Adherence of ion beam sputter deposited metal films on H-13 steel

An electron bombardment argon ion source was used to sputter deposit 17 different metal and metal oxide films ranging in thickness from 1 to 8 micrometers on H-13 steel substrates. The film adherence to the substrate surface was measured using a tensile test apparatus. Comparisons in bond strength were made between ion beam, ion plating, and RF deposited films. A protective coating to prevent heat checking in H-13 steel dies used for aluminum die casting was studied. The results of exposing the coated substrates to temperatures up to 700 degrees are presented

Resistojet propulsion for large spacecraft systems

Resistojet propulsion systems have characteristics that are ideally suited for the on-orbit and primary propulsion requirements of large spacecraft systems. These characteristics which offer advantages over other forms of propulsion are reviewed and presented. The feasibility of resistojets were demonstrated in space whereas only a limited number of ground life tests were performed. The major technology issues associated with these ground tests are evaluated. The past performance of resistojets is summarized and, looks into the present day technology status is reviewed. The material criteria, along with possible concepts, needed to attain high performance resistojets are presented

Ion beam deposited protective films

Single or dual ion beam sources were used to deposit thin films for different applications. Metal and metal oxide films were evaluated as protective coatings for the materials. Film adherence was measured and the most promising films were then tested under environments similar to operating conditions. It was shown that some materials do protect die material (H-13 steel) and do reduce thermal fatigue. Diamondlike films have many useful applications. A series of experiments were conducted to define and optimize new approaches to the manufacture of such films. A dual beam system using argon and methane gases was developed to generate these films

A hollow cathode hydrogen ion source

High current density ion sources have been used to heat plasmas in controlled thermonuclear reaction experiments. High beam currents imply relatively high emission currents from cathodes which have generally taken the form of tungsten filaments. A hydrogen ion source is described which was primarily developed to assess the emission current capability and design requirements for hollow cathodes for application in neutral injection devices. The hydrogen source produced ions by electron bombardment via a single hollow cathode. Source design followed mercury ion thruster technology, using a weak magnetic field to enhance ionization efficiency

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

Optical and electrical properties of ion beam textured Kapton and Teflon

An electron bombardment argon ion source was used to ion etch polyimide (Kapton) and fluorinated ethylene, FEP (Teflon). Samples of polyimide and FEP were exposed to (0.5-1.0) keV Ar ions at ion current densities of (1.0-1/8) mA/sq cm for various exposure times. Changes in the optical and electrical properties of the samples were used to characterize the exposure. Spectral reflectance and transmittance measurements were made between 0.33 and 2.16 micron m using an integrating sphere after each exposure. From these measurements, values of solar absorptance were obtained. Total emittance measurements were also recorded for some samples. Surface resistivity was used to determine changes in the electrical conductivity of the etched samples. A scanning electron microscope recorded surface structure after exposure. Spectral optical data, resistivity measurements, calculated absorptance and emittance measurements are presented along with photomicrographs of the surface structure for the various exposures to Ar ions

Diamondlike carbon protective coatings for optical windows

Diamondlike carbon (DLC) films were deposited on infrared transmitting optical windows and were evaluated as protective coatings for these windows exposed to particle and rain erosion. The DLC films were deposited on zinc selenide (ZnSe) and zinc sulfide (ZnS) by three different ion beam methods: (1) sputter deposition from a carbon target using an 8-cm argon ion source; (2) direct deposition by a 30-cm hollow cathode ion source with hydrocarbon gas in argon; and (3) dual beam direct deposition by the 30-cm hollow cathode ion source and an 8-cm argon ion source. In an attempt to improve the adherence of the DLC films on ZnSc and ZnS, ion beam cleaning, ion implantation with helium and neon ions, or sputter deposition of a thin, ion beam intermediate coating was employed prior to deposition of the DLC film. The protection that the DLC films afforded the windows from particle and rain erosion was evaluated, along with the hydrogen content, adherence, intrinsic stress, and infrared transmittance of the films. Because of the elevated stress levels in the ion beam sputtered DLC films and in those ion beam deposited with butane, films thicker than 0.1 micron and with good adherence on ZnS and ZnSe could not be generated. An intermediate coating of germanium successfully allowed the DLC films to remain adherent to the optical windows and caused only negligible reduction in the specular transmittance of the ZnS and ZnSe at 10 microns

Enhanced thermal emittance of space radiators by ion-discharge chamber texturing

The discharge chamber of a 30-cm argon ion source was successfully used to texture potential space radiator materials for the purpose of obtaining values of thermal emittance greater than 0.85 at 700 and 900 K. Some samples were also treated in acid prior to texturing. To evaluate the durability of the textured materials to atomic oxygen, samples were exposed to an RF air plasma environment. The spectral emittance between 2.0 anf 15.0 microns was measured before and after the textured materials were exposed to the plasma asher. The results indicate that copper with extremely high values of emittance after texturing (0.978 and 0.983) at 700 and 900 K, respectively,did not change its values of emittance after ashing, whereas the emittance of stainless steel fell below 0.85 after ashing. These data, along with scanning electron photomicrographs, and the results of texturing and ashing titanium and Nb(1)Zr are presented

Surface texturing of fluoropolymers

A method is disclosed for improving surface texture for adhesive bonding, metal bonding, substrate plating, decal substrate preparation, and biomedical implant applications. The surface to be bonded is dusted in a controlled fashion to produce a disbursed layer of fine mesh particles which serve as masks. The surface texture is produced by impinging gas ions on the masked surface. The textured surface takes the form of pillars or cones. The bonding material, such as a liquid epoxy, flows between the pillars which results in a bond having increased strength. For bonding metals a thin film of metal is vapor or sputter deposited onto the textured surface. Electroplating or electroless plating is then used to increase the metal thickness in the desired amount

Apparatus for producing oxidation protection coatings for polymers

A polymeric substrate is coated with a metal oxide film to provide oxidation protection in low Earth orbital environments. The film contains about 4 volume percent polymer to provide flexibility. A coil of polymer materials moves through an ion beam as it is fed between reels. The ion beam first cleans the polymer material surface and then sputters the film material from a target onto this surface