X-ray radiography of aluminum cathodes eroded in high-current vacuum arcs

The aim of the study presented in this paper was to characterize quantitatively the erosion of aluminum cathodes in high-current vacuum arcs. The experimental setup comprised two current generators. The first one, capable of generating a current of amplitude up to 350 kA, was used to produce a plasma jet, that is, the object to be investigated. The second generator was used to produce a source of probe radiation for imaging the object under investigation in soft x rays of energy ?ν ≈ 0.5–3 keV. The findings of the study are based on experimental data obtained by electrophysical and radiographic methods. It has been shown that the cathode erosion rate in a high-current vacuum arc is a function of the charge passed through the cathode.     

Experimental observation of high-voltage, low-current vacuum arcs

A poorly explored type of discharge has been investigated in high vacuum (10^-7 to 10^-6 torr), with a DC high voltage across 0.2- to 0.8-mm gaps. The discharge has been found to be quite different from other widely known types of vacuum and gas discharges by the combination of its voltage-current characteristics (hyperbola-type), source and carriers of current (mostly electrons), and spatial potential distribution (a considerable electric field across the gap and a steep potential fall near the cathode)     

Experimental analysis of the electrode products emitted byhigh-current vacuum arcs

The mass distribution of particles produced in the high-current vacuum arc was investigated. The experiments were concentrated on evaluating the spatial mass distribution emitted in the radial as well as in the azimuthal directions calculated from the mass deposition profile on collectors surrounding the arc discharge. The experiments were carried out in a vacuum chamber evacuated to an ambient pressure <10^-4 Pa. High-current arcs in the range from 2-7.5 kA were drawn between butt contacts of 31 and 55 mm in diameter (anode and cathode, respectively) both of a copper-chromium alloy (CuCr25). The surface mass deposited along multi-segment collectors was measured by a micro densitometer, and an inductively coupled plasma (ICP) spectrometer. Two angular mass deposit distributions were determined: the azimuthal distribution on the plane parallel to the cathode surface, and the radial distribution as a function of the angle with respect to the cathode plane. Both distributions were anisotropic and the structure of the deposition layer depended on the angle of incidence of the particles onto the substrate, the density of the particle flux and other factors. The mass deposited on the collectors consisted mostly of chromium molecules (approx. 80% of Cr and 20% Cu) for CuCr25 or CuCr40 electrodes     

Experimental investigations of the currents collected by metalshields in high-current vacuum arcs

This paper presents experimental results of currents collected on the three-element condensation shield connected to the cathode potential in high-current vacuum arcs. The arc current had 900 Hz, 150 Hz, or 50 Hz half-cycle sinusoidal shapes and was conducted between the CuCr40 contacts with a diameter of 50 mm (cathode) and 30 mm (anode) spaced 10 mm apart. Most of the measurements were made for the current of 900 Hz with peak values up to 9 kA. Arc voltage, floating shield potential, and distribution of shield currents were measured. It was found that the current collected by the shield and also the arc voltage and floating shield potential are greater for higher frequency currents, and that they are affected by the arc mode. Considerable shield current is observed during a high-amplitude (HA) oscillation sequence of arc voltage while its mean value is increased. For 900-Hz arcs at the 9-kA peak value (I_am), the ratio of shield current (i_s) to an instantaneous value of arc current (i_a) reaches even 40% near I_am value. In the initial half-cycle period (before the initiation of high-voltage oscillation), the ratio of i_s/i_a increases with i_a and current frequency. A close relationship was found between arc voltage and current distribution on a three-element shield     

Motion of high-current vacuum arcs on spiral-type contacts

Motion of vacuum arcs on spiral-type contacts is not only controlled by self-induced magnetic fields, but also by heating phenomena. An expression is derived which permits the calculation of the speed of the arc from a computation of the time needed to heat the surface up to boiling temperature. The heat flux density of the constricted arc at the anode is required as input for the calculation. Good coincidence is achieved with experimental data. The speed of the arc varies from 5 to 400 m/s, depending on experimental conditions     

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.     

The origin of current constriction in vacuum arcs

The current constriction in a diffuse vacuum arc is shown theoretically and experimentally to be caused by a pressure source, to which the charged particles and neutral particles contribute.     

Some interruption criteria for short high-frequency vacuum arcs

If the contacts of a vacuum interrupter open shortly before a current zero, the transient recovery voltage (TRV) can cause a reignition and reestablish the arc. When the current in a diffuse vacuum arc passes through zero, there is a distinct pause before the TRV builds up (approximately 40 ns for copper). During this pause the gap carries conduction current only with an ion component which depends on dI /dt, varying between 3 A for dI/dt=60 A/μs and 60 A for dI/dt=1235 A/μs. The ion current subsequently decays in tens or hundreds of nanoseconds. It can be distinguished from the displacement current at this time by varying dV/dt, keeping the other parameters constant. Among the interruption criteria for short high-frequency vacuum arcs, dI /dt prior to current zero and initial dV/dt are the most important. High values of dI/dt are more likely to precipitate reignitions, but breakdowns can occur after lower dI/dt's if the gap has been subjected to a high current for a relatively long time (>100 μs)     

Investigation of arc roots of constricted high current vacuum arcs

The anodic and cathodic arc roots of constricted high current vacuum arcs were investigated with a fast framing charge-coupled device camera of 1 μs exposure time. The experiments were performed with cup-shaped contacts, with sinusoidal currents of amplitudes between 20 and 100 kA, and a sine halfwave duration of 10-12 ms. The arcs were drawn by contact separation and accelerated by the Lorentz force between the arc current and the transverse magnetic field generated by the contrate contact. The anode and cathode arc roots behave reproducibility and arc scaleable within the range of currents investigated. Both types of arc roots are elliptical, with a major to minor axis ratio of 1.4. The major axis points are in the direction of arc propagation. Anodic and cathodic arc root cross-sectional areas as a function of current can both be described by a potential law with a common exponent of 0.76. For currents of 20-100 kA, mean current densities of 81-121 and 41-60 kA/cm ² were found in anode and cathode arc roots, respectively. Estimations of their temperature and vapor densities were performed. For the investigated current range T_A≈3300-3600 K, n_A ≈1.6*10¹⁹-2.2*10¹⁹cm^-3 and T _C≈3200-3400 K, n_C≈0.8*10¹⁹-1.2*10 ¹⁹ cm^-3 were found for anode and cathode, respectively     

Two-dimensional observation of copper vapor in vacuum arcs bylaser-induced fluorescence

The density distribution and the velocity of copper neutral atoms emitted from a single cathode spot in 40 A vacuum arc were measured by the two-dimensional (2-D) laser-induced fluorescence method. The density was calibrated from the two-dimensional fluorescence image observed by a CCD camera. The gap space was almost filled with the copper atoms, and the density reached 5×10¹⁹/m³. We varied the wavelength of the laser light and measured the velocity of the copper atoms emitted from the cathode spot using the effect of Doppler shift. The velocity of the copper atoms was about 10 km/s     

Plasma-assisted deposition of a three-layer structure by vacuum andgas arcs

The durability and adhesion of thin coatings often depends on the structure and properties of the layer intermediate between the coating and the substrate, especially in the case where the layer and the substrate are highly different in microhardness. With a vacuum arc and a hot-cathode arc, a process has been arranged which involves cleaning of the surface, nitration of the article, and deposition of a coating. As a result, a three-layer composition has been produced which consists of a TiN layer of thickness up to 5 μm and microhardness 20 GPa, an intermediate Fe₄N layer of thickness up to 8 μm and microhardness 7.5 GPa, and a nitrated layer of thickness up to 100 μm with a gradually varying microhardness. With the TiN layer showing high adhesion, the coating has a durability three of four times greater than that of a coating produced with the use of a conventional technology     

Observation of tungsten particles in vacuum arcs by laser inducedfluorescence

We have clarified the relation between the decay of tungsten ion density in the vicinity of current zero and vacuum arc mode in high current period by using a laser induced fluorescence method in tungsten vacuum arcs of 60 Hz sinusoidal current with the peak value of 3.3, 6.7, and 9.8 kA. In the case of 6.7 kA, the arc mode was the anode spot mode. Because of the generation of the anode spot, the tungsten ion density near the anode was higher than near the cathode and the density near the anode was about ten times as high as the case of 3.3 kA which was the diffuse mode. In the case of 9.8 kA, which was the intense arc mode, the density near the anode was not significantly different from the case of 6.7 kA. The density near the cathode was higher than near the anode and tungsten ions were observed till about 30 μs after current zero while they disappeared at current zero in the other cases     

Residence time of metal ions generated from microsecond vacuum arcs

Vacuum gaps of 1 mm with lead or copper cathode are fired by a 13 μs duration sinusoidal arc or a 10 μs duration exponentially-decaying arc, and time-of-flight (TOF) ion measurements are made at variable times after the arc ignition. At the lead cathode, Pb⁺ and Pb⁺⁺ ions are generated and the upper limit on the times for Pb⁺ ion detection are 48 μs and 46 μs from the arc ignition for the sinusoidal and exponential arcs, respectively. At the copper cathode, Cu⁺, Cu⁺⁺, and Cu⁺⁺⁺ ions are generated and detected within 15 μs and 13 μs from the arc ignition for the sinusoidal and exponential arcs, respectively. The residence time of the Pb⁺ ions in the ion acceleration region is approximately 35 μs, regardless of the waveform of the arc current. The residence time of the copper ions, described by the time constant of the time-of-flight ion current delay characteristics, is 3 μs     

Investigation of ion behavior associated with anode-spot modetransition in vacuum arcs

The ion behavior phenomenon associated with transitions of the anode discharge mode to the anode-spot mode is studied by measuring the wall ion current and by spectroscopic observation in vacuum arcs. The anode mode transfers when the wall ion current attains a certain magnitude that is independent of the cathode, but dependent on the anode. The ion-current function to the arc current increases when the arc current increases in the diffuse arc. Spectral-line intensity of Cu III emitted from the plasma in the anode region increases with an instantaneous arc current of a 5-kA peak (kAp) sinusoidal half-wave. These findings suggest an idea for the mode transition, that an ion generation region appears, and that an increase in the ion density produces a positive potential hump near the anode, which results in the negative anode voltage drop triggering the mode transition. After the mode transition, an arc current is found to reduce the ion current near the crest of a sinusoidal current in a copper arc. This appears to be significant for the arc on a small anode. The decrease in the ion current is attributed to the recombination of ions decelerated by anode vapor with electrons emitted from the hot spot on the anode     

On the ion energy distribution of high current arcs in vacuum

With the experiments presented in this paper, applications of a retarding field analyzer (RFA) for the measurement of the ion energy E _i in a vacuum arc plasma are discussed. The examined plasma was produced by a sinusoidal half-wave vacuum arc current. The experiments were concentrated on evaluating the plasma parameters at the last three milliseconds before current zero. In a current range from 300 A_rms to 10 kA_rms, the ion energy distributions and their peak values were evaluated. With the increase of the arc current, a decrease of the ion energy was found. By additional investigations of the angular distribution of the ion energies, a transition from a collision dominated interelectrode plasma to a freely expanding plasma was observed, depending on the arc current     

The behavior of vacuum arcs between spiral contacts with small gaps

The application of small gaps in high-current vacuum interrupters highlights the interdependence of the contact design, the contact gap, and the arc behavior. In this investigation, a framing camera was used to record the appearance and motion of drawn vacuum arcs between spiral-petal contacts with final gaps of 2 to 3 mm. After the rupture of the molten metal bridge, a high-pressure arc column formed and expanded across the width of the spiral arm. With a single arc column for the duration of the half-cycle, an intense anode spot formed if the peak current exceeded ~15 kA. Compared to results previously obtained at larger gaps, the arc motion was greatly reduced, and severe contact damage was observed at lower currents     

Importance of high local cathode spot pressure on the attachment ofthermal arcs on cold cathodes

The importance of having high local cathode spot pressures for the self-sustaining operation of a thermal arc plasma on a cold cathode is theoretically investigated. Applying a cathode sheath model to a Cu cathode, it is shown that cathode spot plasma pressures ranging 7.4-9.2 atm and 34.2-50 atm for electron temperatures of ~1 eV are needed to account for current densities of 10⁹ and 10¹⁰ A·m^-2, respectively. The study of the different contributions from the ions, the emission electrons, and the back-diffusing plasma electrons to the total current and heat transfer to the cathode spot has allowed us to show the following. 1) Due to the high metallic plasma densities, a strong heating of the cathode occurs and an important surface electric field is established at the cathode surface causing strong thermo-field emission of electrons. 2) Due to the presence of a high density of ions in the cathode vicinity, an important fraction of the total current is carried by the ions and the electron emission is enhanced. 3) The total current is only slightly reduced by the presence of back-diffusing plasma electrons in the cathode sheath. For a current density j_tot=10⁹ A·m^-2 , the current to the cathode surface is mainly transported by the ions (76-91% of j_tot while for a current density j_tot = 10¹⁰ A·m^-2, the thermo-field electrons become the main current carriers (61-72% of j_tot). It is shown that the cathode spot plasma parameters are those of a high pressure metallic gas where deviations from the ideal gas law and important lowering of the ionization potentials are observed     

Measurement of the temperature of evaporating macroparticles aftercurrent zero of vacuum arcs

The concentration of copper and chromium vapor after current zero of vacuum arcs between chromium-copper contacts was measured simultaneously by the atomic-absorption technique. Temperatures between 1900 K and 2200 K were derived from the absorption data, assuming that the ratio of concentrations of copper and chromium vapor is equal to the ratio of vapor pressures at a given temperature. The temperatures obtained in this way were assigned to droplets of molten contact material evaporating in flight     

Neutral copper vapor density and electric recovery after forcedextinction of vacuum arcs

Dielectric recovery data were obtained for vacuum arcs between chromium copper butt contacts 30 mm in diameter and 2 mm apart. The 50-Hz arc current was forced to zero at its maximum of 200 A in about 1 μs. Following current zero, high-voltage pulses of a sufficient amplitude to always cause breakdown were applied to the gap. Gap recovery is characterized by the measured breakdown voltage as a function of time. Dielectric strength of the gap rises sharply within the first few microseconds after current zero, reaching its final value in about 10 μs. Neutral copper concentration in the center of the gap was measured by laser-induced fluorescence under conditions very similar to those of the recovery measurements. In contrast to the fast gap recovery, the copper vapor concentration does not change substantially during the first 100 μs from its value of 1.4×10¹⁸ m ^-3 near current zero. It is concluded that the neutral copper vapor concentration does not play a decisive role in gap recovery under these experimental conditions. This is corroborated by the fact that the mean free path for electron-impact ionization of copper atoms exceeds the gap length by four orders of magnitude     

Plasma deposition of thin films utilizing the anodic vacuum arc

Anodic vacuum arcs operating with cold cathodes in the spot mode and hot evaporating anodes are investigated to explore their technical potential as a plasma deposition technique. This discharge provides a unique source of a highly ionized, metal vapor plasma by autogeneration of the working gas to evaporation of the anode. This gas-free and droplet-free metal vapor plasma expands into the ambient vacuum (10^-4 mbar) and produces thin metallic films at the surface of substrates. An analysis of Al and Cu plasmas at the position of a possible substrate for arc currents between 20 and 200 A leads to the following results: electron densities, 10¹⁵-10¹⁸/ m³; degree of ionization, 0.5-25%; directed ion energy, 5 eV; and electron temperatures, 0.2-1 eV. Metallic coatings generated with deposition rates between 0.1 and 100 nm/s show the following properties: purity, 99.9%; polycrystalline structure with grain sizes between a few and a few hundred nm, same mass density as the respective bulk material, electrical conductivity rather close to that of the bulk material, and excellent optical properties. The coatings show good adhesion, which can be enhanced by a plasma-supported pretreatment of the substrate surface and by an acceleration of the ions towards the substrate