Abstract As an emerging ion acceleration plasma source, the bipolar-pulse high power impulse magnetron sputtering (BP-HiPIMS) discharge has been widely studied by academia and industry due to its ability to adjust the ion kinetic energy. Formation of the double layer (DL) potential structure during the BP-HiPIMS positive pulse is vital for accelerating ions, but its structural characteristics are still unclear. In this work, to understand the DL characteristics affected by various discharge parameters, the evolution of plasma potential V p and ion energy in BP-HiPIMS discharge with copper target has been investigated systematically using an emissive probe and mass spectrometer together. Spatial plasma potential measurements show that the DL is established in front of the target during the positive pulse, whose boundary potential drop U DL to accelerate ions can be increased to ∼60 V at a lower operating gas pressure (p= 0.6 Pa) and a higher applied positive pulse voltage (U + = 200 V). The ignition onset time of DL after applying the positive pulse can be shortened to ∼25 μs by decreasing the gas pressure and increasing the positive pulse voltage or negative pulse duration. After DL ignition, a group of high-energy copper ions with energy higher than the surrounding plasma potential can be recognized in the ion energy distribution function curves in the downstream plasma. This result illustrates that the copper ions can be ionized in the high-potential plasma region and be accelerated by the DL boundary potential drop. In addition, a global current balance model of the DL in BP-HiPIMS is developed, which suggests that the U DL can be well adjusted by increasing the positive pulse voltage U + especially for U + > 200 V as verified by the experimental potential measurements. All results suggest that the copper particles play an important role in the formation of DL and the DL plays an important role in accelerating copper ions.
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