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Continuous Rapid Brazing Made Easy

Good flow, excellent bonding and hardsurfacing as desired

The Cascade e-Ion Plasma™ may be used for high production volume brazing.  Please consider for interconnects, simultaneous nitriding, oxynitriding, oxycarbonitriding or sintering and hardfacing operations with the CleanElectricFlame®

3DBrazing® and 4DSintering® are a registered trademarks of MHI

The heat-up rate is high.

The alloys that can be considered for brazing even with plasmized-air are conducive for high quality brazing or joining type uses.

The CleanElectricFlame® does not use combustion.  Some of the typical easy-to-use Brazing-Jigs and part manipulators are shown below.  Rapid Brazing of metal ceramic-no flux required often because the beam provides protection against oxidation.  By using just air/gas and electric one cuts down considerably on energy usage in brazing while contributing to clean no-emission processes.  Joining electrical leads is now easy and cost effective.  Eliminate open combustion flames
Switching to cascade e-ion for your brazing applications is easy and energy efficient. It also improves productivity, integrates easily in manufacturing lines and eliminates open flames.
  The Cascade e-ion is compared to combustion, lasers, and other heating devices in this table    Consider less than a cent per part in cascade e-ion consumable.  Ions clean the surfaces simultaneously with brazing.  Dissimilar metals like aluminum and iron or metal ceramic composites are often easy to braze/join with the e-Ion Plasma™ machine.  Comprehensive control systems are available which have been field-tested for over fifteen years.


Brazing made easy.   Easy spreading of braze alloy. 

Traditionally, brazing ceramics to metals and metals to ceramics has been particularly difficult. Just as when brazing ferrous to nonferrous metals, specific alloys and specialized brazing furnaces are required for successful ceramic to metal joining. These furnaces are large, expensive and typically suitable just for a few applications. This lack of adaptability has meant high initial capital costs, limited applications and high per piece costs.  Please consider the Cascade e-ion as the modern alternative.

Continuous brazing machine

Special Convective Ovens available

Easy flow of braze alloy.  " I was impressed to see the clean and high integrity interface between WC-Co and stainless steel... .The technology of the .. e-ion Plasma seems to be great".

Shiny Surfaces post brazing.

Wear resistant surfaces may be made within seconds or minutes with the Cascade e-Ion Plasma by immersing in Plume  which represents an increase of over 100 fold in productivity with lower capital cost and lower operating costs.  Given below are typical hardfacing interface microstructures obtained with tungsten carbide nano and with hardfacing/hardsurfacing alloy on a stainless steel substrate.  Please contact MHI for details.

The surfaces below of n-WC were obtained after short exposure to CleanElectricFlame™. Competitive processes are often noted to produce much coarser microstructures.  Nano grained cemented tungsten carbide (n-WC) is currently being researched for many potential applications.

Cascade e-Ion treated parts: Micrographs of n-WC (left) and NiCoMo Hardfacing braze alloy to steel(right).  MHI will be happy to provide process guidelines and special aluminimzing, or boriding pastes as required.


Typical Comments:


The very fast high temperature ramp is very helpful.  As per our discussion with the braze alloy manufacturer, one major problem that is often faced is the microstructure coarseness because of many hours at high temperature (common to traditional multi-hour furnace brazing cycles). This is the cause for the tungsten carbide particle size to increases during traditional furnace heat-treatment sequences and then the metallurgical bond integrity reduces drastically.  Similarly, any  boron carbide particles remain extremely small and well-bonded as do nano-alumina after the bonding.  Rapid heat up and rapid cool-down is a must for the future.


"One minute hardfacing operation replaces 48 hr. operations!  We also do not need nitrogen or argon atmosphere"


"What I like about the Cascade e-ion process is the fact that it allows for rapid continuous production instead of batch production.


With the Cascade e-Ion, the high integrity of the tungsten (carbide) alloy fusion-bond with the base steel is very acceptable. Tool bit bonding by brazing is efficient.  When the bond is of such high integrity and tough (i.e. does not activate or allows cracks to propagate) one is able to quench rapidly subsequent to the the e-Ion CleanElectricFlame™ exposure.




High Integrity Bond for Hardfacing and Toolbits. 

Savings of considerable time and energy.

Please ask MHI for ROI Calculator



With the Cascade e-Ion, the high integrity of the tungsten (carbide) alloy fusion-bond with the base steel is very acceptable. Tool bit bonding by brazing is efficient.  When the bond is of such high integrity and tough (i.e. does not activate or allows cracks to propagate) one is able to quench rapidly subsequent to the the e-Ion CleanElectricFlame™ exposure.

Conventional Limitations.  Replace with Cascade e-Ion Processes.


Having difficulty with copper flow with copper foil brazing on steel.  Contact MHI to be astounted with what the e-ion can do even on "dirty surfaces".  3DBrazing® is a registered trademark of MHI.  Flux can be avoided.


CleanElectricFlame copper flow on stainless in air


Active Metal Brazing and Ceramic Brazing Applications

Cascade e-Ion Plasma™ technology can facilitate ceramic brazing without issues typically faced by brazing furnaces or laser brazing.

  • One Atmosphere Operations - No large enclosure is necessary to treat parts. The e-Ion Plasma™ can braze ceramics to metals, metals to ceramics, ceramics to ceramics and metals to metals without the typical requirements of a vacuum environment.

  • Versatile - The cascade e-Ion Plasma™ can be repositioned with minimal effort, allowing for less downtime between batches and lower capital costs. (1 e-Ion Device may replace multiple specialized furnaces).  Efficent suction of active braze.

  • Efficient - A combination of higher operating temperatures, lower energy consumption and patented technologies allows the Cascade e-Ion Plasma™ to braze faster and more cost effectively than alternative technologies.

Consider for metal-ceramic joining.  What makes brazing ceramics difficult is their lack of wettability. Simply put, it is difficult to ionically bond anything to ceramics. Plate metallization and thin film metalization can be effective in certain circumstances, but high tooling costs and size contraints limit widespread adoption. e-Ion Plasma™ devices are easily movable and can easily handle on-line/in-line processing, virtually eliminating size constraints typically found in existing technologies.  Wish to braze efficient and low cost connectors to silicon nitride. Contact MHI for free use of a patent under select circumstances. Igniter.


Brazing Alloys and the Cascade e-Ion Plasma™ method

Titanium (Ti) brazing

early stages of compressor or exhaust

Dissimilar Metal/Ceramic Brazing

Nickel copper 59 Ni

New braze compositions



New engine crack repair

Braze Alloy

Au-6 (Gold)

Compressor Parts

Hastelloy, Inconels, Waspalloy

Iron Boron Silicon

Auxiliary Power Unit (APU)


Nickel Boron Silicon

Fuel systems/compressor inlets

304 ss or Inconel 600, 625 or RA alloys

Gold 82/Nickel 18 alloy)

High compressor and low turbine

Stainless Steel


Fuel systems leak proof braze

304 ss or Inconel 600, 625 or 718

NiCroly Ni-Cr-Al, Ni-Al

MRO engine repair hot section/high pressure turbine.  Abradable Tip

Superalloys of Nickel and Cobalt

Biomedical Grade alloys

Presintered preform, paste,

paint (PSP)

Fuel systems

Low temp like fuel systems


Low pressure compressor/Ti brazing

Ti-6Al-4V with Mo and other Ti alloys

TiCuNi and Shape Memory Alloys






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750 Redna Terrace Cincinnati, OH 45215, USA
Telephone: 513-772-0404 | Fax: 513-672-3333