e-Ion Plasma™ - Thermal Plasma Generator About e-Ion Devices
The unique e-Ion Plasma™ allows for unique applications of Ions, Electrons, Radiation and Hot Gases, revolutionizing traditional processes such as brazing, hardfacing, sintering and surface cleaning.
The e-Ion Plasma's™ CleanElectricFlame™ technology can reduce 36 hour processes down to a few minutes. CleanElectricFlame™ technology uses just electricity and air, leaving behind no residues. MHI's e-Ion Plasma™ uses less energy, produces less noise and is safer than traditional heating methods.
e-Ion systems are available for use with plastics, metals, ceramics, composites and a number of other materials. e-Ion devices can sinter Titanium in minutes. Even Copper and Tungsten-Copper alloys have shiny finish after e-Ion treatment.
Learn More About e-Ion Plasma™ Technology What is e-Ion Plasma™?
Features of Plasma (Brochure)
Extremely Wide Area Plasma (with LIP)
Contact Us for a Live Demonstration
Not sure if e-Ion Plasma™ is right for your application?
Arrange to have your part treated during a live video chat.
MHI's unique e-Ion Plasma™ features novel technology that allows it to replace existing processes while simultaneously improving efficiency and productivity. Immerse in CleanElectricFlame™ for non line-of-sight processing or bend-heat requirements.
Compare with Laser.
e-Ion Plasma™ Uses
Rapid Degreasing and Stripping
Rapid Deburring and Smoothing from Metals to Plastics. Smooth Finishing.
Nickel or Cobalt Alloy Brazing and Hardfacing (call for details)
Surface treatment without grounding object. Connect to gas and electric.
Plastic Surface Functional Manipulation (please download ideation brochure). Plasma Ideation Brochure.
Heat Treatment for hardening and other processes. Please click on comparison tabs above.
Electron beam replacement
Electron Beam Furnace
Smoothing and conditioning.
Compare to electron beam or laser welding Cleaning extruded plastics. Avoid toxic chemicals. Unique power adjustments possible.
Plasma Ideation Brochure.
Compare to electron or laser beam Melting
Induction Heat Treating
Improving surface adhesion. Cause functionalization. Compare to Induction Heat Treating
EB Welding support
Extremely Wide Area Plasma (with LIP)
Compare to Induction Melting. Please download aluminum processing brochure, Download Plasma Applications for Aluminum Supplement.
Laser Welding support Surface Cleaning
Enable Plastic Welding
Enable Seam Welding. Dissimilar Materials.
Thin Film Deposition Carburization
Rapid Thermal Processing
Output Shaft Hardening
Horizontal Drive Bar Hardening
Shock Absorber Stem Hardening
Axle Shaft Hardening
Constant Velocity Joint Hardening
Hardening of power take-off.
Cardan Shaft Hardening
Bolt Head Hardening
Heating of titanium and/or stainless steel wires and subsequent warm heading on multistage header.
Hard Metal Tool Brazing
On-line tempering of mechanical parts.
Hardening and tempering of chains.
Section hardening of tools for agriculture.
Drive Shaft Hardening
Stub Shaft Hardening
Power Transmission Shaft Hardening
High Wear Application Hardening
Automotive Axle Shaft Hardening
Internal & External Tube Brazing
Oil & Gas Wear Resistance Treating
Rapid Tool Bit Manufacturing (WC-Cobalt)
Manufacturing Shiny Parts without Reducing Gas. Copper Brazing.
Low to mid-carbon steel heat-treatment (4140 grade)
Bio Implants of Plastics, Cobalt alloys or Titanium alloys for various types of surface enhancements from antimicrobial to best fusion with base metal.
Comparisons with directed energy systems (Laser to Sunlight)
Surface Impact Beam up to 150mm, large impact, improves productivity. Large area allows for CleanElectricFlame soaking at various power settings.
Commonly available average beam size is less than 2mm
Commonly less than 0.5mm beam
Depth varies with frequency of machine.
Welding/Joining Yes, even for dissimilar materials
Yes, limited by beam parameters
Yes, limited by beam parameters
Very rare possibilities
No for non-metals or poor electrical conductors like ceramics or plastics
Yes when metallic. Coils need to couple and sometimes be formed into complex shapes.
Vacuum Always Required? No. Plasmize Air to cut down on cost of input gas.
Cannot be used with metal.
Power Density 10
6-10 9 W/m 2 10
6-10 8 W/m 2 for commonly used industrial CO2 continuous lasers. Depends on laser type. ~10
6 W/m 2 Depends on acceleration voltage and wavelength of beam
Commonly about 1 to 2 kW for entire chamber. Power density is low for surface. Bulk volume dominates as major term for power density.
Efficiency depends on Coil spacing, frequency and type of materials keep in coil.
3 W/m 2 (average)
Water Requirement None. High Energy Efficiency.
Energy Efficiency Very high
e-Ion Plasma™ use compared to Combustion
CleanElectricFlame™. Nitrogen e-Ion Plasma™ Plume (possible species include N2, N2+ , N+, N, e-). Discharge is into room air conditions.
(Conventional Plume) MHI Advanced LIP System GEN 3
Emissions, Health & Environment
Likely to produce CO2, SO2 and soot
Uses combustion gas inputs of fuel and air, commonly requiring plumbing
Typical 20,000 BTU/hr burners produce about 22 moles of greenhouse gasses per hour
Fossil fuel powered combustion often leads to toxic byproducts such as Carbon Monoxide
Surfaces impacted by flame may be contaminated with small size soot-like particles
CleanElectricFlame™ technology produces no CO2, SO2 or soot as a byproduct
No toxic emissions. Air is typical input.
Electricity powered, no plumbing or piping needed
No venting required
Uses only air input, no other gasses
No greenhouse gasses
Air to Air. It's like changing your combustion flame to an electric flame
Highly efficient, saving on energy costs
No residues left because of process
May improve shelf life and quality of products
Narrow area impact when requiring intense flame, non-uniform heat application
Uniformity requirements may require multiple burners
User configurable width of plume
Requires less monitoring, saving on labor costs
Highly combustible, volatile
Incomplete combustion may be a down-stream fire hazard
No combustible gasses used as inputs
LIP systems offer integrated over-temperature controls
Flames are energy inefficient, with only around 10% of their energy able to be utilized for heat as quantized radiation may dissipate heat
Over 90% energy efficient
Realized energy savings may approach 80%. (A 30kW combustible flame may be replaced by a 6kW plasma plume)
Lack of precise control
Frequent quality control issues
Available built-in safety controls including an over-temperature shut-off
Noxious odor is often noted from combustion byproducts
Cost of Operations
Consumes expensive reactant gasses
Frequent downtime leads to lost revenues and costs of repair
Higher insurance and other costs because of emissions and other flame hazards
Uses air and electricity
No reliance on supply of combustibles
Less downtime, less lost revenues, less cost of repairs
Possibility of lower insurance premiums from improved safety
Comparison of Surface Deposition Techniques
Deposit Rate Very high, continuous
Species Deposited Atoms and Ions
Atoms and Ions
Complex Shaped Objects Good/Excellent, varying uniformity
Poor, based on line of sight
Alloy Depositing Yes
Simultaneous Gas Heating Yes
Substrate Heating Yes
Zapper and Magnifiers are optimized for metals and ceramic. e-Ion LIP system or
OAB are suggested for polymer 3D sintering.
e-Ion systems allow for continuous sintering (3Dsintering™) or hardfacing without the use of hydrogen. All ionic gasses are of a reducing kind.
Plasma polymerization of many unique polymers and blends and their surface deposits remain unexplored with this new method.