Cascade e-Ion Devices

A Flame with Zero Carbon Emissions

Just immerse the part in the Cascade e-Ion plume for a few seconds. GoldenBlue®.

 In the past the costs associated with testing the myriad options are extremely high for new technologies,.  Then there is the perpetual battle between ideal engineering design and manufacturability on a production scale.  Has the Cascade E-ion solved this?

Stable Thermal Cascade Plasma Generator. CleanElectricFlame®.

The one technology that  advances new mobility applications, increases energy efficiency and reduces emissions.

Glass Bending, Optical Data Transfer, Biomedical Coating/ Deburr, Tool-bit Reconditioning, Abrasive Wheel, Cast-Iron, Stick Resistant Steel Surfaces, Anti-Seize Treatment for Steels Bearings, Bolts & Bushing, Request Information

Uses for the Cascade e ion

A SmartPlasma Power Device

List of Disruptive Applications Technologies

Create Easy Non-Stick Surfaces for Cooking Compare Cost/Performance of NoScratch(TM)

Data Glass Shaping

Communication Glass and Decorative Glass
Biomedical Titanium and Zirconium

Rapid Brazing

Compare.  3DBrazing®



Rapid Deburring of threads and surfaces

Improved Machine Tool and Die Performance

Easily deburr

Cool to machine – save $$$

Low Wear Surfaces (Automobiles)

Reduce friction. Reduce wear.

High Nitrogen Content Alloy Carbonitriding or Austempering

Dross Reduction

Dust Mitigation

Compare with Laser, Electron Beam, Sunlight and more….


More Applications

Special techniques for nano-porous surfaces for possible catalyst, solar and antimicrobial use

with a modern open-plasma device..



Use the SmartPlasma device.  Compare  with DLC and other Plasma methods.  Create nano-scale Carbon Nitrides, Nitrogen Carbon, Borides, Mixed Borides. Hard and Smooth OxyNitride Colors.  High Vickers.  Compound layers in steels form in-situ or by graded layer processing. Use on chromium, molybdenum and managanese steels, titanium alloys, zirconium alloys, diamonds. Oxynitrides are one of the most important new class of materials for use in low wear surfaces, plasmonics, solar cells to glass coatings.  Deburring is enabled by the cascade e-ion beam.  Create Non-stick surfaces for steel and cast iron or treat cell phone glass.  The Cascade e-ion allows for continuous seamless processing for improved tool and die performance. Welcome to the world of two dimensional materials formation of various types.

Microstructure, EDAX and XPS results.

The Cascade e-ion processes allow continuous use.  Traditional furnace based batch treatment techniques could be expensive. Batch processes are often inefficient and expensive due to high furnace and facilities costs. Compare processing time in seconds/minutes with long processing times in furnaces and the associated huge energy consumption.  Other costs from batch coaters include frequent maintenance and repair with specialized labor.  Extra steps like plasma cleaning or blanking parts may be required which are mostly not required with the Cascade e-Ion process.  XPS and other fine electronic probes display the fine structure, depth of ionic penetration and new phase formations which are advantageously used.

The application of titanium, zirconium and iron & steel alloys is limited by low shear strength, high coefficient of friction, low hardness and poor wear resistance.  The cascade e-ion is the first process to offer processing within seconds with no space limitations.  Some of the ROI’s are astounding. Some truly useful phases of iron nitrocarbides, carbontrides, smooth oxynitrides, compound phases/layers for hardness and high wear resistance, epsilon phases, and titania or other antimicrobial nanostructures may be experienced. Experience also the possibilities of rapid bulk heat treating and quick brazing with very low operational costs  – often less than a cent per part.   Create conditions for chromium nitrides, titanium nitrides, tantalum, niobium and zirconium oxynitrides, manganese (oxy)nitrides, vanadium nitrides, oxycarbides, aluminides and aluminum/magnesium/silicon nitrides and oxynitrides (including composite combinations or particulate,fiber, functionally graded or grated layers).  Lanthanum, perovskite Oxynitrides for photocatalytic power and photoconductivity. Ion nitride yittria zirconia films. Create functionally graded or grated layers with nano-scale oxynitrides, oxides, inorganic elements, nitrides and many more.   Change the adherence in organic molecules by plasma polymerization on goggles, pastics, mold surfaces and other parts by direct application. Combust coal and Biomass to less release of aromatics and complete combustion. Please contact MHI.

Case Studies are discussed that range from tool bit reconditioning to easy surface improvement of steels and cast irons.  Bearings, axles, rails, deep-dishes, pans, broaches, drills, carbide drills, cast irons, simple parts like nail clippers and scissors to complex parts that hold up space mirrors and much more can be GoldenBlue® treated effortlessly with the cascade e-ion plume. Enjoy the benefit of high temperatures to create smooth and hard surfaces now made easily.

Choice of Plasma Plumes (chose any gas plus choose circular, wide area or slot). Click on: What is Cascade e-ion? for information on color of plume and color of surfaces


Wide Area

Spaced Slot

circular plume LIP GLASS PLUME Oxynitride Coloring

Is there a simple way to tell if the Cascade e-Ion Plume treated part is smoother? Yes, when nitrided or oxy-nitrided with the GoldenBlue® treatment, the swage-lock, high temperature bolt, ball/roller bearing or machine tool should make less noise when machining, or when putting on the nut.   Less noise is an indicator of smoothness.

How is wear reduced?  Wear is caused by material loss by tribological processes.  The GoldenBlue® reduces galling, adhesion, abrasion and tribo-oxidation depending on the alloy. See samples in the Auto Industry. Rapid new techniques for Austempering and Martempering.

Figures shows Cascade e-Ion Machines.  Permanently color your hard surface.

Bring your designs to life with beautiful colors and improved engineering surfaces

Simplified Surface Engineering Processing: Simply immerse in the Cascade e-Ion Plume


What is a Cascade e-ion
CleanElectricFlame™ Solutions
Selection Guide 
and Comparison

Industrial Applications
Compare with Lasers, Electron Beam and Sunlight
Clean ElectricFlame Technology

The Cascade CleanElectricFlame® technology uses just electricity and air (or other gasses if required, like Nitrogen, Argon or Forming Gas) leaving behind no residues. MHI’s Cascade e-Ion Plasma uses less energy, produces hardly any noise and is safer than traditional heating methods. It is one of the most special plumes available. The Cascade e-Ion systems are available for use with hard alloys, plastics, metals, glass forming, ceramics, composites and a number of other materials – even food or wood. The Cascade e-Ion devices can be used for sintering, for example, titanium and carbon mixed powders in minutes. Large surface plates are easily moved under the beam.. The CleanElectricFlame® provides a Cascade e-Ion environment.

The Cascade e-Ion can bend, nitride, creat surface borides like Zirconium diboride and alloys, and for inducing colorful smooth surface oxynitride of many materials including manganese, chromium, titanium, copper/ graphite and glass.

Possible use for automotive axles, pistons, tappets, piston rings, valve stems, guides crank shafts with quick low cost nitriding(O) – even for space re-entry surfacing. The CleanElectricFlame® provides a new type of reducing environment.  Even difficult materials like copper and tungsten-copper alloys have a shiny finish after the Cascade e-Ion plume treatment. In situ growth of nitrides and oxynitrides is a special “open” feature that only the plume from the Cascade e-ion can accomplish. Adopt early. Early stage pricing and possible MHI partner financing available.  MHI offers an attractive MHI-Never-Down program. Please ask for details on the Cascade e-Ion Models, like the unique the MHI-Never-Down program warranty-type features and, if required, MHI Financing. Click on the left navigation bar “solutions” to view several of the case studies. Contact MHI for tool energy savings and astounding ROI possibilities for engine valve steels like EN grades, 21-4N, 52000 and others.

For Cascade e-Ion

– Heat up rate 100K/s (Kelvin per second).  Ionic heat transfer.
– Price per part for several small parts using only air and electric ~ 0.2US¢/part.

Price of Energy: The price of energy depends on the source but is not that different between different forms of energies that one can use (e.g. gas or electric). Comparisons are given for example on Duke Energy. In the US, when comparing gas and electric a rule of thumb is that gas energy is about 75% lower cost when compared with the same quantity of electric energy. However electric machines are generally much more efficient than gas heaters. For example, the OAB or Cascade e-ion can save you even 90% of traditional energy use in relevant applications. These new machines can dramatically influence operational costs. Often using electric heating is less polluting at the use point. Additionally, electric heaters can be efficiently/accurately controlled. Both KWhr and Therm are units of energy.

1kJ (KiloJoule) = 0.9485 BTU=0.0002778 kWhr. One Million BTU (MBTU) = 10.002 Therm (US). Electric energy is normally priced for every KWhr used, while gas is priced by the number of Therms used.

Source: MHI Energy efficiency

BTU per hr to KW

BTU/hr to KW

  1. Customize for deposition type and shape. Contact MHI.
  2. Compare price and energy efficiency with ordinary transferred arc or induction plasma deposition or laser.
    No electrodes to change in cascade plasmas.
  3. Improve Surfaces from Tool bits, Non-stick to Electrical.  Titanium Oxynitride-Nitride, Yittria Zirconia (with dopants), Boron Carbide, Silicon Carbide, Molybdenum diSilicide.
  4. Super-ionic bending and Ionic Surface Hardened Glass and Nano Surface Depositions.
  5. WC and other high wear resistant surfaces for tool bits.
  6. Tubes and complex shapes. Thick Alumina on Aluminum.  In situ nitriding of tubes for dies.
  7. Easily make functionally graded coatings.
  8. Custom Turnkey Solutions with Complete Electronic Controls. Increase endurance of stamping and hot working dies,
  9. Highly stable e-Ion cascade thermal plasma™
  10. New ionic low-cost surface treating and deposition.  Minimize pollution and minimize noise – improve energy efficiency.
  11. Titanium Oxynitride Nitride coatings on HSS and other surfaces.  Easy oxynitride or nitride nitride formers are Ti, V, Zr, Al, Mn, Mo,Fr, Cr and many others.  In addition various eta phases carbon-niitrides and borides are possible.
  12. Non-Stick high hardness metallic surfaces
  13. MHI provides coating for Nickel Aluminide formation with the cascade e ion.   Contact MHI.
  14. Petrochemical: reforming furnaces, cracking furnaces, pyrolysis and fired heaters,

  15. Clean aluminum production.
  16. Clean Coal Combustion and Ignition (reduced aromatics).
  17. VOC cleaning.
  18. Steel and Heat treatment: radiant tubes, furnace rolls

  19. Glass making industry: Roll barrels for float glass line
  20. Color of surfaces. Contact MHI for Edax, Microstructure and XPS results where available.
  21. Aircraft and automobile engine parts
  22. Printing on plastic food containers
  23. Energy-efficient window coatings
  24. Safe drinking water
  25. Voice and data communications components
  26. Waste processing
  27. Coatings and films
  28. Electronic computer chips and integrated circuits
  29. Advanced materials (e.g., ceramics)
  30. High-efficiency lighting
  31. Plasma enhanced chemistry
  32. Surface cleaning
  33. Processing of plastics
  34. Gas treatment
  35. Spraying of materials
  36. Chemical analysis
  37. Semiconductor production for computers
  38. TVs and electronics
  39. Sterilization of medical tools

From surface crystal growth technology to surface nitriding, the Cascade e-Ion places the technical process and value-addition possibilities squarely in the hands of innovators of tool-bits, steel parts, cast iron and steel manufacturers-both primary and secondary non-stick-surface manufacturers, solar cell materials and shapes, hydrogen storage and wafer manufacturers – thus giving everyone new market opportunities.  The Cascade e-Ion makes it extremely feasible to provide dross reducing covers for melting metals. The DRO models are particularly well designed for this type of solution. The cascade e-ion can make magnets better for corrosion resistance or high temperature oxidation.  How do you know that the surface is harder?  Bounce the ball bearing and watch if it bounces higher than the non-coated bearing.

  MHI Anti-Seize Treatment (Bearings, Bolts, Bushings) 

Learn More About Cascade e-Ion Plasma Technology

 Cascade e ion booms

What is Cascade e-Ion Plasma | Extremely Wide Area Plasma (with LIP) | Extremely Rapid Depositor De-e-Ion Models with arrangements possible for trials on surface reconditioning with purchased units.

  1. Save energy: use ~15kW not ~150kW.  In dollars? Please click here.
  2. Use air as input gas almost for all applications because of the heavy nitrogen ions in plume.
  3. Easy port for steam and any other gases.
  4. If using other gas then OK to switch to air when not in use.
  5. Use time is short.  Grow unusual smooth surfaces within seconds.
  6. Enjoy flexibility of operation (just immerse or impinge plume on part).
  7. Good control over the depth of “white layer” so that finish lapping is not required
  8. Particularly suitable for large or small batch production.
  9. Large or heavy components which normally are not be treated by conventional plasma (because of a lack of process control) can now be economically nitrided/oxynitrided.
  10. Deburr.
  11. Enjoy MHI-Never-Down Program (enrollment is free up 2016 December).
  12. Quick installation and use.
  13. Best of MHI Sales and Service.
  14. 3DBrazing and 4DSintering®are a registered trademarks of MHI.

Contact Us for a Demonstration

We may not yet have all the answers on every application, so we may not be sure if the Cascade e-Ion Plasma is always right for you. However, for most surfaces the CleanElectricFlame provides the best of plasma, ion-implantation and modified chemical species, enough to warrant a trial (payment may be required) on your part. Regardless of whether we know what the treatment offers for a very specific untested surface, we can certainly arrange to have your part treated during a live video conference. Contact MHI. It is worth a try!

Improved Energy Efficiency From:

a)  When the part or tool lasts longer or can be used at  higher speeds.

b)  The tool requires lesser number of replacements.

c)  When dry machining is possible. Dry machining has great potential for improved energy and resource efficiency.

d)  The process for manufacturing of the tool uses the lowest energy procedure so that the total energy cycle is minimum. ( with the Cascade e-Ion).

Please compare GoldenBlue® treated with other tools/drills and bits.