The Time-Resolved Characterization of Erosion Products from High-Current, Copper Vacuum Arcs

A vacuum arc at high enough current can produce gross melting on electrode surfaces as a consequence of anode spot formation and other high-current electrode phenomena. Erosion from the electrodes under this condition is much more rapid than at low-current (where material loss occurs principally from the cathode) and is a process that is presently poorly understood. The present work is aimed at characterizing the erosion products from cathode and anode surfaces during high-current arcs on copper electrodes for single half cycles (60 Hz) arcs having peak currents of 30 kA. Fully open gap lengths were approximately 18 mm. Among the findings were the following. a) Erosion rate determined by electrode weight loss was approximately 8 mg/C of arcing. b) Droplets ejected from the electrodes had masses varying from a few tenths to a few tens of micrograms and velocities typically up to 40 m/s, although higher velocities are seen. c) The greatest number of droplets are produced at, or just after the current peak, and higher droplet velocities are seen in this same time interval. d) Erosion in vapor form detected in the plane of the cathode surface and moving radially is a maximum just after the peak of current and is relatively abundant. Such vapor is essentially absent in the anode plane.     

Measurements of vacuum arc ion charge-state distributions

The charge-state distribution of ions generated in the metal vapor vacuum arc under a wide range of experimental conditions was measured. The experiments were carried out using an ion source in which the metal vapor vacuum arc is used as the method of plasma production and by which a high-quality, high-current beam of metal ions is produced. Charge-state spectra were measured using a time-of-flight diagnostic; arc voltages were also measured. Parameters that were varied include cathode material, arc current, axial magnetic field strength, neutral gas pressure, and arc geometry     

Macroparticle filtering of high-current vacuum arc plasmas

The transport of vacuum arc plasmas through a 90° curved magnetic macroparticle filter was investigated using a high-current pulsed arc source with a carbon cathode. The peak arc current was in the kiloampere range, exceeding considerably the level of what has been reported in the literature. The main question investigated was whether magnetic macroparticle filters could be scaled up while maintaining the transport efficiency of small filters. In front of the cathode, we found that arc current dependent total ion saturation currents were in the range from 10% to 23% of the arc current. The best relative transmission was 25% (time integrated output/time integrated input) at a duct wall bias of 12.5 V and at an axial magnetic field of about 100 mT. The measured relative transmission of the used high-current arrangement is comparable to what has been observed with other low-current filters. The absolute measurable ion saturation currents at the filter exit reached 70 A at an arc current of about 1000 A     

Visualization and characterization of high-current diffuse vacuumarcs on axial magnetic field contacts

We have investigated the behavior of drawn vacuum arcs for several designs of axial magnetic field (AMF) contacts using high-speed digital photography and arc voltage measurements, As the peak current was increased, a gradual transition occurred in the arc appearance from a multiple cathode-spot arc to the high-current diffuse mode, and then to a high-current diffuse columnar mode. Two relatively simple models based on the literature are used to explain the results. The first is an empirical criterion for using the arc voltage behavior to determine the maximum arc current for which an AMF geometry can produce a high-current diffuse mode from the initial bridge column arc. The second model predicts the highest arc current that can be forced into a fully diffuse mode for given values of the AMF and the contact arcing radius. The predictions of these models are compared to our experimental and analytical results     

Low-impedance plasma systems for generation of high-current low-energy electron beams

The results of experimental investigation and numerical modeling of the generation of low-energy (tens of keV) high-current (up to tens of kA) electron beams in a low-impedance system consisting of a plasma-filled diode with a long plasma anode, an auxiliary hot cathode, and an explosive emission cathode. The low-current low-voltage beam from the auxiliary cathode in an external longitudinal magnetic field is used to produce a long plasma anode, which is simultaneously the channel of beam transportation by residual gas ionization. The high-current electron beam is formed from the explosive emission cathode placed in the preliminarily formed plasma. Numerical modeling is performed using the KARAT PIC code.     

Determination of the specific ion erosion of the vacuum arc cathode by measuring the total ion current from the discharge plasma

The specific ion erosion γ_i of cathodes made of C, Mg, Al, Ti, Co, Cu, Y, Mo, Cd, Sm, Ta, W, Pt, Pb, and Bi is determined by measuring the total ion current from the vacuum arc plasma. It is demonstrated that the ratio of the total ion current to the discharge current, α_i in a vacuum arc varies from 5 to 19%, depending on the cathode material. It is found experimentally that the ion current fraction α_i is inversely proportional to the atomic bond energy of the cathode material. It is shown that an increase in the total ion current extracted from the discharge plasma when applying an external magnetic field to the cathode region of the discharge is related solely to the appearance of ions with higher charge numbers in the plasma, while the magnitude of the specific ion erosion γ_i remains unchanged.     

Anode-Spot Formation and Motion of Vacuum Arcs

This paper reports about experimental investigations on high-current vacuum-arc phenomena, especially anode-spot formation, arc states, and motion. The presented work was stimulated by lack of information about the transition process from the diffuse low-current mode to the high-current mode characterized by anode spot(s). Optoelectronic measurements, streak photographs, high-speed movies, and correlated arc voltage/current records yielded remarkable results on power-frequency vacuum arcs. Three different high-current vacuum arc modes can be observed beyond a certain threshold current. Which mode appears depends mainly on the momentary electrode distance. The modes are characterized by different anode-spot behavior and interelectrode phenomena. The transition between different arc modes is continuous. The arc modes observed on ring electrodes producing a magnetic blast field are the same as those appearing on butt-type electrodes. Anode-spot formation is preceded by congregations of cathode spots and may be initiated by thermal overload of the anode surface opposite to these cathode-spot clusters.     

Application of vacuum arc cathode spot model to graphite cathode

A model of near-electrode processes is applied here to describe the behavior of cathode spots on graphite cathode in vacuum arc. The physical model is based on a kinetic treatment of cathode evaporation, electron emission from the cathode, and plasma production. The model consists of physical assumptions and a system of equations that are formulated in the paper. Spot parameters, such as cathode erosion rate, cathode potential drop, cathode surface temperature, current density, electric field, and plasma density, temperature, and velocity in the near-electrode region are calculated numerically. The calculation includes the dependence of spot parameters on spot current and spot lifetime. The variation of spot parameters as a function of spot lifetime are very strong at lifetimes shorter than 10 μs. The calculations indicate that Joule heating in the cathode body is significant, and may exceed cathode heating by the ion heat flux. Calculated spot parameters are compared with the corresponding experimental data for relatively low arc currents (<100 A) and their agreement is discussed     

Contact temperature and erosion in high-current diffuse vacuum arcson axial magnetic field contacts

We have investigated the surface heating effects of drawn vacuum arcs for several industrial designs of axial magnetic field (AMF) contacts, using near infrared (IR) photography of the Cu-Cr arcing surfaces with an image-intensified charge-coupled device (CCD) camera and an IR pyrometer. This enables detailed contact temperature mapping immediately after a half-cycle of arc current. The very homogeneous temperature distribution observed at current zero stands in contrast to the visually nonhomogeneous high-current diffuse arc, which was studied in separately reported experiments using high-speed digital photography and arc voltage measurements. The peak temperature at current zero increased relatively linearly with the peak current I_P, and reached well beyond the melting range. We combine the temperature maps with a heating model to determine the thermal sheath thickness after arcing and its dependence on I_P. The results suggest that near the interruption limit of AMF contacts, the interaction of the stable high-current arc with the anode and cathode is dominated by processes induced by flowing liquid metal, which redistributes the heat input from the axially concentrated arc over most of the contact surface. Furthermore, the flow of liquid metal off the cathode and anode faces contributes to the overall contact erosion     

Phenomenological model of the unstable stage of a vacuum spark discharge

A model of the unstable stage of a spark discharge in vacuum is proposed, which describes all typical manifestations of this stage, including current spikes in the diode, an increase in the potential at the cathode flame front, collective acceleration of ions in vacuum and plasma diodes, change in the cathode erosion mechanism, and the emergence of electron microbeams with a high current density at the anode. It is shown that these processes are associated with the formation of a charged electron layer of a spatially inhomogeneous plasma at the cathode flame boundary at the unstable stage of the spark discharge in vacuum. The emergence of this layer is associated with a limited emissive ability of the plasma at the cathode flame front during its expansion in vacuum. This leads to disruption of the plasma (field-induced emission of electron from the boundary region of the flame) and the formation of a short-lived charged plasma, viz., high-density ion cluster at the cathode flame boundary. The estimates obtained using this model are in good agreement with the experimental data on physical processes at the unstable stage of a vacuum spark discharge.     

Near-cathode potential drop in a vacuum diode with explosive emission of electrons

The near-cathode potential drop u_K is studied in a high-voltage high-current (U=20–40 kV, i=100–500 A) vacuum diode with a cathode operating under explosive emission of electrons. The magnitude of U_K is estimated from oscillograms of the probe current under conditions of breakdown of the layer between the probe and the cathode-flare plasma. It is shown that u_K is the same order of magnitude as the near-cathode potential drop in vacuum arcs. U_K does not change greatly when there are sharp rises in diode current, indicating that oscillations in diode current are probably related to processes at the boundary for drawing of electrons from the flare plasma.     

Experiments with a plasma-filled rod-pinch diode on the MIG generator

Experimental data for creating an X-ray source several millimeters in size on the basis of a plasmafilled rod-pinch diode are reported. Experiments are carried out on the MIG high-current generator. A voltage pulse applied to the diode is sharpened and shortened by injecting plasma into the interelectrode gap up to the plasma-filled diode. Radiation extraction from the vacuum chamber in the paraxial direction is provided by inverting the positions of the cathode and anode using a post-hole vacuum convolute. It is demonstrated that the energy of a low-impedance high-current generator can be deposited with a high efficiency into an electron beam focused on the 1-mm² tip of the rod-shaped anode. With a tapered tungsten rod 1.5 mm in diameter used as an anode, a pulsed X-ray source about 1 mm in size generating 30-ns-long pulses is obtained. The absorbed dose per pulse measured with a LiF thermoluminescent dosimeter behind a 5-mm-thick aluminum screen 1 m away from the source reaches 0.042 Gy.     

Mechanism of ion flow generation in vacuum arcs

The ecton model of the cathode spot is used to analyze the main parameters of ion flow in vacuum arcs (ion erosion, mean charge, and velocity). It is shown that the arc plasma is formed as a result of microexplosions at the cathode surface, induced by the Joule heating by the high-density current of explosive electron emission. Ionization processes are localized in a narrow region of the order of a micrometer near the cathode and the ionization composition of the plasma subsequently remains unchanged. Under the action of the electron pressure gradient, ions acquire directional velocities of the order of 10⁶ cm/s even over small distances of the order of several micrometers.     

Cathode processes in free burning and stabilized by axial magneticfield vacuum arcs

Collective behavior of the cathode spots (CS) has been investigated in free burning and stabilized by axial magnetic field (AMF) vacuum arcs. Experiments carried out proved previously discovered phenomenon of CS group formation in free burning arc to be a general phenomenon for a short high-current vacuum arc. The dependency of CS group size in the developed are on arc current for different contact materials has been analyzed. Application of AMF with even relatively low intensity strongly affects on cathode processes. In short arcs, it hinders formation of the CS group and consequently reduces thermal stress applied to the electrodes. It has been revealed that high current vacuum arc under the action of AMF can exist only at current densities exceeding certain minimal value that depends on AMF intensity, contact gap, and does not depend on current itself. The dependency of this minimal (or normal) current density on AMF intensity has been studied for short and long vacuum arcs. A qualitative model of the cathode spot dynamics has also been proposed     

Experimental Investigation of Anode Activities in High-Current Vacuum Arcs

It is well known that the melting of electrodes (mainly anode melting) in vacuum arc can increase the metal vapor density around current zero and even lead to interruption failure. In order to clarify the anode activities and their influence on arc appearance and interruption capacity, series experiments of cup-shaped axial magnetic field copper electrodes were conducted. Obvious anode melting was detected; the liquid copper flowed on the contact plate of anode and formed a clockwise swirl flow. The appearance of anode melting is likely to correlate to the transition of arc mode from high-current diffuse mode to high-current diffuse column mode. The melting of anode was severer than cathode and was influenced by the distribution of cathode spots. Various kinds of copper particles at macroscopic level can be seen in arc column. Even at the interruption limit, the majority of melted copper of anode sputtered out of gap in form of liquid droplets or was pressed into the cup of anode, the copper vapor evaporated into arc column only accounted for a few portion and no obvious anode jets was found due to large plasma pressure in arc column.      

Evolution of Copper Vapor from the Cathode of a Diffuse Vacuum Arc

The metal-vapor evolution from the cathode of a diffuse vacuum arc is described by a model that starts from the expression for the collisionless expansion into vacuum of atoms originating from an instantaneous point source. The velocity distribution is assumed to be Maxwellian at the moment the atoms are released from the source. By convolution with the vapor generation rate, which is given by an effective erosion rate and the waveform of the arc current, this expression is generalized to yield the atomic density at an arbitrary distance from a point source which emits atoms for a finite period. The result is integrated over the cathode surface which is treated as an extended homogeneous source of vapor. The copper-vapor density was calculated for a vacuum arc driven by a sinusoidal 50-Hz current half-cycle of 500 A rms, for the center of the contact gap. With a vapor temperature of 2000 K and an effective copper-vapor erosion rate of 3 ?/C, the model well describes the measured decay of the copper-vapor density from about 5 × 1017 m-3 at 300 ?s before current-zero to 5 × 1014 m-3 at 400 ?s after current-zero. Comparison with calculations based on the assumption that metal vapor is generated predominantly by molten droplets evaporating in flight indicates that before current-zero the contribution of the droplets to the vapor density is negligibly small, while after current-zero both vapor generation mechanisms produce vapor at the same order of magnitude.     

Characteristics of the statistical distribution of the current transmitted by a cathode spot of a vacuum arc in variously oriented magnetic fields

The influence of variously oriented uniform magnetic fields on the cathodic attachment of a low-current vacuum arc with electrodes made of oxygen-free copper and CuCr30 composition is studied. It is found that, if the current is fixed, cathode spots in the arc attachment are distributed by the normal law in the entire range of variation of the amplitude of magnetic induction vector B and angle α between this vector and the normal to the cathode surface. The parameters of the distribution depend on the magnetic field and cathode material. The magnetic field dependence is appreciable only when angle α exceeds some critical value α* (α* ≈ 30° and ≈45° for cathodes made of copper and CuCr30, respectively). At α > α*, the parameters of the distribution become strongly dependent on α, while the B dependence remains weak. Only when α → π/2 does the field amplitude have a pronounced effect on the parameters of the distribution. From the obtained results, we determine the statistical characteristics of the distribution of the mean current transmitted by a cathode spot in variously oriented magnetic fields. The found relationships make it possible to explain the peculiarities of the structure of the cathodic attachment of the high-current vacuum arc stabilized by an external axial magnetic field.     

Vacuum discharge from perovskite oxide electrodes

This paper presents results of the investigation of electrical discharge in vacuum from perovskite-like La_0.7Sr_0.3CoO₃ and YBa₂Cu ₃O_6.95 electrodes. Data are given on the local chemical composition of cathode surfaces subjected to nanosecond high-current arc discharges and on the erosion of ceramic cathode materials. The results of measurements of the work function and of the emission capability of extended ceramic cathodes and of field emission characteristics of clean surfaces of perovskite-like oxides are presented. A comparative analysis has been carried out of the behavior of ceramic cathodes with results obtained from the discharge of metallic electrodes     

The Ecton Mechanism for the Generation of Ion Flows in a Vacuum Arc

The principal characteristics of the process of generation of the cathode plasma in a vacuum arc (ion erosion, mean charge of ions) are considered in terms of the ecton model of the cathode spot of a vacuum arc. The estimates of the parameters of ions obtained for a unit cell of a cathode spot – an ecton – are in good qualitative and quantitative agreement with experimental data. The following mechanism for the generation of the cathode plasma of a vacuum arc is proposed. When a region of the cathode is destroyed in an explosive manner due to Joule heating, the material of the cathode sequentially goes over a series of states: the condensed state and the states of imperfect and ideal plasma. During this transition the charge state of the plasma is formed and the ions are accelerated under the action of the pressure gradient in the plasma whose density decreases by several orders of magnitude over distances of 10 m from the cathode surface. The increase in current results in an increase in number of cells, and the principal parameters of the ions are formed as a result of the operation of a unit cell of the spot.