Edge-welded products are manufactured using sheets of metal that are hydraulically stamped into the shape of the diaphragm and then welded together, ID to ID then OD to OD, to your specified length using plasma, laser, arc, or electron beam welding equipment to make the flexible bellows. End plates, flanges, or other required hardware are then added to each end. They can also be produced in either round or rectangular configurations.
Metal bellows produced using the edge-welding process allow for the highest stroke length, reaching 90% of its free length. This flexibility allows the bellows to expand and contract as needed. They are highly durable in extreme temperature and pressure environments and can be exposed to liquid and gaseous elements. Pressures above 1,000 PSI between the inside and outside are typically not recommended; however, if greater pressure environments are needed, customizations can be made.
MW Components uses a proprietary welding process that provides longer-lasting & more durable products than traditional methods. In-house
machining & tooling ensure that we’re able to provide fast prototyping and
quick turnarounds of full production runs. We also offer assembly refurbishment
services, replacing damaged bellows in expensive assemblies and allowing for
the re-use of machined components.
Need Bellows Assembly or Repair?
We know that metal bellows can be expensive, that's we offer bellows assembly and repair in addition to custom manufacturing of edge-welding products. Contact us for a custom quote to learn more.
- This process easily forms complex shapes with intricate geometries.
- Various pressure, temperature, stroke, and dimensions available depending on the material used.
- Edge-welding produces a longer possible stroke. Some designs can stroke as long as the free length.
- Reduced risk of catastrophic failure in critical applications due to a high level of precision in manufacturing, creating added durability.
- High max pressure - Certain designs can withstand up to 2,500 psi (external). We have achieved over 15,000 psi (external) with an oil-filled (internal) design.
- Extremely high life cycle rate - Up to 1,000,000,000 cycles (Theoretical “Infinite” Life)
- Achievable leak rate - 1x10-5 to 1x10-9 cc He/sec.
Aircraft bellows are used for many different purposes. Edge welded bellows are often used in aircraft devices to regulate and manage fuel, for instance. In the broader sense, many engineers also use bellows actuators to convert pressure and/or temperature into motion, while volume compensators are used to balance pressure or temperature differentials, ensuring continuous, accurate system operation. Altimeters use bellows to sense barometric pressure. Bellows can also assist in the movement of air through the ducting system.
The medical industry uses edge welded metal bellows for medical test equipment, metal bellows pumps, reservoirs, connectivity, and invasive systems. Using bellows in these systems opens up a range of opportunities to increase performance or efficiency. These types of bellows often have small size requirements, which is why MW Components' standard diaphragms are available in diameters of less than half an inch. To further improve performance in medical applications, MW Components leverages edge welded technology to make it possible for medical-grade bellows assemblies to completely compress onto themselves, creating even smaller sizes and increasing efficiency.
With the right engineering design and manufacturing expertise, metal bellows can maintain temperatures as low as -95°C. This ability makes metal bellows a trusted solution for NASA cryogenic temperature chambers and other, similar applications.
Edge welded bellows are used as flexible penetrations into process chambers in ultra-high vacuum (UHV) and semiconductor manufacturing. The metal semiconductor bellows provides motion inside the process chamber, while also becoming part of the chamber's pressure wall. This allows the metal bellows to hold ultra-high vacuum or moderate positive pressures while offering essential motion within the chamber. By using a metal bellows in this way, it's possible to manipulate stages, probes, sample holders, wafer lifters, valves, actuators, and other mechanical motion needs within the pressure vessel.
Many times hazardous conditions and remote locations create a need for accurate, repeatable measurements for oil and gas bellows. MW Components customizes bellows to survive the high temperatures, pressures, and corrosive media associated with the oil and gas industry. You'll often find our bellows as components in lift valves, inside of down-hole tools, sub-sea ROVs and transformers, and more.
Test stand applications often require customization of ends, diaphragm sizes, and other add-ons. MW Components offers customized edge welded bellows that can be used in expansion joints, vibration dampeners, actuators, and more. We'll help optimize every bellows we manufacture to lower your project cost and time.