A New Pulsed Plasma Technology for Making Micron and Sub-micron Metallic Powders
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Engineering topics
Publications and source records attributed to Brockington, Samuel.
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HyperV Technologies Corp. has successfully designed, built and experimentally demonstrated a full scale 1024 pixel 100 MegaFrames/s fiber coupled camera with 12 or 14 bits, and record lengths of 32K frames, exceeding our original performance objectives. This high-pixel-count, fiber optically-coupled, imaging diagnostic can be used for investigating fast, bright plasma events. In Phase 1 of this effort, a 100 pixel fiber-coupled fast streak camera for imaging plasma jet profiles was constructed and successfully demonstrated. The resulting response from outside plasma physics researchers emphasized development of increased pixel performance as a higher priority over increasing pixel count. In this Phase 2 effort, HyperV therefore focused on increasing the sample rate and bit-depth of the photodiode pixel designed in Phase 1, while still maintaining a long record length and holding the cost per channel to levels which allowed up to 1024 pixels to be constructed. Cost per channel was 53.31 dollars, very close to our original target of $50 per channel. The system consists of an imaging "camera head" coupled to a photodiode bank with an array of optical fibers. The output of these fast photodiodes is then digitized at 100 Megaframes per second and stored in record lengths of 32,768 samples with bit depths of 12 to 14 bits per pixel. Longer record lengths are possible with additional memory. A prototype imaging system with up to 1024 pixels was designed and constructed and used to successfully take movies of very fast moving plasma jets as a demonstration of the camera performance capabilities. Some faulty electrical components on the 64 circuit boards resulted in only 1008 functional channels out of 1024 on this first generation prototype system. We experimentally observed backlit high speed fan blades in initial camera testing and then followed that with full movies and streak images of free flowing high speed plasma jets (at 30-50 km/s). Jet structure and jet collisions onto metal pillars in the path of the plasma jets were recorded in a single shot. This new fast imaging system is an attractive alternative to conventional fast framing cameras for applications and experiments where imaging events using existing techniques are inefficient or impossible. The development of HyperV's new diagnostic was split into two tracks: a next generation camera track, in which HyperV built, tested, and demonstrated a prototype 1024 channel camera at its own facility, and a second plasma community beta test track, where selected plasma physics programs received small systems of a few test pixels to evaluate the expected performance of a full scale camera on their experiments. These evaluations were performed as part of an unfunded collaboration with researchers at Los Alamos National Laboratory and the University of California at Davis. Results from the prototype 1024-pixel camera are discussed, as well as results from the collaborations with test pixel system deployment sites.
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Plasma jets with high density and velocity have a number of important applications in fusion energy and elsewhere, including plasma refueling, disruption mitigation in tokamaks, magnetized target fusion, injection of momentum into centrifugally confined mirrors, plasma thrusters, and high energy density plasmas (HEDP). In Magneto-Inertial Fusion (MIF), for example, an imploding material liner is used to compress a magnetized plasma to fusion conditions and to confine the resulting burning plasma inertially to obtain the necessary energy gain. The imploding shell may be solid, liquid, gaseous, or a combination of these states. The presence of the magnetic field in the target plasma suppresses thermal transport to the plasma shell, thus lowering the imploding power needed to compress the target to fusion conditions. This allows the required imploding momentum flux to be generated electromagnetically using off-the-shelf pulsed power technology. Practical schemes for standoff delivery of the imploding momentum flux are required and are open topics for research. One approach for accomplishing this, called plasma jet driven magneto-inertial fusion (PJMIF), uses a spherical array of pulsed plasma guns to create a spherically imploding shell of very high velocity, high momentum flux plasma. This approach requires development of plasma jet accelerators capable of achieving velocities of 50-200 km/s with very precise timing and density profiles, and with high total mass and density. Low-Z plasma jets would require the higher velocities, whereas very dense high-Z plasma shells could achieve the goal at velocities of only 50-100 km/s. In this report, we describe our work to develop the pulsed plasma gun technology needed for an experimental scientific exploration of the PJMIF concept, and also for the other applications mentioned earlier. The initial goal of a few hundred of hydrogen at 200 km/s was eventually replaced with accelerating 8000 μg of argon or xenon to 50 km/s for the Plasma Liner Experiment (PLX) at Los Alamos National Laboratory (LANL). Initial work used existing computational and analytical tools to develop and refine a specific plasma gun concept having a novel tapered coaxial electromagnetic accelerator contour with an array of symmetric ablative plasma injectors. The profile is designed to suppress the main barrier to success in coaxial guns, namely the blow-by instability in which the arc slips past and outruns the bulk of the plasma mass. Efforts to begin developing a set of annular non-ablative plasma injectors for the coaxial gun, in order to accelerate pure gases, resulted in development of linear parallel-plate MiniRailguns that turned out to work well as plasma guns in their own right and we subsequently chose them for an initial plasma liner experiment on the PLX facility at LANL. This choice was mainly driven by cost and schedule for that particular experiment, while longer term goals still projected use of coaxial guns for reactor-relevant applications for reasons of better symmetry, lower impurities, more compact plasma jet formation, and higher gun efficiency. Our efforts have focused mainly on 1) developing various plasma injection systems for both coax and linear railguns and ensuring they work reliably with the accelerator section, 2) developing a suite of plasma and gun diagnostics, 3) performing computational modeling to design and refine the plasma guns, 4) establishing a research facility dedicated to plasma gun development, and finally, 5) developing plasma guns and associated pulse power systems capable of achieving these goals and installing and testing the first two gun sets on the PLX facility at LANL. During the second funding cycle for this program, HyperV joined in a collaborative effort with LANL, the University of Alabama at Huntsville, and the University of New Mexico to perform a plasma liner experiment (PLX) to investigate the physics and technology of forming spherically imploding plasma liners. HyperV’s tasks focused on developing the plasma guns and associated pulse power systems required for the 30 gun experiment at LANL. Unfortunately, funding for the entire PLX collaborative project was terminated after only two years of the four year project due to program funding realignments which necessitated recompeting the project in midstream. Despite the loss of funding, HyperV installed two Mark1 guns and pulsed power systems on PLX, and jet characterization and merging experiments were subsequently successfully performed at LANL by the PLX Team. In parallel with those PLX experiments, HyperV continued its efforts to develop a plasma gun capable of meeting the PLX goal of 8 mg of argon at 50 km/s. HyperV was ultimately successful in this effort, demonstrating 10.8 mg at 52.8 km/s and 7.5 mg at 62.4 km/s with the Mark2 MiniRailgun.
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