High-energy beam processing technology is at the forefront of modern manufacturing advancements and plays a crucial role in the development of advanced weaponry and equipment. This technology utilizes high-energy-density beams—such as photons, electrons, and plasma—as energy carriers to manipulate materials and components. It is a highly interdisciplinary field that integrates optics, electricity, thermodynamics, metallurgy, material science, vacuum technology, mechanical design, automation, and computer systems. Key areas include laser processing, electron beam processing, ion beam and plasma processing, and hybrid high-energy beam techniques.
In the 1970s and 1980s, developed countries like the U.S., Japan, and Western European nations recognized the importance of high-energy beam processing and incorporated it into their industrial strategies. They established dedicated research centers such as the Osaka University, Aachen University’s Welding Institute, the British and French Welding Research Institutes, and Ukraine’s Barton Welding Research Institute. These institutions have significantly influenced the global direction of this technology.
Electron beam processing, particularly electron beam welding (EBW), has matured over the past three decades and continues to evolve. Current research focuses on real-time seam tracking, simulation of temperature fields, high-power gun development, and the integration of computer control and monitoring systems. Electron beam physical vapor deposition (EB-PVD) is gaining traction in aerospace applications, with notable achievements from Ukrainian and Russian institutions. The Barton Institute in Ukraine has developed a range of EB-PVD systems for lab, pilot, and mass production, while Russia's Kuznetsov Design Bureau has applied this technique to engine blade manufacturing since 1978.
Laser processing has seen a shift from cutting and drilling to welding, especially in aerospace and automotive sectors. High-power COâ‚‚ lasers, such as 45 kW models, are being tested for thick-section welding. Research also covers hybrid techniques like plasma-laser or arc-laser welding, along with quality inspection methods. Semiconductor lasers, known for cost-effectiveness and longevity, are increasingly used in automotive production lines.
Plasma processing has advanced rapidly, driven by aerospace needs. Techniques like plasma cutting, welding, spraying, and ion implantation are widely used. In Russia, Novosibirsk’s Science Campus has made significant contributions to plasma jet research, while Ukraine’s Barton Institute has pioneered supersonic and microplasma spraying. Plasma spray forming technology is expected to see major growth in the 21st century.
China began developing high-energy beam processing in the 1960s through the establishment of the "Key Laboratory of High-Energy Beam Processing Technology" under the China Aviation Industry Corporation. Despite progress in areas like electron beam welding, laser cutting, and plasma spraying, China still lags behind in basic research, quality control, and equipment. To close the gap, the country must enhance international collaboration, focus on key application areas, and promote an open, collaborative research environment.
During the "Ninth Five-Year Plan," the laboratory focused on laser hole-making, precision welding, shock hardening, holography-based inspection, rapid prototyping, multi-functional electron beam processing, and plasma coating technologies. These efforts aim to elevate China’s position in this critical technological domain.
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