E-beam Welding Shunt: Ushering in A New Era Of High-Precision Current Measurement

Electron beam welding uses an accelerated and focused electron beam to bombard a welding surface placed in a vacuum or non-vacuum environment, melting the workpieces and achieving welding. The electron beam is heated by a cathode (usually tungsten or lanthanum hexaboride) and then emitted. It is accelerated to 30%-70% of the speed of light in a high-voltage electric field (usually 30-200 kV). It is focused by an electromagnetic lens, resulting in a beam spot diameter as small as 0.1 mm. A magnetic deflection coil controls the scanning path. When the electron beam strikes the workpiece surface, its kinetic energy is instantly converted into thermal energy, with local temperatures reaching over 2500℃. This melts the material, forming a molten pool and achieving welding.

Manganin Shunts are made of copper, manganese copper, or copper. The copper ends serve as the current-carrying terminals, while the manganese copper alloy in the middle serves as the resistor body. In this structure, copper has excellent electrical and thermal conductivity, enabling efficient current transmission. Manganese copper alloy offers stable resistance and a low temperature coefficient, ensuring the shunt's measurement accuracy. The manganese, copper, and copper are joined together using vacuum electron beam welding to form a single, integrated shunt element.

Electron beam welding enables precise connections, ensuring the accuracy and stability of the Shunt Terminal's resistance value. For example, the EBW5216 series shunt resistors offer tolerances as low as 1%, a measured TCR of 150ppm/℃, a TCR of 20ppm/℃ for resistor alloys, and a thermoelectric EMF of <1µV/°C, enabling accurate current sensing in the hundreds of amperes range.

Copper Manganeses made from electron-beam welded metal strips, such as the CSS4C-1216 series, offer extremely low inductance (<2nH). This ensures accurate and stable operation across a wide operating temperature range of -65°C to +170°C, meeting the precise current measurement requirements of high-performance applications.

Electron-beam welding creates strong welds, and the welding process is performed in a vacuum or shielded gas environment, eliminating the effects of oxidation and impurities, resulting in excellent long-term stability and durability.

For shunt resistors under 3mm, continuous electron beam production lines, such as dual-chamber continuous electron beam welding systems, can be used to continuously weld the seams between the manganese copper and the copper. This ensures consistent quality and significantly improves production efficiency. For precision Electricity Meter Shunts thicker than 3mm, narrow vacuum electron beam welding systems can be used. Using a fixture, 10-20 pieces can be welded at a time, also significantly improving production efficiency.

Our Manganin Shunt electron beam welding shunts are not only suitable for battery management systems, inverters, and power electronics in the automotive industry, but also for welding power supplies, motor drives, energy metering, and process control in the industrial sector. In the consumer electronics sector, our products also provide high-precision, high-reliability current measurement solutions for battery management systems in high-end smartphones and laptops.

Choosing our E-beam Welding Shunt offers the perfect combination of high precision, high reliability, and efficient production. We are committed to providing every customer with the highest-quality products and services, helping your devices stand out in a highly competitive market and achieve safe, stable, and efficient operation.