Cascade e-Ion vs. Lasers

Comparisons

Comparisons with directed energy beam systems (Laser, Electron Beam to Sunlight). The CleanElectricFlame® can be used as a narrow or wide area source (beam). Some comparisons between Laser and Sunlight are provided.

(All information in general comparison tables like the ones shown below should only be treated as approximate or indicative of order of magnitude.)

	Cascade e-Ion Plasma™	Laser	Electron Beam	Microwave	Induction	Sunlight
Surface Impact	The beam’s 250mm diameter significantly impacts productivity and improves efficiency. The large area allows for CleanElectricFlame® soaking at various power settings. Please contact MHI.	The commonly available average beam size is about 2mm	Commonly, less than 0.5mm beam	Poor	Depth varies with the frequency of the machine.	Varies
Welding/Joining	Yes, even for dissimilar materials	Yes, limited by beam parameters	Yes, limited by beam parameters	Scarce 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.	Relative Cost of Gas. Compared to Air Air 1 Nitrogen 10 Hydrogen 40 Argon 60 Helium 210 Vacuum High kW
Drilling	–	Yes	Yes	No
Vacuum Always Required?	No vacuum is required. Plasmize air or other gases.	No	Yes	No It cannot be used with metal.
Power Density	106-109 W/m2	106-108 W/m2 for commonly used industrial CO2 continuous lasers. Depends on the laser type.	~106 W/m2 Depends on acceleration voltage and wavelength of the beam	Low: about 1 to 2 kW for the entire chamber.�Power density is low for the surface. Bulk volume dominates as a major term for power density.	Efficiency depends on coil spacing, frequency, and type of materials kept in the coil.	1.3 x103 W/m2 (average)
Water Requirement	None.  Adds to High Energy Efficiency.	High	High	No	Extremely high	N/A
Energy Efficiency	Very high	Very low	Very low	Variable	Very Low	N/A

The relative price to use a gas or maintain a vacuum is above. The SmartPlasma(TM) Cascade e-Ion machine can use air as the gas input.

Surface Deposition Comparisons

Comparison Price with Conventional Batch Type Ion Nitriding Machine

Type	Conventional RF Type Small Volume	Conventional RF Type Mid-Volume	Cascade e-Ion System
Working volume, m3 Price* (*We encourage users to compare prices independently, as discounts, exchange rates, and other issues may impact the prices discussed.) This table shows only rough estimates.	0.1m3 (~3.5 cu. ft). Price about $100,000	10m3 (~350 cu. ft) Prices start at $500,000	Unlimited Volume Call or Contact MHI
Working surface diameter x height estimate	500 mm by 610 mm	1100 mm by 5100 mm	Unlimited because it is disconnected from machine features.
Draw to Part Power Efficiency	1-5 % typical		over 90% typical
Typical Machine	~20 / 25 kW	~200 kW 200kW operational price is about US$32000 per 200 days/ year @10¢/KWhr and 8 hrs of use per day	From 3kW-20kW. Several Powers are offered.
Working gases	Mostly inert or nonoxidizing. Nitrogen, hydrogen, ammonia, propane, natural gas, methane, argon		This includes air and steam nitrogen and other elements as required.
Typical Operation Pressure	1 – 8 millibar. Vacuum required. Costly.		No Vacuum Requirement. 1 atmosphere