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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

ARCTRON: A Rapid Experimental Proving Ground for TPS Experiments and Arcjet Technology Development

Innovation in high-enthalpy facilities is fundamentally limited by the cost and risk of experimentation. New concepts for plasma control, diagnostics, facility components, and plasma-material interaction often require repeated iterations that are impractical to perform in production arcjets. As a result, promising ideas may remain unexplored or reach operational facilities only after significant development effort. ARCTRON is being developed as a rapid experimental proving ground where new ideas in plasma science, arcjet engineering, diagnostics, and material response can be conceived, tested, and quantitatively evaluated before transition to large-scale facilities. The platform combines radio-frequency (RF) and DC arc plasma generation, externally applied magnetic fields, configurable gas composition, reduced-pressure operation, laser heating, electrical biasing, and modular diagnostic access. These capabilities permit the plasma source, applied forcing, test article, and measurement configuration to be modified independently, allowing individual physical mechanisms to be isolated more readily than in a traditional test environment. One class of investigations addresses fundamental plasma-surface interaction physics. Conventional material tests often expose a specimen simultaneously to convective heating, reactive species, pressure, shear, radiation, and surface-current effects. The resulting material response may be measured accurately, while the contribution of each mechanism remains difficult to identify. ARCTRON is designed to vary these effects selectively. Plasma chemistry can be changed independently through configurable gas mixtures; magnetic fields and electrical biasing can modify charged-particle transport; laser heating can provide a non-plasma thermal input; and pressure, flow, and discharge mode can be varied over a broad operating space. This enables controlled tests of hypotheses involving surface catalycity, reactive-species transport, plasma-assisted oxidation, electromagnetic effects, shear, and the relative contributions of thermal and chemical loading. A second class of investigations enabled by this approach concerns the engineering of high-enthalpy facilities themselves. Arc-heated facilities are limited by electrode erosion, unstable arc attachment, localized heating, and damage to nozzles and other plasma-facing components. ARCTRON provides a lower-cost environment for testing concepts intended to mitigate these limitations. Candidate investigations include the use of applied magnetic fields to alter current paths and reduce plasma interaction with nozzle walls, ExB forcing to introduce controlled plasma rotation, magnetic or geometric approaches for distributing arc attachment, and alternative electrode or discharge configurations intended to reduce erosion and improve stability. Because the platform is reconfigurable, these concepts can be evaluated through repeated design--build--test cycles before they are considered for implementation in operational facilities. The platform also supports the development and validation of diagnostics that may be difficult to introduce initially into a large arcjet. Current and planned measurements include spatially resolved optical emission spectroscopy, electrostatic probes, fast imaging, pyrometry, calorimetry, laser-induced fluorescence, and absorption spectroscopy. These diagnostics are intended not merely to document a nominal operating condition, but to constrain the local plasma state and its relationship to component or material response. The modular facility geometry allows diagnostic concepts to be tested, calibrated, and compared under repeatable conditions before deployment in more demanding environments. ARCTRON is also supported by an integrated software suite. Automated control and data acquisition allow discharge parameters, gas composition, magnetic fields, diagnostic timing, and test configuration to be recorded as part of each experiment (STARDAC - Software for Testing, Analysis, Research Data, and Control). The Backend for Experiment Analysis, Storage, and Traceability (BEAST) is a database that provides the infrastructure needed to associate heterogeneous measurements with facility configuration, specimen identity, calibration state, geometry, and analysis provenance. This backend is particularly important for exploratory campaigns, in which many related configurations may be tested, and the value of an individual experiment depends on its connection to earlier and subsequent iterations. Complementary analysis capabilities, including computer-vision-based transient response measurements (arcjetCV), three-dimensional surface reconstruction (STARSCAN), and model-based Bayesian inference (SHIELD), and tomography data analysis (TOMATO, PuMA) can be incorporated when required by a specific hypothesis without becoming the focus of every campaign. The central objective of ARCTRON is therefore not to maximize heat flux or reproduce a complete flight environment. Its purpose is to reduce the cost and time required to ask consequential questions about plasma behavior, plasma-facing materials, diagnostics, and arcjet technology. By providing a controlled environment for rapid reconfiguration, mechanism isolation, quantitative measurement, and iterative engineering, ARCTRON can help mature concepts that would otherwise remain too speculative or too risky for evaluation in production facilities. The resulting knowledge can then guide the design of material models, focus test objectives in larger arcjets, reduce facility-development risk, and improve the physical basis of high-enthalpy ground testing. This work will present the ARCTRON architecture, operating modes, diagnostic suite, and digital experimental workflow. Initial experimental results from the first integrated operation of the facility will be presented, including flow characterization, power limitations, and deployment of the initial diagnostic suite. Ongoing development efforts aimed at catalycity characterization, magnetic plasma control, and advanced optical diagnostics will also be discussed, illustrating how the platform supports rapid iteration from concept to experiment.

experimental diagnostics↗
NASA NTRSDate not supplied

ARCTRON: A Rapid Experimental Proving Ground for TPS Experiments and Arcjet Technology Development

Innovation in high-enthalpy facilities is fundamentally limited by the cost and risk of experimentation. New concepts for plasma control, diagnostics, facility components, and plasma-material interaction often require repeated iterations that are impractical to perform in production arcjets. As a result, promising ideas may remain unexplored or reach operational facilities only after significant development effort. ARCTRON is being developed as a rapid experimental proving ground where new ideas in plasma science, arcjet engineering, diagnostics, and material response can be conceived, tested, and quantitatively evaluated before transition to large-scale facilities. The platform combines radio-frequency (RF) and DC arc plasma generation, externally applied magnetic fields, configurable gas composition, reduced-pressure operation, laser heating, electrical biasing, and modular diagnostic access. These capabilities permit the plasma source, applied forcing, test article, and measurement configuration to be modified independently, allowing individual physical mechanisms to be isolated more readily than in a traditional test environment. One class of investigations addresses fundamental plasma-surface interaction physics. Conventional material tests often expose a specimen simultaneously to convective heating, reactive species, pressure, shear, radiation, and surface-current effects. The resulting material response may be measured accurately, while the contribution of each mechanism remains difficult to identify. ARCTRON is designed to vary these effects selectively. Plasma chemistry can be changed independently through configurable gas mixtures; magnetic fields and electrical biasing can modify charged-particle transport; laser heating can provide a non-plasma thermal input; and pressure, flow, and discharge mode can be varied over a broad operating space. This enables controlled tests of hypotheses involving surface catalycity, reactive-species transport, plasma-assisted oxidation, electromagnetic effects, shear, and the relative contributions of thermal and chemical loading. A second class of investigations enabled by this approach concerns the engineering of high-enthalpy facilities themselves. Arc-heated facilities are limited by electrode erosion, unstable arc attachment, localized heating, and damage to nozzles and other plasma-facing components. ARCTRON provides a lower-cost environment for testing concepts intended to mitigate these limitations. Candidate investigations include the use of applied magnetic fields to alter current paths and reduce plasma interaction with nozzle walls, ExB forcing to introduce controlled plasma rotation, magnetic or geometric approaches for distributing arc attachment, and alternative electrode or discharge configurations intended to reduce erosion and improve stability. Because the platform is reconfigurable, these concepts can be evaluated through repeated design--build--test cycles before they are considered for implementation in operational facilities. The platform also supports the development and validation of diagnostics that may be difficult to introduce initially into a large arcjet. Current and planned measurements include spatially resolved optical emission spectroscopy, electrostatic probes, fast imaging, pyrometry, calorimetry, laser-induced fluorescence, and absorption spectroscopy. These diagnostics are intended not merely to document a nominal operating condition, but to constrain the local plasma state and its relationship to component or material response. The modular facility geometry allows diagnostic concepts to be tested, calibrated, and compared under repeatable conditions before deployment in more demanding environments. ARCTRON is also supported by an integrated software suite. Automated control and data acquisition allow discharge parameters, gas composition, magnetic fields, diagnostic timing, and test configuration to be recorded as part of each experiment (STARDAC - Software for Testing, Analysis, Research Data, and Control). The Backend for Experiment Analysis, Storage, and Traceability (BEAST) is a database that provides the infrastructure needed to associate heterogeneous measurements with facility configuration, specimen identity, calibration state, geometry, and analysis provenance. This backend is particularly important for exploratory campaigns, in which many related configurations may be tested, and the value of an individual experiment depends on its connection to earlier and subsequent iterations. Complementary analysis capabilities, including computer-vision-based transient response measurements (arcjetCV), three-dimensional surface reconstruction (STARSCAN), and model-based Bayesian inference (SHIELD), and tomography data analysis (TOMATO, PuMA) can be incorporated when required by a specific hypothesis without becoming the focus of every campaign. The central objective of ARCTRON is therefore not to maximize heat flux or reproduce a complete flight environment. Its purpose is to reduce the cost and time required to ask consequential questions about plasma behavior, plasma-facing materials, diagnostics, and arcjet technology. By providing a controlled environment for rapid reconfiguration, mechanism isolation, quantitative measurement, and iterative engineering, ARCTRON can help mature concepts that would otherwise remain too speculative or too risky for evaluation in production facilities. The resulting knowledge can then guide the design of material models, focus test objectives in larger arcjets, reduce facility-development risk, and improve the physical basis of high-enthalpy ground testing. This work will present the ARCTRON architecture, operating modes, diagnostic suite, and digital experimental workflow. Initial experimental results from the first integrated operation of the facility will be presented, including flow characterization, power limitations, and deployment of the initial diagnostic suite. Ongoing development efforts aimed at catalycity characterization, magnetic plasma control, and advanced optical diagnostics will also be discussed, illustrating how the platform supports rapid iteration from concept to experiment.

experimental diagnostics↗
NASA NTRS2001

An Experimental Investigation of the Effects of Charging on the International Space Station

An experimental investigation has been undertaken to determine the effects associated with operating the International Space Station (ISS) without a Plasma Contactor Unit (PCU). The role of the PCU is to maintain the potential of the ISS to within 40 volts of the ambient plasma potential. In the event of a PCU failure, ISS structure may charge to - 160 volts with respect to the Low Earth Orbit (LEO) plasma, due to the use of high voltage photovoltaic solar arrays. Operation without a PCU will result in the charging of the oxide layers on anodized aluminum components facing into the RAM direction. In this investigation, arcs were observed as a result of anodized materials charging in a plasma environment. Actual ISS materials were used in the investigation. The materials included meteoroid and debris shield samples, as well as components from the Extravehicular Mobility Unit (EMU). Results show that the occurrence of arcs was dependent on several factors including material composition and applied voltage. The breakdown thresholds for the materials tested will be shown, as well as the voltage and current waveforms during an arc event. The damage resulting from an arc will also be described. In addition, a description of associated operational hazards resulting from arcing on the spacecraft will be provided.

Schneider, Todd↗
NASA NTRS2001

Large-Scale Mini-Magnetosphere Plasma Propulsion (M2P2) Experiments

Mini-Magnetosphere Plasma Propulsion (M2P2) is an innovative plasma propulsion system that has the potential to propel spacecraft at unprecedented speeds of 50 to 80 km/s, with a low power requirement of approx. 1 kW per 100 kg of payload and -1 kg of neutral gas [fuel] consumption per day of acceleration. Acceleration periods from several days to a few months are envisioned. High specific impulse and efficiency are achieved through coupling of the spacecraft to the 400 km/s. solar wind through an artificial magnetosphere. The mini-magnetosphere or inflated magnetic bubble is produced by the injection of cold dense plasma into a spacecraft-generated magnetic field envelope. Magnetic bubble inflation is driven by electromagnetic processes thereby avoiding the material and deployment problems faced by mechanical solar sail designs. Here, we present the theoretical design of M2P2 as well as initial results from experimental testing of an M2P2 prototype demonstrating: 1) inflation of the dipole magnetic field geometry through the internal injection of cold plasma; and 2) deflection of and artificial solar wind by the prototype M2P2 system. In addition, we present plans for direct laboratory measurement of thrust imparted to a prototype M2P2 by an artificial solar wind during the summer of 2001.

Winglee, R. M.↗
NASA NTRS2001

Large-Scale Mini-Magnetosphere Plasma Propulsion (M2P2) Experiments

Mini-Magnetosphere Plasma Propulsion (M2P2) is an innovative plasma propulsion system that has the potential to propel spacecraft at unprecedented speeds of 50 to 80 km per second with a low-power requirement of approx. 1 kW per 100 kg of payload and approx. 1 kg of neutral gas [fuel] consumption per day of acceleration. Acceleration periods from several days to a few months are envisioned. High specific impulse and efficiency are achieved through coupling of the spacecraft to the 400 km per second solar wind through an artificial magnetosphere. The mini-magnetosphere or inflated magnetic bubble is produced by the injection of cold dense plasma into a spacecraft-generated magnetic field envelope. Magnetic bubble inflation is driven by electromagnetic processes thereby avoiding the material and deployment problems faced by mechanical solar sail designs, Here, we present the theoretical design of M2P2 as well as initial results from experimental testing of an M2P2 prototype demonstrating: 1) inflation of the dipole magnetic field geometry through the internal injection of cold plasma; and 2) deflection of and artificial solar wind by the prototype M2P2 system. In addition, we present plans for direct laboratory measurement of thrust imparted to a prototype M2P2 by an artificial solar wind during the summer of 2001.

Winglee, R. M.↗
NASA NTRS2005

Ferroelectric Devices Emit Charged Particles and Radiation

Devices called solid-state ferroelectric- based sources (SSFBSs) are under development as sources of electrons, ions, ultraviolet light, and x-rays for diverse applications in characterization and processing of materials. Whereas heretofore it has been necessary to use a different device to generate each of the aforementioned species of charged particles or radiation, a single SSFBS can be configured and operated to selectively generate any of the species as needed using a single source. Relative to comparable prior sources based, variously, on field emission, thermionic emission, and gaseous discharge plasmas, SSFBSs demand less power, and are compact and lightweight. An SSFBS exploits the unique physical characteristics of a ferroelectric material in the presence of a high-frequency pulsed electric field. The basic building block of an SSFBS is a ferroelectric cathode -- a ferroelectric wafer with a solid electrode covering its rear face and a grid electrode on its front face (see figure). The application of a voltage pulse -- typically having amplitude of several kilovolts and duration of several nanoseconds -- causes dense surface plasma to form near the grid wires on the front surface.

Bar-Cohen, Yoseph↗
NASA NTRS1992

Long Duration Exposure Facility (LDEF) preliminary findings: LEO space effects on the space plasma-voltage drainage experiment

The Space Plasma-High Voltage Drainage Experiment (SP-HVDE) provided a unique opportunity to study long term space environmental effects on materials because it was comprised of two identical experimental trays; one tray located on the ram facing side (D-10), and the other on the wake facing side (B-4) of the LDEF. This configuration allows for the comparison of identical materials exposed to two distinctly different environments. The purpose of this work is to document an assessment of the effects of five and three quarters years of low Earth orbital space exposure on materials comprising the SP-HVDE (experiment no. A0054). The findings of the materials investigation reported focus on atomic oxygen effects, micrometeor and debris impact site documentation, thermal property measurements, and environmentally induced contamination.

Blakkolb, Brian K.↗
NASA NTRS1988

The origin and energetics of CTB 80

Deep narrow-band images of the core of the unusual supernova remnant CTB 80 are presented, and the origin and energetics of the remnant are discussed. Based on a description of the core as a wind-blown bubble or bow shock around a pulsar, a scenario is presented relating the core and extended components to a single supernova explosion about 100,000 yr ago. The physical nature of the interface between the pulsar wind and the ambient thermal plasma is considered, and it is concluded that the pulsar is probably moving through shock-compressed material associated with the evolved remnant. It is argued that the core geometry is probably a bow shock viewed partially face-on.

Hester, J. Jeff↗
NASA NTRSDate not supplied

Why Developing A Full-Sun UV Spectrograph Sounding Rocket Is Difficult but Necessary

For a conference focused on a 20-year perspective of where we have been and where we are going, this talk will highlight specifically why we need a sounding rocket to lead the way in obtaining high-resolution UV spectroscopy of our sun-as-a-star. The currently available data is either sparse or at a much lower resolution when compared with Hubble (HST) spectra of other stars. Because of this, we cannot say with certainty if our Sun’s variability is typical. This limitation is hindering our quest to place our Sun in it’s rightful place on our star-charts. Ultraviolet light is a key component in determining this. Elements such as Hydrogen and Iron have strong emission lines here, and from them we can determine many things about the star from which they originate. The width of these spectral features can tell us about the relative plasma activity on the surface of the star, the abundance of those elements, and of course the temperatures. This has of course been done with many instruments that have very narrow field of views and/or narrow bandwidths. The only way to directly compare our Sun’s UV ”fingerprint” with other stars is to take an image of it in the same manner by which HST does: as a point source object. Our team’s aim has been to develop a sounding rocket capable of doing just that. Along the way, the many challenges we face are producing many solutions. A unique take on the traditional Rowland circle spectrograph will allow us to cover a large range of UV spectra with minimal moving parts. A novel in-situ gain calibration technique will be used in order to maintain the high level of radiometric accuracy desired. Naturally, complications arise when one takes UV measurements as you are flying out of earth’s atmosphere and back into it. Though it may be minor, the absorbed UV spectra from the atmosphere will have to be accounted for. In preparing for this, we have stumbled across a way in which those ”telluric” absorption lines may prove useful for spectral calibration purposes. In addition, raw data from previous sounding rocket missions may have hidden within them useful information for the atmospheric-physics community. In this talk, we will highlight the unique calibration problems and solutions we have faced, and how those are of greater importance to the greater heliophysics and atmospheric communities. With these amazing developments at hand, the future of heliophysics instrumentation is looking bright. This material is based upon work supported by the NSF EPSCoR RII-Track-1.2a (Non-invasive plasma diagnostics for LTP) Cooperative Agreement OIA-1655280. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the authors and do not necessarily reflect the views of the National Science Foundation.

NASA, UAH, MSU, Sounding Rocket, Aeronomy, Instrum↗
NASA NTRS1993

LDEF Space Plasma-High Voltage Drainage Experiment post-flight results

The Space Plasma-High Voltage Drainage Experiment (SP-HVDE) was comprised of two identical experimental trays. With one tray located on the leading (ram facing, B10) edge and the other located on the trailing (wake facing, D4) edge of the Long Duration Exposure Facility (LDEF), it was possible to directly compare the effects of ram and wake spacecraft environments on charged dielectric materials. Six arrays of Kapton dielectric samples of 2 mil, 3 mil, and 5 mil thicknesses maintained at +/- 300, +/- 500, and +/- 1000 voltage bias formed the experimental matrix of each tray. In addition, each tray carried two solar cell strings, one biased at +300 volts and the other at -300 volts, to study current leakage from High Voltage Solar Arrays (HVSA). The SP-HVDE provides the first direct, long-term, in-flight measurements of average leakage current through dielectric materials under electric stress. The experiment also yields information on the long term stability of the bulk dielectric properties of such materials. Data and findings of the SP-HVDE are an extension of those from shorter term flight experiments such as the PIX-1 (Plasma Interaction Experiment) and PIX-2 and are therefore valuable in the design and evaluation of long-lived space systems with high voltage systems exposed to the low earth orbital environment. A summary of the SP-HVDE post flight analysis final report delivered to the LDEF Project Office under contract to the National Aeronautics and Space Administration is presented.

Yaung, J. Y.↗
NASA NTRS2005

NASA Tech Briefs, June 2005

Topics covered include: Apparatus Characterizes Transient Voltages in Real Time; Measuring Humidity in Sealed Glass Encasements; Adaptable System for Vehicle Health and Usage Monitoring; Miniature Focusing Time-of-Flight Mass Spectrometer; Cryogenic High-Sensitivity Magnetometer; Wheel Electrometer System; Carbon-Nanotube Conductive Layers for Thin-Film Solar Cells; Patch Antenna Fed via Unequal-Crossed-Arm Aperture; LC Circuits for Diagnosing Embedded Piezoelectric Devices; Nanowire Thermoelectric Devices; Code for Analyzing and Designing Spacecraft Power System Radiators; Decision Support for Emergency Operations Centers; NASA Records Database; Real-Time Principal- Component Analysis; Fuzzy/Neural Software Estimates Costs of Rocket- Engine Tests; Multicomponent, Rare-Earth-Doped Thermal-Barrier Coatings; Reactive Additives for Phenylethynyl-Containing Resins; Improved Gear Shapes for Face Worm Gear Drives; Alternative Way of Shifting Mass to Move a Spherical Robot; Parylene C as a Sacrificial Material for Microfabrication; In Situ Electrochemical Deposition of Microscopic Wires; Improved Method of Manufacturing SiC Devices; Microwave Treatment of Prostate Cancer and Hyperplasia; Ferroelectric Devices Emit Charged Particles and Radiation; Dusty-Plasma Particle Accelerator; Frozen-Plug Technique for Liquid-Oxygen Plumbing; Shock Waves in a Bose-Einstein Condensate; Progress on a Multichannel, Dual-Mixer Stability Analyzer; Development of Carbon- Nanotube/Polymer Composites; Thermal Imaging of Earth for Accurate Pointing of Deep-Space Antennas; Modifications of a Composite-Material Combustion Chamber; Modeling and Diagnostic Software for Liquefying- Fuel Rockets; and Spacecraft Antenna Clusters for High EIRP.

Source record↗
NASA NTRS1983

Thermionic energy converters

The efficiency of thermionic energy converters is improved by internal distribution of tiny sorted cesium diodes driven by the thermal gradient between the primary emitter and the collector. The tiny, sorted diode distribution comprises protrusions of the emitter material from the main emitter face which contact the main collector face thermally but not electrically. The main collector ends of the protrusions are separated from the main collector by a thin layer of insulation, such as aluminum oxide. The shorted tiny diode distribution augments cesium ionization through internal thermal effects only within the main diode. No electrical inputs are required. This ionization enhancement by the distribution of the tiny shorted diodes not only reduces the plasma voltage drop but also increases the power output and efficiency of the overall thermionic energy converter.

Morris, J. F.↗
NASA NTRS1973

Pulsed plasma microthruster for synchronous meteorological satellite /SMS/

Two completely self contained variable thrust flight prototype plasma propulsion systems using solid teflon as propellant were designed, built and laboratory tested. The impulse bit amplitude of each thruster is 25 micro lb-sec. Impulse bits can be provided at rates varying from 50 ppm to 110 ppm. The total impulse capability is 400 lb-sec. Only 23 watts of bus power are required at maximum pulse rate. The system was subjected and passed the required vibration schedule and thermal vacuum test after a minor change in capacitor end face material. A 13 million discharge life test of the system was subsequently performed.

Guman, W. J.↗
NASA NTRS1994

Preliminary far-field plume sputtering characterization of the Stationary Plasma Thruster (SPT-100)

For electric propulsion devices to be considered for use on communications satellites, integration impacts must be examined in detail. Two phenomena of concern associated with highly energetic plumes are contamination via sputtered material from the thruster and sputter erosion of downstream surfaces. In order to characterize the net effect of both phenomena, an array of witness plates were mounted in several types of holders and were exposed to the SPT-100 thruster plume for 50 hours. Surface analysis of the witness plates revealed that in the most energetic regions of the plume, there was a net removal of material from the samples facing the thruster. In the peripheral regions, net deposits were observed and characterized by the changes in optical properties of these samples. Changes in surface properties of samples located in collimators were within experimental uncertainty.

Pencil, Eric J.↗
NASA NTRS1994

New Trends in Coatings Developments for Turbine Blades: Materials Processing and Repair

Turbine engines for aeronautic applications now have to face strenuous requirements concerning not only operating performances but also reliability and repairability. This evolution of the specifications induces important consequences regarding the choice and the design of turbine blade protective coatings. This paper presents several key features concerning the deposition techniques and the real-life behavior of such coatings: (1) complex aluminides well suited to the protection against high temperature oxidation and hot corrosion of directionally solidified nickel-base superalloy turbine blades; (2) ceramic coatings used as thermal barriers - they have to exhibit both high resistance to thermomechanical fatigue and adequate smoothness; (3) processing techniques for thermal barriers, including plasma spraying, electron beam physical vapor deposition and plasma enhanced chemical vapor deposition; and (4) blades and coatings repair techniques.

S Alpérine↗
NASA NTRS1981

Regenerator seal

A method for manufacturing a hot side regenerator cross arm seal assembly having a thermally stablilized wear coating with a substantially flat wear surface thereon to seal between low pressure and high pressure passages to and from the hot inboard side of a rotary regenerator matrix includes the steps of forming a flat cross arm substrate member of high nickel alloy steel; fixedly securing the side edges of the substrate member to a holding fixture with a concave surface thereacross to maintain the substrate member to a slightly bent configuration on the fixture surface between the opposite ends of the substrate member to produce prestress therein; applying coating layers on the substrate member including a wear coating of plasma sprayed nickel oxide/calcium flouride material to define a wear surface of slightly concave form across the restrained substrate member between the free ends thereon; and thereafter subjecting the substrate member and the coating thereon to a heat treatment of 1600.degree. F. for sixteen hours to produce heat stabilizing growth in the coating layers on the substrate member and to produce a thermally induced growth stress in the wear surface that substantially equalizes the prestress in the substrate whereby when the cross arm is removed from the fixture surface following the heat treatment step a wear face is formed on the cross arm assembly that will be substantially flat between the ends.

Davis, Leonard C.↗
NASA NTRS2011

Optimization of Indium Bump Morphology for Improved Flip Chip Devices

Flip-chip hybridization, also known as bump bonding, is a packaging technique for microelectronic devices that directly connects an active element or detector to a substrate readout face-to-face, eliminating the need for wire bonding. In order to make conductive links between the two parts, a solder material is used between the bond pads on each side. Solder bumps, composed of indium metal, are typically deposited by thermal evaporation onto the active regions of the device and substrate. While indium bump technology has been a part of the electronic interconnect process field for many years and has been extensively employed in the infrared imager industry, obtaining a reliable, high-yield process for high-density patterns of bumps can be quite difficult. Under the right conditions, a moderate hydrogen plasma exposure can raise the temperature of the indium bump to the point where it can flow. This flow can result in a desirable shape where indium will efficiently wet the metal contact pad to provide good electrical contact to the underlying readout or imager circuit. However, it is extremely important to carefully control this process as the intensity of the hydrogen plasma treatment dramatically affects the indium bump morphology. To ensure the fine-tuning of this reflow process, it is necessary to have realtime feedback on the status of the bumps. With an appropriately placed viewport in a plasma chamber, one can image a small field (a square of approximately 5 millimeters on each side) of the bumps (10-20 microns in size) during the hydrogen plasma reflow process. By monitoring the shape of the bumps in real time using a video camera mounted to a telescoping 12 magnifying zoom lens and associated optical elements, an engineer can precisely determine when the reflow of the bumps has occurred, and can shut off the plasma before evaporation or de-wetting takes place.

Jones, Todd J.↗
NASA NTRS1990

Study of diamond film growth and properties

The objective was to study diamond film growth and its properties in order to enhance the laser damage threshold of substrate materials. Calculations were performed to evaluate laser induced thermal stress parameter, R(sub T) of diamond. It is found that diamond has several orders of magnitude higher in value for R(sub T) compared to other materials. Thus, the laser induced damage threshold (LIDT) of diamond is much higher. Diamond films were grown using a microwave plasma enhanced chemical vapor deposition (MPECVD) system at various conditions of gas composition, pressure, temperature, and substrate materials. A 0.5 percent CH4 in H2 at 20 torr were ideal conditions for growing of high quality diamond films on substrates maintained at 900 C. The diamond films were polycrystalline which were characterized by scanning electron microscopy (SEM) and Raman scattering spectroscopy. The top surface of the growing film is always rough due to the facets of polycrystalline film while the back surface of the film replicates the substrate surface. An analytical model based on two dimensional periodic heat flow was developed to calculate the effective in-plane (face parallel) diffusivity of a two layer system. The effective diffusivity of diamond/silicon samples was measured using a laser pulse technique. The thermal conductivity of the films was measured to be 13.5 W/cm K, which is better than that of a type Ia natural diamond. Laser induced damage experiments were performed on bare Si substrates, diamond film coated Si, and diamond film windows. Significant improvements in the LIDT were obtained for diamond film coated Si compared to the bare Si.

Albin, Sacharial↗