Electron beams can be used for welding, manufacturing precision parts, sterilizing medical supplies and food, and eliminating microbial organisms. Advantages include a narrow weld zone and the absence of a filler material, but there are downsides such as x-ray production and high costs. Electron Beam Freeform Fabrication (EBF3) can fabricate parts from raw materials, saving space and time. Bioreduction uses electron beams to eliminate microbes without toxic chemicals. Medical supplies and pharmaceuticals can also be sterilized with electron beams.
An electron beam (e-beam) is a controlled flow of negatively charged electrons that are propelled at high speed. The most common low-intensity electron beam is the cathode ray tube (CRT) used in televisions and computer monitors. A high-intensity electron beam can also cut metal or heat and melt different pieces of metal in a process called electron beam welding. E-beam technology can be used to manufacture precision parts for use in aircraft and aerospace industries, as well as to sterilize medical devices, pharmaceutical materials, food, and even mail.
With electron beam welding, a high intensity stream of concentrated electrons is directed onto the surface of a material such as steel or titanium. The electrons in the weld beam are accelerated to travel between 30 and 70% the speed of light, providing the energy to heat and melt the metal. The advantages of electron beam welding are the preservation of the vacuum, a narrow weld zone and the absence of the need for a filler material to fill the weld. The beam heats the pieces and seals them together to form an airtight seal. However, this type of welding has some downsides, including x-ray production, high setup costs, and high equipment costs.
Electron Beam Freeform Fabrication (EBF3) is a layered additive process that can fabricate a part from raw materials. The process uses a high-intensity electron beam to melt and rearrange steel, titanium or other metal into a ready-to-use part. This ability to create on-demand parts and tools would save a lot of space time, eliminating the need for expensive launches to carry heavy parts or tools. EBF3 technology is further developed by several aerospace companies and, as of 2011, is used in the manufacture of the F-35 Joint Strike Fighter.
Bioreduction is a process made possible by the use of precisely controlled electron beams to reduce or eliminate microbial organisms without the use of toxic chemicals. In the mail and shipping industry, high-energy electron beams are streamed onto and through letters, packages, envelopes, boxes, and other shipping containers. The e-beam irradiates the unopened contents of the containers killing microorganisms. Some foods, such as bagged salad, which is ready to eat without washing, have been irradiated using an electron beam before being shipped to local supermarkets. This eliminates the need for additives that could affect the taste or vibrancy of the food.
Medical supplies and pharmaceuticals can also be irradiated with a high-energy electron beam, effectively sterilizing them. A computer program directs the exact amount of energy needed to sterilize these items. Electrons kill microbes and destroy vital molecules through an indirect chemical reaction caused by electron beam radiation. Medical supplies, parts and devices can be irradiated while still in their unopened containers. The process and subsequent sterilization is similar to the gamma radiation process, but with less material degradation in pharmaceuticals.
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