An electromagnetically focused electron beam line source

A directly heated thermionic electron beam source was constructed. A tungsten wire of length 140 mm with diameter 0.9 mm was used as a cathode. An emission current of 5000 mA was achieved at an input heating power of 600 W. Cathode to anode distance of 6 mm with acceleration voltage of 10 kV was used. A uniform external magnetic field of 50 G was employed to obtain a well-focused electron beam at a deflection of 180°, with cathode to work site distance of 130 mm. Dimensions of the beam (1.25×120 mm) recorded at the work site were found to be in good agreement with the designed length of cathode. The deformation of the cathode was overcome by introducing a spring action mechanism, which gives uniform emission current density throughout the emission surface. We have achieved the saturation limit of the designed source resulting in smooth and swift operation of the gun for many hours (10–15 h continuously). The design of gun is so simple that it can accommodate longer cathodes for obtaining higher emission values. This gun has made it possible to coat large substrate surfaces at much faster evaporation rate at lower cost. It can also be useful in large-scale vacuum metallurgy plants for melting, welding and heat treatment.