Arc Cathode Spot Research Articles

Investigation of arc spot splitting behavior on aluminum, titanium, and their alloy cathodes under different gas flows

This paper presents an experimental study on the spot splitting behavior of aluminum, titanium, and their alloy cathodes during electric arc discharge. Utilizing high-speed digital cameras, we dynamically captured the splitting motion of cathode arc spots and analyzed their behavior under different pressures of argon, nitrogen, and oxygen. The study also examined the effects of pulsed arc current parameters on spot splitting. We observed a ringlike expansion of pulsed arc spots during splitting, with aluminum cathodes showing better performance than titanium in promoting spot splitting and stabilizing the subsequent motion of the split spots. Oxygen was found to enhance spot splitting more effectively than nitrogen. Furthermore, the parameters of the pulsed arc can control the extent of spot splitting and expansion. These findings provide valuable insights for optimizing arc parameter control in metal film deposition processes.

A Semi-Empirical Model of Cathodic Arc Spot Motion under the Influence of External Magnetic Fields

Plasma generation by cathodic arc spots plays a crucial role for coating processes that make use of the Arc-PVD technology. Usually, the arc spot motion over the cathode is steered by a magnetic field of a particular distribution and magnitude to ensure a continuous plasma generation, the avoidance of liquid droplets, and a proper utilization of cathode material by homogeneous erosion. This study presents a semi-empirical model that allows for an examination and characterization of the arc spot motion with regard to direction and speed as a function of an imposed magnetic field. This model considers the different components of random walk, retrograde, and Robson drift motion. Introduced empirical coefficients were determined by corresponding experimental investigations. The calibrated model describes the arc spot motion in good agreement to the recorded spot tracks and can therefore be applied for an evaluation of different magnetic field configurations.

Comparative study of the microspot splitting characteristics of direct-current and pulsed cathodic vacuum arc

Ejection of macroparticles is an inherent and unavoidable characteristic of cold cathode arc discharges. The size of the cathode arc spot's melt pool is closely related to the emitted particle size, and existing studies mostly indicate that motion velocity of arc spots can be heightened primarily by magnetic fields, thereby reducing the ejection of macroparticles. However, scant consideration has been given to avoid the fundamental nature of arc spot current concentration discharge by exploring the phenomenon of arc spot splitting. In this paper, microspot splitting characteristics of direct current and pulsed cathodic vacuum arc were compared and analyzed to investigate the effect of pulsed discharges on the arc spot's internal structure, splitting, and kinematic characteristics. The results showed that pulsed arc discharges emit a dense, highly ionized plasma flow which impacts the relatively thin positive charge layer instantaneously during the peak pulsed period. This then produces a highly ionized plasma region, while also promoting an effect by which the arc spot is split into multiple microspots. Additionally, the degree of dispersion resulting from microspot splitting is positively correlated with the ratio of the plasma flow density to the concentration of the positive charge layer at the moment of microexplosion. Therefore, the microspot splitting effect of a second-order pulsed arc is weaker than that of a first-order pulsed arc. Moreover, the splitting characteristics indicated a trend toward the progressive splitting state of the direct current cathode arc. When the peak current of the single-order pulsed arc was increased from 100 to 400 A, the particle refinement effect on the surface of the CrN coating became much more evident compared to the effect of a 200 A arc in the direct current mode. And upon reaching a peak current of 500 A (and up to 600 A), the number of splits did not increase linearly due to the continuous increase in the discrete degree of microspot splitting and concurrent decrease in microspot stability. This resulted in relatively high individual microspot currents, while some relative macroparticles still appeared on the coating surface.

Molecular dynamics simulation of cathode crater formation in the cathode spot of vacuum arcs

A three-dimensional model based on molecular dynamics has been developed to describe the formation of a single cathode spot in vacuum arcs. The formation of the cathode spot is assumed to be controlled by the plasma ions, the effect of which is simulated in LAMMPS through the process of ion bombardment. The cathode is represented by structured copper atoms, while the ions are continuously injected into the domain with a certain velocity towards the cathode surface. Ion bombardment leads to the appearance of a crater, which is caused by the accumulation of pressure effect against the relaxation of substrate temperature. The size of the crater is found to be determined by the spatial distribution of the injected ions. The formation of the cathode spot is also scrutinised by electron emission from the cathode surface with variable surface temperature during the cathode spot development process. In addition, the evaporated atoms forming the metal vapour are observed. This study provides a description of the formation of the cathode spot at microscale, which shall be helpful to further studies of the arc rooting and arc contact (electrode) erosion in vacuum environment.

Study on microspot splitting characteristics in cathode spot motion of vacuum arc

The control of cathode arc spot and the removal of macroparticles have always been key problems in the preparation of coatings of vacuum arc ion plating. This work aims to explore the internal structure and the formation mechanism of cathode arc spot as well as the effects of different parameters on its characteristics. Moreover, the work attempts to find a way to improve the arc spot discharge fundamentally from the inside of the spot by photographing the cathode arc spot dynamically with a high-velocity digital camera. The results show that there are the microscopic phenomena of microspot splitting, microspot accompanying motion and periodic motion in the interior of the cathode arc spot. The continuous self-splitting characteristic of microspot is unstable under the intermittent microexplosive emission mechanism, resulting in periodic splitting and merging. Although the stability of microspot splitting can be relatively improved by adjusting the deposition parameters, the nature of the phenomenon that relatively concentrated discharge occurs periodically under the DC arc cannot be changed. In this work, the idea of promoting arc spot splitting is further analyzed and proposed in the mechanism level, and the feasibility of reducing and refining MPs defects by arc spot splitting is also discussed.

Threshold parameters of vacuum arcs with W-fuzz cathodes

An experimental technique was developed and performed to investigate the threshold currents and operation times of vacuum arcs with tungsten cathodes having a nanostructured (so-called “fuzz”) surface. The fuzz layer, pre-formed due to exposure of the tungsten samples with helium plasma, reduced the threshold current for arc initiation by an order of magnitude. For currents of tenths of an ampere, the average arc operation time was in the microsecond range. The experimental data were interpreted using the explosive emission (ecton) model of a vacuum arc cathode spot.

Research on the Energy Characteristics of a Transferred Arc Plasma-Chemical Reactor for Waste Treatment

This study has been performed to reveal the main characteristics of operating a direct current (DC) plasma-chemical reactor (PChR) designed for hazardous waste treatment. The PChR employs thermal plasma as the operating environment. The investigations presented in this paper were conducted to study the electrical and energy characteristics of the plasma torch and plasma-chemical reactor during the destruction of inorganic waste. The PChR is equipped with a plasma torch with a nominal capacity of 50 kW and a free-burning arc. The zone of heat release from the atmospheric pressure DC arc cathode and arc anode (melted waste) spot is combined with the area of chemical reactions. The plasma torch (PT) parameters vary in the range of arc current I = 120–180 A, arc voltage U = 250–280 V, arc length x = 0–100 mm, and gas flow rate G = 1–3 g/s at atmospheric pressure, using air as the plasma-forming gas. The experimental results confirmed that plasma technology has several advantages over conventional incineration, including higher temperatures, heat source independence from the waste being processed or additional fuel, and a shorter exposure time in the high-temperature area. It was determined that the arc current increases with increasing arc length. With increasing arc length, the initial part begins to operate in a turbulent regime. This study determines the dependence on the heat flux transferred by electrons to the anode on the arc current. The convective heat flux density distribution over the anode heating spot was measured and discussed.

Revealing phase transitions and instabilities in pseudospark discharges

AbstractPseudospark discharge is a low‐pressure high‐voltage pulsed discharge with hollow electrodes, and the overall discharge experiences several distinctive sub‐phases. The instability phenomena, characterised by the sudden oscillations or distortions of discharge voltage and current, restrict the applications of pseudospark discharge. This study presents an investigation into phase transitions and instabilities in pseudospark discharge by combining the evidences from multiple discharge waveforms, time‐resolved images, electron beam current profiles, 2D kinetic simulation results, and the spectral line emission of cathode material. The process of a normal pseudospark discharge is firstly discussed, and the threshold conditions of the transition from the superdense glow discharge (SGD) phase to the high current phase with arc cathode spots are addressed. According to temporal profiles and voltage‐current characteristics, two types and four occurrences of instabilities are distinguished: type I—in the pre‐breakdown phase; type II‐1—in the SGD phase; type II‐2—in the transition of cathode spots propagating from cathode hole edge to cathode plane; type II‐3—in the re‐initiation of spots near current reversal. It is found that the instability of type I is caused by the stepwise penetration of virtual anode plasma, and type II is closely related to the cyclic nature and finite lifetime of cathode spots. It is induced by the fact that the decay of cathode spots is faster than the formation under certain conditions, and the existing spots are not able to provide the current required by the external circuit. Important features and the suppression methods of the instabilities are discussed based on the proposed mechanisms.

Determination of Cooling Rate and Temperature Gradient during Formation of Cathode Spot Craters in a Vacuum Arc

Due to the extreme thermal conditions and short lifetimes, experimental exploration of cathode spots in vacuum arcs is very difficult. The intensive heat in the cathode spot is believed to be generated by ion bombardment and by Joule heating. However, thermal conditions occurring inside the re-melted material in craters created by cathode spots are not accurately known. During the exposure to cathodic arc plasmas, an Al-Cr cathode’s surface was locally melted by successive ignition and extinction of cathode spots. The melted layer, that quickly solidified, was characterized by the formation of several thin layers with a thickness of a few micrometers that were stacked on top of each other. The corresponding solidification patterns displayed cellular and dendritic microstructures. A phase field-based model was used to simulate and determine the thermal process conditions that led to the dendritic structures observed within the re-melted layer. Different combinations of cooling rates and temperature gradients were numerical explored to determine the most probable thermal conditions under which the cathode material re-solidifies. The results showed that the material in the vicinity of the cathode spot crater re-solidified under the condition of a cooling rate of about 3 × 105 K/s and a temperature gradient of about 6 × 107 K/m. These results constitute valuable data for the validation of numerical models dedicated to cathode spot formation.

Theoretical Model of the Retrograde Motion of Cathode Spots of Vacuum Arc

The phenomenon of cathode spot (CS) retrograde motion has been attracting extensive research in the field of vacuum arc. Although a number of theoretical models have been proposed to explain this phenomenon, up to now, the first-principle understanding is still missing. In this work, based on the generalized Ohm’s law, it is proposed that there is a transport current in the explosive emission center when a transverse magnetic field (TMF) is applied. The investigation of the influence of the transport current on the strength of the electric field in the cathode sheath suggests that the transport current affects the ignition of new CS in the retrograde direction. In the framework of the ecton model, combined with the dynamics of explosive emission plasma, the relationship between the strength of applied TMF and the ignition probability of new CS in different directions is established, and the retrograde motion characteristics of CS are simulated using a statistical model. The simulation results show that the directionality of retrograde motion of CS is enhanced with an increase in TMF, and the retrograde motion speed of CS increases with the increase of the applied TMF. When the strength of TMF is small, the motion speed of a single CS has a linear relationship with the strength of TMF, but with the increase of the strength of TMF, the motion speed of a single CS is gradually saturated, which is consistent with experimental facts. The feasibility of the model is verified by comparing the simulation results with relevant experimental results.

Narrow Groove Laser-Arc Hybrid Welding of Thick-Sectioned HSLA Steel Using Laser Beam Oscillation

In this study, a sine-oscillating laser was used to obtain narrow groove laser-arc hybrid welding (NGHW) of high-strength low-alloy (HSLA) steel. Then the effects of laser beam oscillation amplitude and space constraint on arc behavior, droplet transfer, weld geometry, and incomplete fusion of the weld beads were analyzed. Due to the minimum arc voltage principle and inherent arc self-regulation, when the laser did not oscillate, it was observed that the arc cathode spot was typically attached to one sidewall. As a result, the molten pool did not spread through the entire width of the gap , resulting in incomplete fusion. When the laser beam oscillated in a sinusoidal path, the energy density on both sides of the amplitude was higher than the centerline, and the aspect ratio of the weld decreased. The speed of the beam along the centerline was found to be much higher than the speed on both sides of the amplitude. The molten pool oscillated in the width direction under the action of the oscillating beam, forming a concave surface, which promoted melting of the sidewalls of the groove and suppressed incomplete fusion defects in the sidewalls. The technical feasibility of NGHW assisted by laser beam oscillation was verified using a 60-mm-thick weld, which was characterized by a smooth layer transition and the absence of visible defects.

Determination of the critical temperature of Nb–Al alloys from the plasma parameters of a vacuum arc cathode spot

The plasma of pulsed-periodic splashes of explosive electron emission forms a vacuum arc cathode spot. The average parameters of the plasma can be evaluated from the parameters of the critical state of a metal for different materials. According to the measurements (Zöhrer et al 2020 Plasma Sources Sci. Technol. 29 025022) of the average charge and the kinetic energy of plasma ions, the critical temperature and cohesive energy for Nb–Al alloys was evaluated within our model. It was close to the value corresponding to pure aluminum for all component ratios Nb/Al = ¼, ⅔, ¾. We have described the experimentally measured values of the cathode potential fall using the obtained magnitudes of critical temperature in the empirical ‘cohesive energy rule’ and have reproduced the observed deviation from linearity in form of U or V shaped dependencies. The obtained results make possible to evaluate the critical temperature and cohesive energy from the parameters of the vacuum arc plasma.

Experimental Investigation on the Current Carried by a Cathode Spot of Vacuum Arc in Axial Magnetic Fields

The splitting and threshold currents of vacuum arc cathode spots in axial magnetic fields (AMFs) up to 220 mT are investigated experimentally. Measurements are made on electrodes of Cu and CuCr25 with electrode separations of 2 and 6 mm. The electrode diameter is 30 mm. All the experiments are conducted in a demountable vacuum chamber evacuated continuously by a turbo-molecular pump to a pressure of the order of 10−3 Pa. The spots are photographed using a high-speed digital camera with an exposure time of $2~\mu \text{s}$ . The AMF is applied by means of two permanent magnets placed symmetrically inside the chamber. The experimental results indicate that the splitting and threshold current decrease in the presence of AMF and tend to certain constant values when the field gets stronger. The splitting and threshold currents are considerably larger than Cu electrodes than those with CuCr25 electrodes. With increasing electrode separation, the splitting current decreases while the threshold current increases. Possible explanations are proposed to account for the experimental observations.

Simulation of vacuum arc cathode spot movement between transverse magnetic field contacts

Vacuum switches have been extensively used in the field of medium voltage. Carrying out relevant research on vacuum arc is particularly important for improving the performance and reliability of vacuum switches. The vacuum arc cathode spots provide metal vapor and electrons, which determine the breaking capacity of the vacuum switches to some extent. Therefore, based on the simulation model of the cathode spots between the transverse magnetic field (TMF) contacts, the motion phenomenon and distribution of the cathode spot were simulated and the characteristics of the initial diffusion stage of cathode spots between TMF contacts were studied. The simulation results showed that the probability of generating a cathode spot in the direction of retrograde motion increased with the increase in the TMF component and the direction of motion varied with the angle between the magnetic field and the contact. The diffusion process of cathode spots under wan-shaped contacts, cup-shaped contacts, and spiral-shaped contacts was simulated. The ring-shaped distribution of the cathode spots between cup-shaped contacts with a large current in the initial diffusion stage was formed by the self-generated magnetic field of cathode spots, while the axial magnetic field component and the clustered cathode spots destroyed the ring-shaped distribution. Taking the distribution of cathode spots and current from experiments as initial conditions, the simulation results of cathode spot distribution in the initial diffusion stage and the arc root radius were consistent with the experimental results.

Interaction of cathode spots of a vacuum-arc discharge with a metal surface during its deactivation

For the first time, the possibility of deactivation of a metal surface by the dry method by means of treatment with cathode spots of a vacuum-arc discharge is shown. A high deactivation coefficient is obtained by squeezing the liquid phase of the metal from the cathode spot with a high pressure created by the plasma flow at the base of the cathode jet. Some principles of controlling the movement of cathode spots of a vacuum arc on the surface are shown.

Three‐dimensional electromagnetic thermal fluid simulation of re‐strike phenomenon in magnetically driven arc between parallel electrodes with edges

A magnetically driven arc does not advance smoothly between parallel electrodes with edges. The anode spot stagnates on the anode surface when the arc column and cathode spot move forward. According to experimental results, when the arc column moves closer to the anode surface, or a high‐temperature gas comes into contact with the anode, a new anode spot appears and electrical breakdown occurs. Meanwhile, the original anode spot disappears. It is well known as the re‐strike phenomenon. Also, it can be observed using a bandpass filter (520 nm) that a large amount of Cu vapor is generated whenever a new anode spot appears. Because the Cu vapor considerably increases the arc's radiative emission and has a dissimilar effect on the gas's electrical conductivity at different concentrations, a three‐dimensional electromagnetic thermal fluid simulation program that considers the metal vapor from the electrodes is proposed in this paper. Based on the experimental figures, it is able to simulate the re‐strike process by controlling the electrical conductivity of the control volume at the anode surface. In addition, the physical properties of the arc plasma, the original anode spot area, and the re‐strike point area are analyzed, in order to elucidate the occurrence conditions of the re‐strike phenomenon. The results show that the arc form is affected by the electrode jets, which leads to an increase in the electric field density between the re‐strike point and the arc column, thereby causing the re‐strike phenomenon to occur. © 2020 Institute of Electrical Engineers of Japan. Published by John Wiley & Sons, Inc.

Cathode and plasma phenomena in vacuum-arc sources of hydrogen isotope ions: I. Desorption of hydrogen isotopes during the operation of vacuum arc cathode spots

A model is proposed to describe the desorption of deuterium from a deuterated cathode during the operation of the vacuum arc cathode spot. The model treats a cathode spot as consisting of individual cells and involves a numerical simulation of the temperature fields that arise during the hydrodynamic processes responsible for the formation of microcraters on the cathode surface. Using a deuterated ZrD0.67 cathode as an example, it is shown that the amount of deuterium desorbed immediately from the crater formed during the operation of the cathode spot cells is several times smaller than the total amount of desorbed deuterium. The main portion of deuterium is desorbed from the hot cathode region adjacent to the crater and from the crater at the stage of its cooling. For a deuterated ZrD0.67 cathode, the percentage of desorbed deuterium can reach 80% of the total number of evaporated atoms, and it can be even greater if the cathode spot cells operate in the immediate vicinity of each other.

Investigation of unstable motion characteristics of vacuum arc cathode spots between transverse magnetic field contacts

AbstractWith the improvement of the current level of power grids, the requirements of the opening level of the vacuum switches are also increasing. Vacuum arc cathode spots provide steam and electrons and, to a certain extent, determine the opening capacity of the vacuum switch. In this paper, a vacuum arc cathode spot research platform based on the de‐mountable vacuum chamber is constructed. The characteristics of the vacuum arc cathode spots under the transverse magnetic field (TMF) contacts are assessed by a high‐speed charge coupled device. The experimental results show that the cathode spot diffusion process can be divided into three processes through cathode spot distribution, arc voltage and current: initial diffusion stage of cathode spots, unstable motion stage of cathode spots, and extinguishing stage. The motion mode of cathode spots during unstable motion stage can be divided into cathode spots group stagnation (CSGS) to multi‐cathode jet (MCJ) switch mode, cathode spots group motion (CSGM) to MCJ switch mode, CSGM mode, and MCJ mode. The effects of peak current and contact diameter on unstable motion mode were analysed.

The Effect of Cathodic Arc Guiding Magnetic Field on the Growth of (Ti0.36Al0.64)N Coatings

We use a modified cathodic arc deposition technique, including an electromagnetic coil that introduces a magnetic field in the vicinity of the source, to study its influence on the growth of (Ti0.36Al0.64)N coatings. By increasing the strength of the magnetic field produced by the coil, the cathode arc spots are steered toward the edge of the cathode, and the electrons are guided to an annular anode surrounding the cathode. As a result, the plasma density between the cathode and substrate decreased, which was observed as a lateral spread of the plasma plume, and a reduction of the deposition rate. Optical emission spectroscopy shows reduced intensities of all recorded plasma species when the magnetic field is increased due to a lower number of collisions resulting in excitation. We note a charge-to-mass ratio decrease of 12% when the magnetic field is increased, which is likely caused by a reduced degree of gas phase ionization, mainly through a decrease in N2 ionization. (Ti0.36Al0.64)N coatings grown at different plasma densities show considerable variations in grain size and phase composition. Two growth modes were identified, resulting in coatings with (i) a fine-grained glassy cubic and wurtzite phase mixture when deposited with a weak magnetic field, and (ii) a coarse-grained columnar cubic phase with a strong magnetic field. The latter conditions result in lower energy flux to the coating’s growth front, which suppresses surface diffusion and favors the formation of c-(Ti,Al)N solid solutions over phase segregated c-TiN and w-AlN.

Revisiting Theoretical Description of the Retrograde Motion of Cathode Spots of Vacuum Arcs

A fresh attempt to develop a self-consistent description of the retrograde motion of cathode spots on volatile cathodes is undertaken. Three potential mechanisms of effect of transversal magnetic field on the distribution of parameters in the spot are studied: the effect of magnetic field on hydrodynamics processes in the spot, in particular, on the formation of liquid-metal jet and the droplet detachment, and the effect of transversal magnetic field over the motion of ions and emitted electrons in the near-cathode space-charge sheath. It is found that for typical conditions of cathode spots in vacuum arcs the effect of magnetic field over the formation of liquid-metal jet and the droplet detachment is negligible; the motion of the ions in the near-cathode space-charge sheath is not disturbed; and the motion of the emitted electrons is disturbed only marginally. Thus, the above-mentioned potential mechanisms are hardly relevant and the first-principle understanding is still missing. A phenomenological description of the retrograde motion is developed as an alternative. The description employs general considerations without relying on specific assumptions and the (only) unknown parameter can be determined from comparison with the experiment.