Electron Beam Welding Services

At CASRAM SA we provide contract electron beam welding (EBW) so you can access vacuum clean, ultra deep welds without investing in specialised equipment. Our Swiss-made, 24 kW / 60 kV EB welder delivers repeatable results for copper, steel and mixed-metal assemblies across demanding industries.

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Why ElectronBeam Welding?

• Deep penetration (≤ 35 mm) in a single pass—ideal for thick sections.
• Minimal distortion & narrow heat affected zone thanks to high vacuum keyhole welding.
• Oxide free, zero porosity joints—no filler wire, flux or post cleaning required.
• Reliable for copper and copper to steel where conventional arc or laser processes struggle.

 

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Key Benefits of Outsourcing EBW to CASRAM

 

Swiss precision & process control	4-axis Siemens Sinumerik CNC, repeatability ±15 µm
Quick pump down (≤ 3 min to 8 × 10³ mbar)	Short cycle times, competitive lead times
Up to Ø 800 mm × 500 mm, 35 kg	Suitable for medium sized components & sub-assemblies
Integrated QC: X-ray, helium leak, metallography	Traceable, standards compliant documentation
Flexible batch sizes—from prototypes to series	Scale production without capital expenditure

 

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Industries & Use-Cases We Support

• E-mobility & Power Electronics – copper busbars, high-current terminals
• Aerospace & Defence – rotor bars, cryogenic transition joints
• Vacuum & Scientific Instruments – leak tight sensor housings, RF cavities
• Energy & Heat Exchange – Cu-steel heat exchanger plates, pressure vessels, CuW electrical contacts
• Medical & Semiconductor – contamination free Cu/Cu welds for clean room parts

 

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Typical Components

• Busbars • End rings • Vacuum flanges • Sensor bodies • Heat-exchanger plates
• Copper-to-steel transition joints • Battery tabs • Cryogenic feed-throughs
• Copper Tungsten Electrical Contacts • Contact Rings • Contact Tulips and Pins

 

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Technical Specification

ParameterCapability

Gun power	24 kW (60 kV)
Max. weld depth	35 mm
Work envelope	Ø ≤ 800 mm, L ≤ 500 mm
Max. part weight	35 kg
Chamber pressure	≤ 8 × 10 ³ mbar
Axes / Control	4 CNC (Siemens Sinumerik)
Qualified materials	Cu/Cu, Cu/Steel

 

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Request a Technical Review

Upload your STEP/PDF drawing and material data → our welding engineers will return a feasibility assessment and quotation—usually within a couple of days.

Email: info@casram.com | Phone: +41 91 611 21 10