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NASA NTRS1991

Multi-cathode unbalanced magnetron sputtering systems

Ion bombardment of a growing film during deposition is necessary in many instances to ensure a fully dense coating, particularly for hard coatings. Until the recent advent of unbalanced magnetron (UBM) cathodes, reactive sputtering had not been able to achieve the same degree of ion bombardment as other physical vapor deposition processes. The amount of ion bombardment of the substrate depends on the plasma density at the substrate, and in a UBM system the amount of bombardment will depend on the degree of unbalance of the cathode. In multi-cathode systems, the magnetic fields between the cathodes must be linked to confine the fast electrons that collide with the gas atoms. Any break in this linkage results in electrons being lost and a low plasma density. Modeling of the magnetic fields in a UBM cathode using a finite element analysis program has provided great insight into the interaction between the magnetic fields in multi-cathode systems. Large multi-cathode systems will require very strong magnets or many cathodes in order to maintain the magnetic field strength needed to achieve a high plasma density. Electromagnets offer the possibility of independent control of the plasma density. Such a system would be a large-scale version of an ion beam enhanced deposition (IBED) system, but, for the UBM system where the plasma would completely surround the substrate, the acronym IBED might now stand for Ion Blanket Enhanced Deposition.

Sproul, William D.↗

NASA NTRS1973

Pulsed electromagnetic gas accelleration

Direct measurement with thermocouples of the power deposited in the anode of a multi-megawatt magnetoplasmadynamic discharge has shown the fractional anode power to decrease from 50% at 200 kW to 10% at 20 MW. Using local measurements of current density, electric potential, and electron temperature, the traditional model for heat conduction to the anode is found to be inadequate. Other experiments in which the voltage-current characteristics and exhaust velocities of MPD arcs using Plexiglas and boron nitride chamber insulators and various mass injection configurations show that ablation can affect nominal accelerator operation in several distinct ways. The incorporation of a hollow cathode in a 7 kA plasma discharge has shown that a stable current attachment can be realized in the cavity without the aid of cathode heaters, keeper electrodes, or emissive coatings.

Jahn, R. G.↗

NASA NTRS1961

Quantum Yield of Gold-Cathode Photomultipliers

Two gold-cathode EMI 6255G tubes have been investigated for their quantum yield between 3100 and 1900 A. The tubes had cathodes of different appearances. One of these, numbered 3012, had a slight bluish tinge and was very transparent to visible light; the other, numbered 3021, had a definite gold coloration. The relative quantum yield of each tube was determined with the aid of a Cary model 14 recording spectrophotometer used as a monochromator. The monochromator relative-energy output was determined from the current output of a sodium-salicylate-coated RCA 1P21 photomultiplier. Each gold-cathode tube was then operated at 3000 v, and the central 1.8 cm cube of the cathode was exposed to the monochromator output.

Childs, Charles B.↗

NASA NTRS1976

Long lifetime hollow cathodes for 30-cm mercury ion thrusters

An experimental investigation of hollow cathodes for 30-cm Hg bombardment thrusters was carried out. Both main and neutralizer cathode configurations were tested with both rolled foil inserts coated with low work function material and impregnated porous tungsten inserts. Temperature measurements of an impregnated insert at various positions in the cathode were made. These, along with the cathode thermal profile are presented. A theory for rolled foil and impregnated insert operation and lifetime in hollow cathodes is developed. Several endurance tests, as long as 18000 hours at emission currents of up to 12 amps were attained with no degradation in performance.

Mirtich, M. J.↗

NASA NTRS1976

Long lifetime hollow cathodes for 30-cm mercury ion thrusters

An experimental investigation of hollow cathodes for 30-cm Hg bombardment thrusters was carried out. Both main and neutralizer cathode configurations were tested with both rolled foil inserts coated with low work function material and impregnated porous tungsten inserts. Temperature measurements of an impregnated insert at various positions in the cathode were made. These, along with the cathode thermal profile are presented. A theory for rolled foil and impregnated insert operation and lifetime in hollow cathodes is developed. Several endurance tests, as long as 18,000 hours at emission currents of up to 12 amps were attained with no degradation in performance.

Mirtich, M. J.↗

NASA NTRS1977

Low-temperature thermionic emitter

An improved photodelineatable cathode material is disclosed comprising a combination of triple carbonate (TC) and a hydrocarbon polymeric photoresist PR. A mixture of TC powder and PR is applied to a cathode by spraying, spinning or dipping and is then subjected to activation at a temperature from about 800.degree. C up to the melting temperature. The cathodes can be activated at a temperature as low as 800.degree. C and still deliver a 0-field, temperature-limited current density of 750 milliamperes per sq. centimeter at 600.degree. C. If a pattern is desired, the coating is exposed through a suitable mask to actinic light to harden the photoresist in the desired areas. Following exposure, the exposed image areas are developed and the unexposed portions of the coating are removed with solvent. When dry, the cathode is ready for activation.

Remington, Richard W.↗

NASA NTRS1998

Cathodic Protection Deployment on Space Shuttle Solid Rocket Boosters

Corrosion protection of the space shuttle solid rocket boosters incorporates the use of cathodic protection(anodes) in concert with several coatings systems. The SRB design has large carbon/carbon composites(motor nozzle) electrically connected to an aluminum alloy structure. Early in the STS program, the aluminum structures incurred tremendous corrosive attack due primarily to the galvanic couple to the carbon/carbon nozzle at coating damage locations. Also contributing to the galvanic corrosion problem were stainless steel and titanium alloy components housed within the aluminum structures and electrically connected to the aluminum structures. This paper will highlight the evolution in the protection of the aluminum structures, providing historical information and summary data from the operation of the corrosion protection systems. Also, data and information will be included regarding the evaluation and deployment of inorganic zinc rich primers as anode area on the aluminum structures.

Zook, Lee M.↗

NASA NTRS2010

Physical and Electrical Characterization of Aluminum Polymer Capacitors

Conductive polymer aluminum capacitor (PA capacitor) is an evolution of traditional wet electrolyte aluminum capacitors by replacing liquid electrolyte with a solid, highly conductive polymer. On the other hand, the cathode construction in polymer aluminum capacitors with coating of carbon and silver epoxy for terminal connection is more like a combination of the technique that solid tantalum capacitor utilizes. This evolution and combination result in the development of several competing capacitor construction technologies in manufacturing polymer aluminum capacitors. The driving force of this research on characterization of polymer aluminum capacitors is the rapid progress in IC technology. With the microprocessor speeds exceeding a gigahertz and CPU current demands of 80 amps and more, the demand for capacitors with higher peak current and faster repetition rates bring conducting polymer capacitors to the center o( focus. This is because this type of capacitors has been known for its ultra-low ESR and high capacitance. Polymer aluminum capacitors from several manufacturers with various combinations of capacitance, rated voltage, and ESR values were obtained and tested. The construction analysis of the capacitors revealed three different constructions: conventional rolled foil, the multilayer stacking V-shape, and a dual-layer sandwich structure. The capacitor structure and its impact on the electrical characteristics has been revealed and evaluated. A destructive test with massive current over stress to fail the polymer aluminum capacitors reveals that all polymer aluminum capacitors failed in a benign mode without ignition, combustion, or any other catastrophic failures. The extraordinary low ESR (as low as 3 mOMEGA), superior frequency independence reported for polymer aluminum capacitors have been confirmed. For the applications of polymer aluminum capacitors in space programs, a thermal vacuum cycle test was performed. The results, as expected, show no impact on the electrical characteristics of the capacitors. The breakdown voltage of polymer capacitors has been evaluated using a steady step surge test. Initial results show the uniform distribution in the breakdown voltage for polymer aluminum capacitors. Polymer aluminum capacitors with a combination of very high capacitance, extraordinary low ESR, excellent frequency stability, and non-ignite benign failure mode make it a niche fit in space applications for both today and future. Polymer capacitors are apparently also the best substitutes of the currently used MnO2-based tantalum capacitors in the low voltage range. However, some critical aspects are still to be addressed in the next phase of the investigation for PA capacitors. These include the long term reliability test of 125 C dry life and 85 C/85%RH humidity, the failure mechanism and de-rating, the radiation tolerance, and the high temperature performance. All of the above requires the continuous NEPP funding and support.

Liu, David (Donghang)↗

NASA NTRS1988

Arc Plasma Gun With Coaxial Powder Feed

Redesigned plasma gun provides improved metallic and ceramic coatings. Particles injected directly through coaxial bore in cathode into central region of plasma jet. Introduced into hotter and faster region of plasma jet.

Zaplatynsky, Isidor↗

NASA NTRS1998

Thermal Control using Electrochromism

The applicability of a charge balanced electrochromic device to modulate the frequencies in the thermal infrared region is examined in this study. The device consisted of a transparent conductor, WO3 anode, PMMA/LiClO4 electrolyte, V2O5 cathode and transparent conductor. The supporting structure in the device is SnO2 coated glass and the edges are sealed with epoxy to reduce moisture absorption. The performance evaluation comprised of cyclic voltammetric measurements and determination of transmittance at various wavelengths. The device was subjected to anodic and cathodic polarization by sweeping the potential at a rate of 10 mV/sec from -0.8V to 1.8V. The current versus voltage profile indicated no reaction between -0.5 and +0.5 V. The device is colored green at 1.8V with a transmittance of 5% at a wavelength, lambda=900 nm and colorless at -0.8V with a transmittance of 74% at lambda=500 nm. The optical modulation is limited to 400-1500 nm and there is no activity in the thermal infrared. The switching time is 75 seconds for transmittance to decrease from 74% to 50%. The device yielded reproducible values for transmittance when cycled between colored and bleached states by application of 1.8V and -0.8V, respectively.

Vaidyanathan, Hari↗

NASA NTRS1998

Thermal Control Using Electrochromism

The applicability of a charge balanced electrochromic device to modulate the frequencies in the thermal infra red region is examined in this study. The device consisted of a transparent conductor, WO3 anode, PMMA/LiClO4, electrolyte, V2O5, cathode and transparent conductor. The supporting structure in the device is SnO2 coated glass and the edges are sealed with epoxy to reduce moisture absorption. The performance evaluation comprised of cyclic voltammetric measurements and determination of transmittance at various wavelengths. The device was subjected to anodic and cathodic polarization by sweeping the potential at a rate of 10 mV/sec from -0.8 V to 1.8 V. The current versus voltage profile indicated no reaction between -0.5 and +0.5 V. The device is colored green at 1.8 V with a transmittance of 5% at a wavelength, lambda = 900 nm and colorless at -0.8 V with a transmittance of 74% at X = 500 nm. The optical modulation is limited to 400-1500 nm and there is no activity in the thermal infrared. The switching time is 75 seconds for transmittance to decrease from 74% to 50%. The device yielded reproducible values for transmittance when cycled between colored and bleached states by application of 1.8 V and -0.8 V, respectively.

Vaidyanathan, Hari↗

NASA NTRS1999

Thermal Control Using Electrochromism

The applicability of a charge balanced electrochromic device to modulate the frequencies in the thermal infrared region is examined in this study. The device consisted of a transparent conductor, WO3, anode, PMMA/LiClO4 electrolyte, V2O5 cathode and transparent conductor. The supporting structure in the device is SnO2 coated glass and the edges are sealed with epoxy to reduce moisture absorption. The performance evaluation comprised of cyclic voltammetric measurements and determination of transmittance at various wavelengths. The device was subjected to anodic and cathodic polarization by sweeping the potential at a rate of 10 mV/sec from -0.8V to 1.8V. The current versus voltage profile indicated no reaction between -0.5 and +0.5 V. The device is colored green at 1.8 V with a transmittance of 5% at a wavelength, lambda = 900 nm and colorless at -0.8 V with a transmittance of 74% at lambda = 500 nm. The optical modulation is limited to 400-1500 nm and there is no activity in the thermal infrared. The switching time is a function of temperature and time for coloring reaction was slower than the bleaching reaction. The device yielded reproducible values for transmittance when cycled between colored and bleached states by application of 1.8V and -0.8V, respectively.

Vaidyanathan, Hari↗

NASA NTRS1979

Method and device for the detection of phenol and related compounds

A method is described which permits the selective oxidation and potentiometric detection of phenol and related compounds in an electrochemical cell. An anode coated with a gel immobilized oxidative enzyme and a cathode are each placed in an electrolyte solution. The potential of the cell is measured by a potentiometer connected to the electrodes.

Schiller, J. G.↗

NASA NTRS1993

Measured optical performance of three Fabry-Perot interferometers for use in a tunable ultraviolet filter

A narrowband ultraviolet (UV) filter would allow the first monochromatic two-dimensional images of astrophysical plasmas to be obtained in UV emission lines. The high etendue and spectral resolving power of the Fabry-Perot (FP) interferometer make it an excellent candidate for use in a tunable UV filter, provided that adequate optical performance can be obtained. Laboratory measurements of three UV FP interferometers with progressively greater dielectric mirror reflectances are described. The measurements demonstrate the adequate reflectivity, absorption, and small-scale smoothness of currently available coatings and substrates for UV interferometry. The measurements are conducted at 228.8 nm utilizing a cadmium hollow cathode light source. The best performing interferometer has a finesse of 41 and maximum transmittance of 0.38 over a coating-performance-dominated 3-mm-diam subaperture and a finesse of 26 and maximum transmittance of 0.32 over a parabolic-defect-dominated 30-mm-diam aperture. This interferometer is well suited for use in a UV filter system.

Korendyke, Clarence M.↗

NASA NTRS1986

Apparatus for producing diamond-like carbon flakes

A vacuum arc from a spot at the face of a graphite cathode to a graphite anode produces a beam of carbon ions and atoms. A carbon coating from this beam is deposited on an ion beam sputtered target to produce diamond-like carbon flakes. A graphite tube encloses the cathode, and electrical isolation is provided by an insulating sleeve. The tube forces the vacuum arc spot to be confined to the surface on the outermost end of the cathode. Without the tube the arc spot will wander to the side of the cathode. This spot movement results in low rates of carbon deposition, and the properties of the deposited flakes are more graphite-like than diamond-like.

Banks, Bruce A.↗

NASA NTRS2010

Compact Rare Earth Emitter Hollow Cathode

A compact, high-current, hollow cathode utilizing a lanthanum hexaboride (LaB6) thermionic electron emitter has been developed for use with high-power Hall thrusters and ion thrusters. LaB6 cathodes are being investigated due to their long life, high current capabilities, and less stringent xenon purity and handling requirements compared to conventional barium oxide (BaO) dispenser cathodes. The new cathode features a much smaller diameter than previously developed versions that permit it to be mounted on axis of a Hall thruster ( internally mounted ), as opposed to the conventional side-mount position external to the outer magnetic circuit ("externally mounted"). The cathode has also been reconfigured to be capable of surviving vibrational loads during launch and is designed to solve the significant heater and materials compatibility problems associated with the use of this emitter material. This has been accomplished in a compact design with the capability of high-emission current (10 to 60 A). The compact, high-current design has a keeper diameter that allows the cathode to be mounted on the centerline of a 6- kW Hall thruster, inside the iron core of the inner electromagnetic coil. Although designed for electric propulsion thrusters in spacecraft station- keeping, orbit transfer, and interplanetary applications, the LaB6 cathodes are applicable to the plasma processing industry in applications such as optical coatings and semiconductor processing where reactive gases are used. Where current electrical propulsion thrusters with BaO emitters have limited life and need extremely clean propellant feed systems at a significant cost, these LaB6 cathodes can run on the crudest-grade xenon propellant available without impact. Moreover, in a laboratory environment, LaB6 cathodes reduce testing costs because they do not require extended conditioning periods under hard vacuum. Alternative rare earth emitters, such as cerium hexaboride (CeB6) can be used in this configuration with possibly an even longer emitter life. This cathode is specifically designed to integrate on the centerline of a high-power Hall thruster, thus eliminating the asymmetries in the plasma discharge common to cathodes previously mounted externally to the thruster s magnetic circuit. An alternative configuration for the cathode uses an external propellant feed. This diverts a fraction of the total cathode flow to an external feed, which can improve the cathode coupling efficiency at lower total mass flow rates. This can improve the overall thruster efficiency, thereby decreasing the required propellant loads for different missions. Depending on the particular mission, reductions in propellant loads can lead to mission enabling capabilities by allowing launch vehicle step-down, greater payload capability, or by extending the life of a spacecraft.

Watkins, Ronald↗

NASA NTRS1990

Effects of an unbalanced magnetron in a unique dual-cathode, high rate reactive sputtering system

Simple plasma and magnetic field measurements are presented to illustrate the opportunities afforded by using unbalanced magnetrons in a dual-cathode system. The system employs a pair of opposed cathodes, 38 cm x 13 cm, placed 27.5 cm apart, to coat specimens mounted on a rotational substrate holder. Comparisons are drawn between the original 'balanced' magnetron and several unbalanced configurations in terms of field strengths, deposition rates, etching characteristics, and substrate ion current densities for the growth of TiN films. The effects of 'unbalancing' on the nature of the plasma within the 3D geometry of the deposition chamber are elucidated via plasma probe and magnetic field studies performed under a variety of conditions. All the unbalanced configurations examined provided enhanced ion bombardment at the surface of the growing film. The closed-field or opposed magnet geometry resulted in a threefold or greater increase in current density when compared with that obtained using the corresponding mirrored geometry under the same conditions.

Rohde, S. L.↗

NASA NTRS1995

Galvanic Protection Of 2219 Al By Al/Li Powder

Coatings consisting of aluminum/lithium powders incorporated into acrylic resin found to protect panels of 2219 aluminum from corrosion by salt spray better than coating consisting of 2219 aluminum in same acrylic resin. Exact mechanism by which aluminum/lithium coatings protect against corrosion unknown, although galvanic mechanism suspected. These coatings (instead of chromium) applied to fasteners and bars to provide cathodic protection, both with and without impressed electrical current.

Daech, Alfred↗