The unique e-Ion Plasma™ allows for novel applications of Ions, Electrons, Radiation and Hot Gases, revolutionizing traditional processes such as brazing, hardfacing, sintering, general heating, 3DSintering™ and surface cleaning. The e-Ion Plasma's™ CleanElectricFlame™ technology can often reduce 36 hour processes down to a few minutes.
CleanElectricFlame™ technology uses just electricity and air (or other gasses), leaving behind no residues. MHI's e-Ion Plasma™ uses less energy, produces less noise and is safer than traditional heating methods. The e-Ion systems are available for use with plastics, metals, ceramics, composites and a number of other materials. The e-Ion devices can sinter titanium in minutes. Even copper and tungsten-copper alloys have shiny finish after e-Ion treatment.
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.
Cleaning extruded plastics. Avoid toxic chemicals. Unique power adjustments possible. High value parts such as Transportation (Landbased of Aircraft dePainting). Ecological Problem, for health reliability monitoring of parts for inspection" Plasma Ideation Brochure. Use e-Ion source or De-e-Ion™ for cleaning and simultaneous application of dyes and other defect markers.
Thin Film Deposition. Molybdenum DiSilicide by ionic deposition and deposition of other nitrides and carbides. Quick ion-assisted deposition. Thermal barrier coatings including graded coatings with both ceramics and metals. Easy use with precursors.
Ion/Plasma Nitriding, Rapid Diffusion Brazing, Diffusion Brazing, 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 , Hard Metal Tool Brazing, Resistance Brazing, Gauge Brazing, On-line tempering of mechanical parts, Shrink Fitting, Hardening and tempering of chains, Agricultural Tool Sectional Hardening, Drive Shaft Hardening, Stub Shaft Hardening, Power Transmission Shaft Hardening, High Wear Application Hardening, Automotive Axle Shaft Hardening, Internal & External Tube Brazing, Honeycomb brazing, Oil & Gas Wear Resistance Surface 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, Decontamination, Textile Processing, Non-line of Sight Heat Processing, Fluorocarbon deposition, Fluoropolymer deposition, Silicon Deposition, Rapid Epoxy Deposition and Curing, Glass Substrate Deposition, Electronic Polymer Applications, MEMS, Carbon Nanotube or Fiber Production, Compare to electron or laser beam Melting. RTP processing of semiconductors like Si, Diamond and GaN. Ionic synthesis methods or ion-assisted methods for improving luminescent properties of nitrides, silicates and phosphors. Electronic Materials Fabrication.
Comparisons with directed energy systems (Laser to Sunlight)
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.
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.
106-108 W/m2 for commonly used industrial CO2 continuous lasers. Depends on laser type.
~106 W/m2 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.
1.3x103 W/m2 (average)
None. High Energy Efficiency.
Surface Deposition Comparisons
Very high, continuous
Atoms and Ions
Atoms and Ions
Complex Shaped Objects
Good/Excellent, varying uniformity
Poor, based on line of sight
Simultaneous Gas Heating
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.
The heating system can be used for composite curing or heat treating on large surface areas of several square meters.
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
Noisy combustion process
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