimized for different application needs and engineering challenges. The technique is particularly suited for projects requiring higher penetration welds or involving gas-sensitive materials, where standard laser welding may face challenges.
The successful conclusion of the KTP project positions CVE as one of the pioneers in Laser in Vacuum welding technology, reflecting its vision to advancing industrial welding techniques. The company is now incorporating the developed technology into Laser in Vacuum welding machines for its industrial customers.