Weld joint design for automatic welding of tubular detectors

1. A detector including:

an outer shell having a shell profile in which a welded portion of the shell profile extends as an annular flange in an outward direction relative to a center axis of the outer shell; and

an end cap positioned adjacent the welded portion of the outer shell, the end cap and the welded portion of the outer shell being configured to be welded together to form a seal.

2. The detector of claim 1 , wherein the end cap includes a welded annular shoulder such that the welded annular shoulder and the welded portion of the outer shell are configured for automatic welding and are welded together as part of an automated welding process.

3. The detector of claim 1 , wherein the shell profile of the outer shell includes an annular recess positioned between the welded portion on one longitudinal side along the axis and a shell projection on an opposing longitudinal side along the axis.

4. The detector of claim 3 , wherein the end cap includes a cap profile that substantially matches at least a portion of the shell profile.

5. The detector for claim 4 , wherein the cap profile includes a cap recess positioned between the shoulder on one longitudinal side along the axis and a cap projection on an opposing longitudinal side along the axis.

6. The detector of claim 5 , wherein the welded portion of the outer shell is positioned longitudinally adjacent and in contact with the shoulder.

7. The detector of claim 6 , wherein the shell profile has an aspect ratio of a radial length of the welded portion to a thickness of the outer shell of at least 1.0.

8. The detector of claim 7 , wherein the radial length of the welded portion is approximately 1.5 millimeters and the thickness of the outer shell is approximately 0.9 millimeters.

9. The detector of claim 1 , wherein a welded annular shoulder of the end cap and the welded portion of the outer shell are configured to for welding from a radial direction and are welded together as part of a welding process directed from a radial direction.

10. A detector including:

an outer shell, acting as a cathode, extending along an axis, the outer shell having a shell profile in which a welded portion of the shell profile extends as an annular flange in a radially outward direction relative to the axis;

an anode extending along the axis within the outer shell; and

an end cap supporting the anode and extending within an end of the outer shell, the end cap including a cap profile that matches the shell profile of the outer shell, wherein the end cap includes a welded annular shoulder that extends radially outward with relative to the axis, and the welded shoulder and the welded portion of the outer shell are adjacent each other and welded together to form a seal.

11. The detector of claim 10 , wherein the shoulder and the welded portion of the outer shell are configured to for welding from a radial direction and are welded together as part of a welding process directed from a radial direction.

12. The detector of claim 11 , wherein the shoulder and the welded portion of the outer shell are configured to for automatic welding and are welded together as part of an automated welding process.

13. The detector of claim 10 , wherein the shell profile of the outer shell includes a recess positioned between the welded portion on one longitudinal side along the axis and a shell projection on an opposing longitudinal side along the axis.

14. The detector of claim 13 , wherein the shell projection is spaced a distance apart from the welded portion such that the shell projection is not welded.

15. The detector of claim 10 , wherein the radial length of the welded portion is approximately 1.5 millimeters and the thickness of the outer shell is approximately 0.9 millimeters.

16. The detector of claim 10 , wherein the shell profile has an aspect ratio of a radial length of the welded portion to a thickness of the outer shell of at least 1.0.

17. A method of making a detector, the method including:

providing an outer shell, acting as a cathode, extending along an axis,

providing an anode extending along the axis within the outer shell;

positioning an end cap within an end of the outer shell to support the anode, the end cap including a cap profile in which a shoulder of the end cap extends in a radially outward direction;

crimping a portion of the outer shell to form a shell profile that matches the cap profile of the end cap, wherein a welded portion of the outer shell extends in a radially outward direction adjacent the shoulder of the end cap; and

welding the welded portion of the outer shell and shoulder of the end cap together from the radially outward direction.

18. The method of claim 17 , further including rotating the neutron detector during the step of welding such that the outer shell and shoulder are welded at substantially 360° around the neutron detector.

19. The method of claim 18 , wherein the outer shell and end cap are hermetically sealed.

20. The method of claim 17 , wherein the shell profile has an aspect ratio of a radial length of the welded portion to a thickness of the outer shell of at least 1.0.