Die vorliegende Dissertation behandelt Charakterisierung, Modellbildung sowie Anwendung einer magnetfeldgestützten Hohlkathoden-Bogenentladung. Hohlkathoden sind seit den 1960er Jahren Gegenstand grundlagen- sowie anwendungsorientierter Forschung und werden seit 20 Jahren am Fraunhofer-Institut für Elektronenstrahl- und Plasmatechnik für die Anwendung auf dem Gebiet der Vakuumbeschichtung weiterentwickelt. Ziel dieser Arbeit ist es, die technologischen Fortschritte physikalisch zu verstehen und gezielte Weiterentwicklungen für spezifische Einsatzgebiete zu ermöglichen. In der untersuchten Hohlkathodenbauform ist das aus Tantal bestehende, vom Arbeitsgas Argon durchströmte Kathodenröhrchen koaxial von einer Ringanode sowie von einer Magnetfeldspule umgeben. Die Entladung wird durch Hochspannungspulse gezündet, worauf sich ein diffuser Bogen im Röhrchen (internes Plasma) ausbildet. Das Röhrchen wird von Plasmaionen auf hohe Temperaturen geheizt, die eine thermionische Emission von Elektronen ermöglichen, welche das Plasma speisen. Das technologisch nutzbare externe Plasma wird im Vakuumrezipienten durch Wechselwirkung der Gasteilchen mit Strahlelektronen aus der Kathode erzeugt. Bei starker Reduktion des Arbeitsgasflusses wird die Entladung durch das Magnetfeld der Spule stabilisiert. Der experimentelle Befund, dass dadurch Plasmadichte und -reichweite sowie ggf. die Ladungsträgerenergien im Rezipienten aufgrund des intensiveren Elektronenstrahls wesentlich gesteigert werden können, wird durch ortsaufgelöste Langmuir-Sondenmessung, optische Emissionsspektroskopie und energieaufgelöste Massenspektrometrie ausführlich belegt und nach der Lösung von Strom- und Wärmebilanzgleichungen durch die Verhältnisse im Kathodenröhrchen begründet. Neben Argon werden auch typische Reaktivgase der Vakuumbeschichtung im Hohlkathodenplasma betrachtet: zum einen Stickstoff und Sauerstoff, die in reaktiven PVD-Prozessen (physikalische Dampfphasenabscheidung) zur Beschichtung mit Oxid- bzw. Nitridschichten zum Einsatz kommen und durch Ionisation, Dissoziation und Anregung im Hohlkathodenplasma verbesserte Schichteigenschaften ermöglichen; zum anderen Azetylen, das bei PECVD (plasmagestützte chemische Dampfphasenabscheidung) von amorphen wasserstoffhaltigen Kohlenstoffschichten z. B. für tribologische oder biokompatible Beschichtungen genutzt wird. Azetylen wird durch Streuprozesse mit Elektronen und Ionen im Plasma aufgespalten, wodurch schichtbildende Spezies erzeugt werden, die am Substrat kondensieren. Durch die Wahl der Plasmaparameter sowie durch abgestimmte Substratbiasspannung und Substratkühlung lassen sich die Beschichtungsrate einstellen sowie polymer-, graphit- oder diamantartige Eigenschaften erzielen. Neben der Plasmadiagnostik mittels energieaufgelöster Massenspektrometrie werden die erzeugten Kohlenstoffschichten vorgestellt und hinsichtlich Härte, Zusammensetzung und Morphologie analysiert. / In the present thesis, characterization, modeling and application of a magnetically enhanced hollow cathode arc discharge are presented. Since the 1960s, hollow cathodes are being studied in basic and applied research. At Fraunhofer Institute for Electron Beam and Plasma Technology, further development concerning the application in vacuum coating technology has been carried out for about twenty years. The present work targets on physically understanding the technological progress in order to enable specific further development and application. In the investigated hollow cathode device, a ring-shaped anode and a magnetic field coil are arranged coaxially around the tantalum cathode tube, which is flown through by argon as the working gas. The discharge is ignited by high voltage pulses establishing a diffuse arc within the cathode tube (internal plasma). The cathode is being heated by the plasma ions to high temperatures, which leads to thermionic emission of electrons sustaining the plasma. The external plasma in the vacuum chamber, which can be used for technological applications, is generated by collisions of gas atoms with beam electrons originating from the cathode. In the case of strongly reduced working gas flow, the discharge is stabilized by the magnetic field of the coil; the related experimental findings such as significantly increased plasma density and range as well as higher charge carrier energies in the external plasma are extensively proved by spatially resolved Langmuir probe measurements, optical emission spectroscopy, and energy-resolved ion mass spectrometry. Furthermore, the results are correlated to the conditions within the cathode tube by solving the current and heat balance equations. Besides argon, typical reactive gases used in vacuum coating are examined in the hollow cathode plasma, too. First, nitrogen and oxygen, which are applied in PVD (physical vapor deposition) processes for the deposition of oxide and nitride layers, are ionized, dissociated, and excited by plasma processes. In the case of practical application, this plasma activation leads to improved film properties. Second, acetylene is used as a precursor for PECVD (plasma-enhanced chemical vapor deposition) of amorphous hydrogenated carbon films, e.g. for tribological or biocompatible applications. Acetylene is cracked by electron and ion scattering in the plasma providing film-forming species to be deposited on the substrate. The deposition rate as well as the polymeric, graphitic, or diamond-like properties can be controlled by plasma parameters, a defined substrate bias, and substrate cooling. The hollow cathode-generated acetylene plasma has been characterized by energy-resolved ion mass spectrometry, and the carbon films obtained are analyzed regarding hardness, film composition, and morphology.

Ultra-high strength steels is known to be susceptible for hydrogen embrittlement at very low concentrations of hydrogen. In this thesis three methods to prevent or reduce the hydrogen embrittlement in martensitic steel, with tensile strength of 1500 MPa, were studied. First, a barrier layer of aluminium designed to prevent hydrogen to enter the steel, which were deposited by vacuum evaporation. Second, a decarburization process of the steels surface designed to mitigate the induced stresses from cutting. Last, a hydrogen relief treatment at 150°C for 11 days and 200°C for 4 days, to reduce the hydrogen concentration in the steel. The effect of the hydrogen embrittlement was analyzed by manual measurements of the elongations after a slow strain rate testing at 5*10-6 mm/s, and the time to fracture in an in-situ constant load test with a current density of 1.92 mA/cm2 in a 0.5 M Na2SO4 solution. The barrier layer showed an increase in time to fracture, but also a decrease in elongations. The decarburized steel had a small increase in the time to fracture, but not enough to make it a feasible process. The hydrogen relief treatment showed a general decrease in hydrogen concentrations, but the elongation measurements was irregular although with a tendency for improvement. The simplicity of the hydrogen relief treatment makes it an interesting process to reduce the influence of hydrogen embrittlement. However, more investigations are necessary.

Thesis (Ph. D.)--Ohio State University, 2006. / Title from first page of PDF file. Includes bibliographical references (p. 209-217).

Η ηλιακή ενέργεια μπορεί να συμβάλει στην αντιμετώπιση του ενεργειακού προβλήματος, με την ευρεία αξιοποίηση των φωτοβολταϊκών και των θερμικών ηλιακών συλλεκτών. Τα φωτοβολταϊκά συστήματα που συνδυάζονται με θερμικές μονάδες κυκλοφορίας νερού ή αέρα, για την απολαβή της θερμότητας από αυτά και την ικανοποιητική διατήρηση της απόδοσής των, αποτελούν τα υβριδικά φωτοβολταϊκά/θερμικά συστήματα (φβ/θ). Τα συστήματα αυτά παράγουν ηλεκτρική και θερμική ενέργεια ταυτόχρονα, αυξάνοντας την ολική παραγόμενη ενέργεια. Με τη χρήση ορισμένων διατάξεων βελτίωσης της απολαβής της θερμότητας από τα φωτοβολταϊκά και της αύξησης της αποδιδόμενης ενέργειας των φωτοβολταϊκών και των θερμικών ηλιακών συλλεκτών, είναι δυνατή η βελτίωση της αποδοτικότητας των συσκευών αυτών, για μια πιο αποτελεσματική εφαρμογή τους στα κτήρια. Η διπλωματική εργασία που ακολουθεί περιλαμβάνει τη μελέτη φωτοβολταϊκών, υβριδικών φωτοβολταϊκών και θερμικών ηλιακών συσκευών. Πραγματοποιήθηκε μελέτη υβριδικού φωτοβολταϊκού/θερμικού συστήματος αέρα με διάφορες βελτιώσεις της αποδοτικής λειτουργίας του και με την προσθήκη μεταλλικών φύλλων ή σωλήνων ροής νερού στον αεραγωγό. Ακόμη, μελετήθηκε επίπεδος ηλιακός θερμικός συλλέκτης με προσθήκη διάφορων τύπων ανακλαστήρων (λευκή επιφάνεια, γαλβανιζέ μεταλλικό φύλλο και καθρέφτης). Πραγματοποιήθηκαν επίσης πειράματα με σωλήνα κενού, ο οποίος συνδυάστηκε με ανακλαστήρες για την αύξηση της προσλαμβανόμενης ηλιακής ακτινοβολίας και βελτίωση της αποδιδόμενης θερμότητας. Με βάση τα αποτελέσματα παρατίθενται συμπεράσματα και προτάσεις σχετικά με τις σύνθετες διατάξεις που αναφέρθηκαν. / Solar energy systems can contribute to energy demand by the proper synergy of photovoltaics and solar thermal collectors. The PV modules which are combined with thermal units and circulating water or air to extract the heat from them, constitute the hybrid photovoltaic/thermal systems (PV/T). These systems provide electrical and thermal energy simultaneously, increasing the total energy output. Adapting some effective heat extraction elements to PV modules and applying devices to have solar radiation increase by the absorbing surfaces of PV and of thermal collectors, an improvement of operation and performance of these systems can be achieved regarding their application to buildings. The thesis that follows includes a study of photovoltaics, hybrid photovoltaic/ thermal systems and solar thermal collectors. More specifically, a study of an air heating hybrid photovoltaic/thermal system was performed, improving suitably the heat extraction by inserting corrugated metallic sheets or water pipes, inside the air channel that is attached to rear surface of PV modules. In addition, a solar thermal collector was studied, by applying several types of reflectors (white plate reflector, galvanized iron plate reflector and specular reflector). Furthermore, a vacuum tube type collector was tested, combined also with reflectors to increase input solar radiation and increase thermal performance. Finally, conclusions and suggestions for a further study, on the above mentioned solar energy systems is included, based on the reported experimental results.

To study electron emissions and dark currents in the accelerating structures in particle colliders, a test facility with a spectrometer has been constructed at CERN. This spectrometer has been simulated in the C++ toolkit GEANT4 and in this project the simulation has been improved to handle new realistic input data of the emitted electrons. The goal was to find relations between where the electrons are emitted inside the accelerating structure and the energy or position of the particles measured by the spectrometer. The result was that there is a linear relation between the initial position of the electrons and the width in the positions of the particles measured by the spectrometer. It also appears to be a relations between energy the emitted electrons get in the accelerating structure, which is related to the position, and the energy they deposit in the spectrometer. Further studies where the simulations are compared with real measurement data are required to determine whether these relations are true or not, find better reliability in the relations and get a better understanding of the phenomena.

Vacuum glazing is a vital development in the move to more energy efficient buildings. In vacuum glazing, an evacuated cavity supresses gaseous conduction and convection to provide high thermal resistance. A high vacuum pressure (less than 0.1 Pa) is required and must be maintained by a hermetic seal around the periphery, currently formed with either indium (i.e. low temperature sealing method) or solder glass (i.e. high temperature sealing method). This thesis reports the results of an experimental and theoretical investigation into the development of new low temperature (less than 200°C) and novel high temperature (up to 450°C) glass edge seals. A new low temperature composite edge seal was developed in which double and triple vacuum glazings each of dimensions 300x300mm were fabricated with measured vacuum pressures of 4.6x10-2Pa and 4.8x10-2Pa achieved respectively. A three dimensional finite element model of the fabricated design of composite edge sealed triple vacuum glazing was developed.

In the planned linear accelerator called Compact Linear Collider, CLIC, electrons and positrons will be accelerated to velocities near the speed of light. A limiting factor in accelerating structures are vacuum breakdowns, which are electrical discharges from a surface as a result of a large electric field being applied. In the preparatory studies for the CLIC, Uppsala University in collaboration with The European Organization for Nuclear Research, CERN, is building a DC Spark system to analyze vacuum breakdowns. This system containing large planar electrodes will be cooled down all the way down to around 4 K in order to limit the rate of wich vacuum breakdowns happen. When cooling a system like this, which consists of different components made of different materials there is the question of how the system will be affected. The objective of this project is to investigate how the cooling will affect the stability in terms of stresses and to analyze the cool down time of the system. Another goal is to make a material recommendation for a few parts based on the results. This will be done by simulating the cooling in COMSOL Multiphysics, which is a program that uses finite element analysis to solve complex problems where different branches of physics interact. The conclusion is that the system will most likely be stable as it is and there is no need to redesign it. The choice of recommended material is alumina with the reason being it should cause the least stress and the smallest gap between the electrodes when the cooling is done. There was no big difference in the cool down time between the materials. Further studies and simulations on the system is also recommended since there are many factors not taken into consideration in this study.

Dans le procédé de refusion à l’arc sous vide, la structure et la dynamique de l’arc électrique conditionnent les distributions spatiales d’énergie et de courant au sommet du lingot refondu. Ces distributions impactent fortement les champs de température et de vitesse du métal liquide, qui gouvernent les conditions de solidification du lingot et donc la qualité finale du produit. Une étude par mesures optiques, de la dynamique de l’arc aux longues échelles de temps lors de refusions industrielles d’alliages de titane a été entreprise. Cette analyse a été effectuée par une méthode qualitative, à l’aide d’enregistrements vidéo, et par une nouvelle méthode de diagnostic quantitative développée spécifiquement dans ce travail, à base de photodiodes. L’analyse de la dynamique de l’arc confirme la présence d’un mouvement d’ensemble de l’arc électrique lors de refusions d’alliages de titane et montre une forte corrélation entre la dynamique observée et l’intensité du brassage électromagnétique imposé. Nos résultats ont de plus permis de prédire la dynamique probable de l’arc dans des conditions non étudiées et de proposer de possibles origines à la dynamique observée. Enfin, une première approche de modélisation de cette dynamique dans le logiciel de simulation RAVEL est proposée afin d’étudier son impact sur la solidification du lingot. Ce travail présente également une modélisation détaillée des rayonnements thermiques émis au sommet du lingot, basée sur la méthode des radiosités / In the vacuum arc remelting process, the structure and dynamics of the electric arc are responsible for the spatial distributions of energy and current at the top of the remelted ingot. Those distributions strongly impact the ingot temperature field and the liquid metal velocity field, which govern the ingot solidification conditions, hence the final product quality. A study based on the optical measurement of the electric arc dynamics at a long time-scale during vacuum arc remelting of titanium alloys was undertaken. This analysis was performed either qualitatively using melt video recordings, or quantitatively by a new specifically developed diagnostic technique based on the use of photodiodes. The analysis of the electric arc dynamics confirmed the presence of an ensemble arc motion during vacuum arc remelting of titanium alloys and showed a strong correlation between the observed dynamics and the magnitude of the imposed electromagnetic stirring. Furthermore, our results allow to predict the arc dynamics in non-studied conditions and to propose possible origins for the observed behaviors. Finally, a first simulation of the influence of the arc behavior is proposed in order to study its impact on the ingot solidification. This work comprises also a detailed modelling of the thermal radiation at the ingot top, based on the radiosity method

The following report conducted with the collaboration of the University of Halmstad and HGFrubber company (Halmstad).The focus on the project is eliminating the dust particles from the inner surface of the EPDM basedrubber module.As a part of improving knowledge about the quality and surface finishing and understanding thematerial’s characteristics. This project initiated in February 2018 and end date was set to August2018.The methodology used in this project is based on the Six-Sigma tools which is widely appreciatedglobally to obtain the Zero-defect production.The implementations of this method and other tools are efficient and beneficial to reduce thedefects in the production without compromising the initial quality of the product.This thesis resulted in a quality improvement approach for eliminating the dust using methods suchas Six-Sigma and 5 why’s.

Le procédé VAR (Vacuum Arc Remelting ou refusion à l'arc sous vide en français) est employé dans la production d'alliages à haute performance pour les industries aéronautique (aciers spéciaux, superalliages et alliages de titane) et nucléaire (alliage de zirconium). Comme pour tous les procédés de fonderie, la maîtrise de l'homogénéité chimique et de la structure métallurgique des lingots coulés par le procédé VAR constitue un enjeu industriel important. Les travaux présentés dans ce mémoire visent à identifier, pour les alliages de zirconium en particulier, les effets de la convection naturelle et de la convection forcée due au brassage électromagnétique sur la macroségrégation. Dans ce but, un modèle numérique a été développé. Il est basé sur la résolution couplée des équations de conservation d'énergie, de quantité de mouvement et de solutés, dans des conditions d'écoulement laminaire ou turbulent. La modélisation de la solidification tient compte du couplage fort entre le transport d'énergie et de solutés dans la zone pâteuse. Afin de décrire la microségrégation, la diffusion restreinte des solutés dans les phases liquides et solides peut être prise en compte. Parallèlement, deux électrodes chimiquement homogènes d'alliages Zircaloy-4 et M5® ont été spécialement refondues dans un four VAR industriel sur le site de CEZUS à Ugine (Savoie, France). La macroségrégation des lingots obtenus a été caractérisée.La comparaison entre les mesures expérimentales et les résultats de simulation a montré que pour un alliage dont l'intervalle de solidification est important (comme l'alliage Zircaloy-4), la convection solutale dans la zone pâteuse peut avoir une influence essentielle sur la macroségrégation de la région centrale du lingot. Par ailleurs, le mouvement de grains équiaxes lors de l'application d'un brassage électromagnétique de forte intensité semble accentuer significativement la macroségrégation dans la région externe du lingot. Pour un alliage dont l'intervalle de solidification est faible (comme l'alliage M5®), nous avons montré que la macroségrégation dépend plus spécifiquement de la convection forcée due au mode de brassage électromagnétique appliqué au cours de la refusion / Vacuum Arc Remelting (VAR) is used to produce high performance alloys for the aeronautic (special steels, superalloys, titanium alloys) and nuclear (zirconium alloys) industries. As for all casting processes, the control of the chemical homogeneity and the metallurgical structure in VAR ingots is an important industrial issue. The goal of this thesis is to identify, for zirconium alloys in particular, the effects of the natural convection and the forced convection due to the electromagnetic stirring on macrosegregation. To this purpose, a numerical model has been developed. It is based on the solution of the coupled transient energy, momentum and solute transport equations, under laminar or turbulent flow conditions. The solidification modeling accounts for a full coupling between energy and solute transport in the mushy zone. The finite diffusion of solutes in both solid and liquid phases can be taken into account to describe microsegregation. In addition, chemically homogeneous Zircaloy-4 and M5® electrodes have been specially remelted in an industrial VAR furnace at the CEZUS plant in Ugine (Savoie, France). The macrosegregation of the ingots has been measured. The comparison between the experimental measurements and the simulation results showed that for an alloy with a large solidification interval (like Zircaloy-4), the solutal convection in the mushy zone could have an essential influence on the macrosegregation in the inner part of the ingot. Furthermore, the motion of equiaxed grains caused by a strong stirring seems to seriously intensify macrosegregation in the outer part of the ingot. For an alloy with a small solidification interval (like M5®), we have shown that the macrosegregation depends more specifically on the forced convection due to the type of stirring applied during the remelting