High frequency electron beam drilling: an economic and environmentally sustainable production process

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Electron beam drilling is a novel technique whereby small holes are made at rates in excess of 1,000 holes per second. The high productivity and reproducibility of the process is useful for materials that are difficult or slow to drill using conventional techniques. The finished product has thousands or even millions of small holes, which are useful for high performance filters and screens. These products are often found in aerospace, food processing, pulp and paper, consumer goods and medical devices. The electron beam drilling process is both dynamic and explosive. The hole location is targeted using magnetic coils, then the beam is energized such that a large amount of heat is focussed onto a very small area. As the beam spot heats, the underlying material transitions from a solid to liquid, then vaporizes beneath the surface, resulting in the explosive ejection of material and the formation of a hole. We will evaluate the environmental impact of electron beam drilling as a sustainable alternative to processes such as chemical drilling. The equipment, installed at McGill, is fabricated in Canada by PAVAC Industries. Since the hole shape and depth are a direct result of the electron beam hardware, McGill will further its understanding of the electron/matter interaction, with a specific focus on the vaporization process. These results will further our evaporative coating research, while lending insight into future projects surrounding pulsed electron beam welding, drilling and additive manufacturing. As a direct result of this work, PAVAC will advance their theoretical understanding of the drilling process, which will be used to improve current equipment and develop new equipment, while also gaining insight into new market opportunities. By directly partnering an advanced equipment manufacturer with a team of materials processing experts, this grant will advance both Canadian research and business.