There are several methods of coating tools, machine parts and other materials with another substance, including e-beam evaporation and other physical vapor deposition methods. These methods are often used to extend the life of tools and other critical items used in the manufacturing process by coating them with a tougher substance.

E-beam evaporation systems heat a material, often a metal, until it evaporates and boils. Eventually, the material settles on all surfaces within the vacuum chamber, including the object you wish to coat. Before you begin using e-beam evaporation systems in your manufacturing, keep these things in mind:

1. E-beam evaporation works with metals, but does not distribute alloys well. If your object requires an alloy, it's best to use another coating method.

2. Electron beam evaporation provides poor step coverage, which can cause shorts and other electrical problems, depending on its use.

3. An electron beam system works best at high temperatures, so make sure the material you're coating will not warp or crack under heat.

Action Steps
The best contacts and resources to help you get it done

Buy basic e-beam evaporation equipment and supplies from a manufacturer

You'll need an electron beam evaporation gun, a power supply, and crucibles for the evaporation material. Don't forget a vacuum chamber large enough to fit all your e-beam evaporation supplies.

I recommend: Pick up an e-beam gun and crucible from Vieetech, or check out the Kurt J. Lesker Company's vacuum systems.

Clean the e-beam evaporation system substrate with a ultrasonic cleaning system

Depending on the size of the materials you plan to cover, you may need a large cleaning system. Ultrasonic systems are normally measured in gallons, so it's best to take a few measurements before-hand. Some companies will work with you to custom design a specific ultrasonic cleaning system for your needs.

I recommend: Choose a model and contact the Ultrasonic Power Corporation to get a quote on a custom ultrasonic washing system of that type. Or, ask Branson Ultrasonics to provide you with a system.

Use an ion source to get your coating perfect with electron beam evaporation equipment

An ion beam is a type of particle beam that consists of ions. It allows you to strengthen the material by compressing it, or changing the grain size of the film. You can also use an ion beam to achieve sputtering, which is similar to sandblasting in that parts of the object's film covering are blasted away.

I recommend: Buy one of Angstrom Engineering's sputtering systems or choose one of Veeco's ion beams instead.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Adding oxygen gas into your e-beam evaporation system can help keep the evaporation process of multiple materials in their intended ratio, and help the film settle more evenly. In addition, a thickness monitor will let you know if the coating is even and thick enough.