Engineering topics

Robinson, R. S.

Publications and source records attributed to Robinson, R. S..

At least 37 records · Page 2

NASA NTRS1981

Experimental Simulation of the Interaction of Biased Solar Arrays with the Space Plasma

The phenomenon of unexpectedly large leakage currents collected by small exposed areas of high voltage solar arrays operating in a plasma environment was investigated. Polyimide (Kapton) was the insulating material used in all tests. Both positive bias (electron collection) and negative bias (ion collection) tests were performed. A mode change in the electron collection mechanism was associated with a glow discharge process and was found to be related to the neutral background density. Results indicate that the glow discharge collection mode does not occur in a space environment where the background density is considerably lower than that of the vacuum facility used.

Kaufman, H. R.↗

NASA NTRS1981

A 5 x 40 cm rectangular-beam multipole ion source

A rectangular ion source particularly suited for the continuous sputter processing of materials over a wide area is discussed. A multipole magnetic field configuration was used to design an ion source with a 5 x 40 cm beam area, while a three-grid ion optics system was used to maximize ion current density at the design ion energy of 500 eV. An average extracted current density of about 4 mA/sq cm could be obtained from 500 eV Ar ions. The difference between the experimental performance and the design value of 6 mA/sq cm is attributed to grid misalignment due to thermal expansion. The discharge losses at typical operating conditions ranged from about 600 to 1000 eV/ion, in reasonable agreement with the design value of 800 eV/ion. The use of multiple rectangular-beam ion sources to process wider areas than would be possible with a single source was also studied, and the most uniform coverage was found to be obtainable with a 0 to 2 cm overlap.

Robinson, R. S.↗

NASA NTRS1981

Ion source design for industrial applications

The more frequently used design techniques for the components of broad-beam electron bombardment ion sources are discussed. The approach used emphasizes refractory metal cathodes and permanent-magnet multipole discharge chambers. Design procedures and sample calculations are given for the discharge chamber, ion optics, the cathodes, and the magnetic circuit. Hardware designs are included for the isolator, cathode supports, anode supports, pole-piece assembly, and ion-optics supports. A comparison is made between two-grid and three-grid optics. The designs presented are representative of current technology and are adaptable to a wide range of configurations.

Kaufman, H. R.↗

NASA NTRS1981

Inert-gas thruster technology

Attention is given to recent advances in component technology for inert-gas thrusters. It is noted that the maximum electron emission of a hollow cathode with Ar can be increased 60-70% by using an enclosed keeper configuration. Operation with Ar but without emissive oxide has also been attained. A 30-cm thruster operated with Ar at moderate discharge voltages is found to give double-ion measurements consistent with a double-ion correlation developed earlier on the basis of 15-cm thruster data. An attempt is made to reduce discharge losses by biasing anodes positive of the discharge plasma. The performance of a single-grid ion-optics configuration is assessed. The ion impingement on the single-grid accelerator is found to approach the value expected from the projected blockage when the sheath thickness next to the accelerator is 2-3 times the aperture diameter.

Kaufman, H. R.↗

NASA NTRS1981

Experimental simulation of space plasma interactions with high voltage solar arrays

Operating high voltage solar arrays in the space environment can result in anomalously large currents being collected through small insulation defects. Tests of simulated defects have been conducted in a 45-cm vacuum chamber with plasma densities of 100,000 to 1,000,000/cu cm. Plasmas were generated using an argon hollow cathode. The solar array elements were simulated by placing a thin sheet of polyimide (Kapton) insulation with a small hole in it over a conductor. Parameters tested were: hole size, adhesive, surface roughening, sample temperature, insulator thickness, insulator area. These results are discussed along with some preliminary empirical correlations.

Stillwell, R. P.↗

NASA NTRS1981

Simulation of charge exchange plasma propagation near an ion thruster propelled spacecraft

A model describing the charge exchange plasma and its propagation is discussed, along with a computer code based on the model. The geometry of an idealized spacecraft having an ion thruster is outlined, with attention given to the assumptions used in modeling the ion beam. Also presented is the distribution function describing charge exchange production. The barometric equation is used in relating the variation in plasma potential to the variation in plasma density. The numerical methods and approximations employed in the calculations are discussed, and comparisons are made between the computer simulation and experimental data. An analytical solution of a simple configuration is also used in verifying the model.

Robinson, R. S.↗

NASA NTRS1981

Passivation of carbon steel through mercury implantation

An experiment, in which carbon steel samples were implanted with mercury ions from a broad beam ion source and their corrosion characteristics in air were evaluated, is described. Mercury doses of a few mA min/square cm at energies of a few hundred electron volts are shown to effect significant improvements in the corrosion resistance of the treated surfaces. In a warm moist environment the onset of rusting was extended from 15 min. for an untreated sample to approximately 30 hrs. for one implanted at a dose of 33 mA min/square cm with 1000 eV mercury ions.

Wilbur, P. J.↗

NASA NTRS1981

Computer code for charge-exchange plasma propagation

The propagation of the charge-exchange plasma from an electrostatic ion thruster is crucial in determining the interaction of that plasma with the associated spacecraft. A model that describes this plasma and its propagation is described, together with a computer code based on this model. The structure and calling sequence of the code, named PLASIM, is described. An explanation of the program's input and output is included, together with samples of both. The code is written in ASNI Standard FORTRAN.

Robinson, R. S.↗

NASA NTRS1981

Ion source design for industrial applications

The design of broad-beam industrial ion sources is described. The approach used emphasizes refractory metal cathodes and permanent-magnet multipole discharge chambers. Design procedures and sample calculations are given for the discharge chamber, ion optics, cathodes, and magnetic circuit. Hardware designs are included for the isolator, cathode supports, anode supports, pole-piece assembly, and ion-optics supports. There are other ways of designing most ion source components, but the designs presented are representative of current technology and adaptable to a wide range of configurations.

Kaufman, H. R.↗

NASA NTRS1980

Inert gas thrusters

Some advances in component technology for inert gas thrusters are described. The maximum electron emission of a hollow cathode with Ar was increased 60-70% by the use of an enclosed keeper configuration. Operation with Ar, but without emissive oxide, was also obtained. A 30 cm thruster operated with Ar at moderate discharge voltages give double-ion measurements consistent with a double ion correlation developed previously using 15 cm thruster data. An attempt was made to reduce discharge losses by biasing anodes positive of the discharge plasma. The reason this attempt was unsuccessful is not yet clear. The performance of a single-grid ion-optics configuration was evaluated. The ion impingement on the single grid accelerator was found to approach the value expected from the projected blockage when the sheath thickness next to the accelerator was 2-3 times the aperture diameter.

Kaufman, H. R.↗

NASA NTRS1980

Interaction of high voltage surfaces with the space plasma

High voltage solar arrays provide spacecraft power while optimizing mass and power efficiency. Operating such arrays in the space plasma environment can result in anomalously large currents being collected through insulation defects. Two thicknesses of the insulating material were tested, with no effect found due to insulator thickness. In these tests the polyimide thickness was always much less than the pinhole diameter. The pinhole area was varied over an area range of more than 30:1. It was found that the current collected was independent of the pinhole area for hole diameters from 0.35 to 2.0 mm. Two types of adhesives were tried in two different configurations. The adhesives were chosen for their extreme difference in vacuum qualifications. Neither adhesive types nor configuration made a significant difference in current collection. The temperature of the insulating material was also varied. It was found that current collection decreased with increasing temperature. Tests were conducted to see if pinhole current collection decreased with time, as was indicated by the effects of several short tests. Current was collected for over four hours while the conductor potential was held constant at 1000 volts. A smooth decrease with time was not observed, but rather a roughly constant current collection with brief surges to high values. Tests were also conducted with the simulated solar cell biased negative. The current was found to be proportional to pinhole area.

Kaufman, H. R.↗

NASA NTRS1979

Industrial ion source technology

In reactive ion etching of Si, varying amounts of O2 were added to the CF4 background. The experimental results indicated an etch rate less than that for Ar up to an O2 partial pressure of about .00006 Torr. Above this O2 pressure, the etch rate with CF4 exceeded that with Ar alone. For comparison the random arrival rate of O2 was approximately equal to the ion arrival rate at a partial pressure of about .00002 Torr. There were also ion source and ion pressure gauge maintenance problems as a result of the use of CF4. Large scale (4 sq cm) texturing of Si was accomplished using both Cu and stainless steel seed. The most effective seeding method for this texturing was to surround the sample with large inclined planes. Designing, fabricating, and testing a 200 sq cm rectangular beam ion source was emphasized. The design current density was 6 mA/sq cm with 500 eV argon ions, although power supply limitations permitted operation to only 2 mA/sq cm. The use of multiple rectangular beam ion sources for continuous processing of wider areas than would be possible with a single source was also studied. In all cases investigated, the most uniform coverage was obtained with 0 to 2 cm beam overlay. The maximum departure from uniform processing at optimum beam overlap was found to be +15%.

Kaufman, H. R.↗

NASA NTRS1979

Inert gas thrusters

Inert gas thrusters considered for space propulsion systems were investigated. Electron diffusion across a magnetic field was examined utilizing a basic model. The production of doubly charged ions was correlated using only overall performance parameters. The use of this correlation is therefore possible in the design stage of large gas thrusters, where detailed plasma properties are not available. Argon hollow cathode performance was investigated over a range of emission currents, with the positions of the inert, keeper, and anode varied. A general trend observed was that the maximum ratio of emission to flow rate increased at higher propellant flow rates. It was also found that an enclosed keeper enhances maximum cathode emission at high flow rates. The maximum cathode emission at a given flow rate was associated with a noisy high voltage mode. Although this mode has some similarities to the plume mode found at low flows and emissions, it is encountered by being initially in the spot mode and increasing emission. A detailed analysis of large, inert-gas thruster performance was carried out. For maximum thruster efficiency, the optimum beam diameter increases from less than a meter at under 2000 sec specific impulse to several meters at 10,000 sec. The corresponding range in input power ranges from several kilowatts to megawatts.

Kaufman, H. R.↗

NASA NTRS1979

Plasma processes in inert gas thrusters

Inert gas thrusters, particularly with large diameters, have continued to be of interest for space propulsion applications. Two plasma processes are treated in this study: electron diffusion across magnetic fields and double ion production in inert-gas thrusters. A model is developed to describe electron diffusion across a magnetic field that is driven by both density and potential gradients, with Bohm diffusion used to predict the diffusion rate. This model has applications to conduction across magnetic fields inside a discharge chamber, as well as through a magnetic baffle region used to isolate a hollow cathode from the main chamber. A theory for double ion production is presented, which is not as complete as the electron diffusion theory described, but it should be a useful tool for predicting double ion sputter erosion. Correlations are developed that may be used, without experimental data, to predict double ion densities for the design of new and especially larger ion thrusters.

Kaufman, H. R.↗

NASA NTRS1979

Interaction of high voltage surfaces with the space plasma

Tests were conducted using plasma densities of approximately 10 to the 5th power - 10 to the 6th power/cu cm. Insulating materials tested were polyimide (Dapton), mica and glass. Surface-area effects were found to be substantially reduced from those previously reported at lower plasma densities. The difference in typical plasma density was felt to be the major cause of this change, although a saturation effect may also be involved. At the 10 to the 5th power/cu cm plasma density range, surface effects on collection current appear limited to roughly 1 cm from the hole. A factor of several reduction of collected current was obtained with both surface scribing and a 2 x 2 cm conducting mesh. It appears possible that the effects of surface treatment might be more significant at lower plasma densities. Effects of repeated tests were also noted, with current collection decreasing with successive tests. Depending on the materials involved, the effect appeared due to either the smoothing of the inside of the insulator hole or the sputtering of insulator on the exposed conductor. A general conclusion was made from a variety of observations, that the generation of vapor is a major factor in the enhancement of collected current.

Kaufman, H. R.↗

NASA NTRS1979

Ion beam texturing of surfaces

Textured surfaces, typically with conical structures, have been produced previously by simultaneously etching a surface and seeding that surface with another material. A theory based on surface diffusion predicts a variation in cone spacing with surface temperature, as well as a critical temperature below which cones will not form. Substantial agreement with theory has been found for several combinations of seed and surface materials, including one with a high sputter yield seed on a low sputter yield surface (gold on aluminum). Coning with this last combination was predicted by the theory for a sufficiently mobile seed material. The existence of a minimum temperature for the formation of cones should also be important to those interested in ion-beam machining smooth surfaces. Elements contained in the environmental contaminants or in the sputtered alloys or compounds may serve as seed material.

Kaufman, H. R.↗

NASA NTRS1979

Energetic binary collisions in rare gas plasmas

Calculations have been made of cross sections for energy and momentum transfer in binary collisions between like pairs of Ar, Kr, and Xe atoms in the energy range from about 1 to 1000 eV. These calculations were made using a classical model with pair interaction potentials for the rare gases developed from experimental sources, e.g., investigations of specific heats, viscosities, solid-state parameters, and scattering data. Cross sections in this energy range have not been available. The cross sections exhibit a rapid decrease from accepted values at thermal energies as the interaction energy increases. This behavior can be used to understand directed beam propagation limits as well as particle propagation within a plasma. Experimental data have also been fit to a theoretical expression for the Ar resonance charge exchange cross section over the same energy range.

Robinson, R. S.↗

NASA NTRS1979

Physical processes in directed ion beam sputtering

The general operation of a discharge chamber for the production of ions is described. A model is presented for the magnetic containment of both primary and secondary or Maxwellian electrons in the discharge plasma. Cross sections were calculated for energy and momentum transfer in binary collisions between like pairs of Ar, Kr, and Xe atoms in the energy range from about 1 eV to 1000 eV. These calculations were made from available pair interaction potentials using a classical model. Experimental data from the literature were fit to a theoretical expression for the Ar resonance charge exchange cross section over the same energy range. A model was developed that describes the processes of conical texturing of a surface due to simultaneous directed ion beam etching and sputter deposition of an impurity material. This model accurately predicts both a minimum temperature for texturing to take place and the variation of cone density with temperature. It also provides the correct order of magnitude of cone separation. It was predicted from the model, and subsequently verified experimentally, that a high sputter yield material could serve as a seed for coning of a lower sputter yield substrate. Seeding geometries and seed deposition rates were studied to obtain an important input to the theoretical texturing model.

Robinson, R. S.↗