A method for the measurement of the cathode surface temperature for a high

current freeburning arc

J. Haidar and A. J. D. Farmer

Citation: Review of Scientific Instruments 64, 542 (1993); doi: 10.1063/1.1144230

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 A method for the measurement of the cathode surface temperature
for a high-current free-burning arc
J. Haidar and A. J. D. Farmer
CSIRO Division of Applied Physics, P. 0. Box 218, Lindfield NSW 2070, Australia
(Received 5 March 1992; accepted for publication 19 October 1992)
A method using two-wavelength pyrometry has been developed for the measurement of the
cathode surface temperature of high-current free-burning arcs. The method measures the total
thermal radiation flux emitted from the cathode and the surrounding plasma and subtracts the
derived plasma component using a modified Abel-inversion transformation. The effects
associated with the plasma radiation reflected by the cathode are minimized by using
measurements near the cathode edges. Experimental data are used to account for the
dependency of the cathode emissivity on wavelength. In this paper the details of this technique
are discussed and measurements of cathode surface temperature are presented for pure and
thoriated tungsten cathodes.

I. INTRODUCTION plate anode. The cathode tip is in a conical shape in order

The cathode surface temperature of a high-current arc
is a major parameter in the determination of the arc mode
of operation. An accurate measurement of the temperature
is therefore necessary for an understanding of the processes
occurring in the plasma and at the plasma-cathode inter-
face during the operation of the arc. Pyrometric techniques
are particularly appropriate for such measurements; how-
ever, their successful application requires that the prob-
lems associated with the radiation from the surrounding
plasma and the unknown cathode emissivity be overcome.
Solutions to these problems proposed in the literature in-
clude measurement of the cathode temperature immedi-
ately after rapidly switching off the arc,’ measurement of
the temperature of a graphite insert in the cathode,’ cath-
ode bulk temperature measurement by means of a thermo-
couple,3 surface temperature measurement using infrared
radiation, and other techniques.2’4-7 The major problem in
most of these measurements is associated with the radia-
tion from the plasma, the perturbation of the plasma char-
acteristics by the measurement technique, or the inability
to provide temperature measurement at more than one po-
sition.
Electrodes of high-current free-burning arcs, often
made of tungsten-based materials, have a nonuniform tem-
perature distribution over their surface due to a combina-
tion of effects of the cathode geometry, radiative heating
and thermal conduction from the plasma, ohmic heating in
the cathode, and thermionic and convective cooling of the
cathode tip. A two-wavelength pyrometry technique has
been developed and used to determine the cathode temper-
ature profile for such arcs. This technique overcomes the
problem associated with the- radiation from the plasma,
minimizes the error resulting from the unknown cathode
emissivity, and does not perturb the arc. The details of this
technique are discussed in Sets. II-IV.
II. EXPERIMENTAL ARRANGEMENT
A dc arc is struck between a water-cooled, cylindrical-
rod tungsten-based cathode and a water-cooled copper-
to stabilize the arc. Optical radiation from the arc is im-
aged by a lens system on the entrance slits of a 1 m mono-
chromator at a magnification of 5:l and detected with a
photomultiplier at the monochromator exit slits. The effec-
tive spatial resolution at the arc and the cathode is equal to
an area A of approximately 20 x 50 pm2. The width of the
monochromator exit slit is of 1500 pm which gives a spec-
tral band width of about 1.5 nm. The relative spectral re-
sponse of the system is calibrated against a standard tung-
sten ribbon lamp.
The arc is mounted on a motor-driven table which
provides horizontal and vertical scanning of the plasma
and the cathode.’ The scanning step size is 25 pm in the
horizontal direction and 5 ,um in the vertical direction. The
signal from the photomultiplier at the exit slits of the
monochromator is usually recorded every 25 pm of travel
in the horizontal direction and stored in a data acquisition
computer. Radial scans over the plasma and the cathode
are made at various axial positions with a frequency de-
pending upon the distance from the cathode tip.
The geometry of the arc and the cathode are consid-
ered relative to a coordinate system [Fig. 1 (a)] detined
such that the x-y plane is parallel to the anode surface and
the arc is always observed in a direction parallel to the y
axis. The z axis has its positive direction upward in the
anode-cathode direction and the z coordinate defines the
axial positions relative to the cathode tip.
Scans over the arc and the cathode are made in a di-
rection parallel to the x axis. Figure 2 shows an example of =
the measurements at the wavelengths 634.0 and 700.5 nm
for a scan made at z=O.2 mm for a 200 A arc operated in
argon with a thoriated tungsten cathode. As the distance
from the arc axis decreases the intensity of the measured
radiation E;;, increases. The interception of the line of sight
with the cathode is associated with a sudden increase in the
radiation intensity due to radiation emitted from the cath-
ode surface.

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 .g
2 0.5
J’
,
d
i
:i
i
lE
/j Y/ Plasma ‘,

0
-3 -2 -1 0 1 2
Position along X-axis (mm)
X
FIG. 2. Side-on integrated intensity of the emission from the plasma and
the cathode at the wavelengths 634.0 and 700.5 nm at z=O.Z m m . (Arc
current is 200 A, gas flow is 5 C’min argon, arc length is 5 m m , cathode
of thoriated tungsten 90” cone and 3.2 m m diameter.

R f(r)rdr

FIG. 1. (a) Arc and cathode geometry; the x-y plane is parallel to the
Fm(x>re,a,A,T)=Fp(x>re,jl)=2A
I x (IL-x2)1’2 ’
(2)
anode surface. (b) Horizontal cross section of the cathode at the z level of
the scan. Note that the z-axis origin is at the cathode tip and the positive where r is the radial position and R is the plasma radius,
direction is upward, along the cathode axis.
defined so that f(r) =0 if r>R.
This equation is known as the Abel integral equation
Ill. ANALYSIS whose solution is9

In general the energy flux recorded by the monochro-

mator F,,(x,a,;l,T) consists of the sum of the flux FP(x,d)
emitted by the plasma, the flux F,(x,a,A,T) emitted by the
cathode at temperature T, and the flux FJx,a,A,T) result-
ing from the plasma radiation reflected by the cathode.
Thus,
F,,zbx~W) =F,W) +F,(x,a,&T) +F,(x,a,il,T),
(1)
where x is the position along the horizontal axis perpen-
dicular to the line of sight, a is the angle between the line
of sight and the horizontal component of the normal to the
cathode surface [Fig. l(b)], A is the wavelength of the
measured radiation, and T is the cathode surface temper-
ature.
If a horizontal scan of F,(x,a,/Z,T) is made, extending
from the edge of the arc to the center of the cathode, and
if the plasma radiation is assumed to have cylindrical sym-
metry, it is possible to eliminate F,(x,A) from Eq. ( 1).
This is achieved by using an Abel transformation which.
has been appropriately modified in the region character-
ized by x < r,, where r, is the cathode radius at the z coor-
dinate of the scan. When the line of sight does not intercept
the cathode (i.e., x> rJ, the measured radiation flux con-
sists only of the emission from the plasma. In this case
F,,, (~,a,& T) can be expressed in terms of the plasma emis-
sion coefficient f(r) as9
f(r) = -A Sp FfG>re’f,:p, (3)
where the prime indicates the differentiation of Fp with
respect to x.
Equation (3) is numerically integrated in the region
x>r,, where F,=F,=O, to evaluate f(r) for r> r, [f(r)
=0 for r<rJ and this plasma emission coefficient can then
be used to calculate F,(x<r,,A), the direct plasma compo-
nent of the measured radiation in the electrode region. For
measurements made over the cathode surface in the arc
attachment region this flux can represent up to 30% of the
total measured flux F,(x,a,A,T) (see, for example, Fig.
2).
The separation of the remaining two terms Fe and F, of
Eq. ( 1) is very difficult.” In order to estimate the impor-
tance of the intensity of the reflected radiation relative to
the intensity of the radiation emitted from the cathode,
total flux measurements were made at 696.55 nm (a neu-
tral argon emission line) and at the nearby continuum
wavelength 700.5 nm. If the variation of the plasma con-
tinuum emission and of the cathode emission between
these two wavelengths is neglected, then the difference in
the two total flux measurements represents the sum of the
plasma line emission and the reflected radiation at 696.55
nm. As discussed above the plasma radiation can be re-
moved by use of a modified Abel-inversion transformation
leaving only the radiation reflected by the cathode.

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 =;‘
.M
1.u
7--... , I ...‘
- ...‘.I
k =‘.3m m
2
e
-2 II.75 A,
\A
d
.i!
i\ I’1
m 0.5
2
2
a
‘lx,
2
c
m

e,
0.25
Ky\ ‘l\\,
=
2 0.0
0 2.0 0.25
Position along x-axis (mm)

FIG. 3. Plasma radiation at the wavelength 696.55 n m reflected by the

cathode; z is the axial distance from the cathode tip. Arc current is 200 A,
-3 -2 -1 0 1 2
gas flow is 5 timin argon, arc length is 5 mm, cathode of thoriated Position along X-axis [mm)
tungsten 90’ cone and 3.2 m m diameter.

The amount of the radiation reflected by the cathode
depends on the nature of its surface. The reflected radiation
flux F, has been found to change with both the purity of the
gas provided to the arc and the axial position on the cath-
ode. For a high-purity argon gas (containing less than 2
ppm of oxygen) Fr is maximal for measurements made
over the cathode surface between the end of the arc-
cathode attachment region and the end of the conical sec-
tion of the cathode. For tungsten-based cathodes operating
with a high-purity argon gas, Fr is slightly dependent on
the time for which the arc has been burning. For a gas with
an oxygen impurity higher than a few ppm, the reflected
radiation flux decreases in time and the cathode surface
keeps changing due to redeposition on the cathode surface
of tungsten eroded from the cathode tip in the arc-cathode
attachment region.
The reflected radiation flux Fr has been measured
across the cathode at various distances from the tip and for
many conical angles, and is seen to be minimal near the
edges of the cathode, where a is close to 90”. Figure 3
shows F,(x) for the wavelength 696.55 nm at several axial
positions over the cathode for a thoriated tungsten cathode
of 3.2 m m diameter and 90”cone angle operated with a 200
A arc in argon. It is seen that F, decreasestoward zero as
the cathode edge is approached where a--,90”. As a *first
approximation, we assume these results for reflected line
radiation to also be true for the continuum wavelengths
used in the cathode temperature measurements.
Figure 4 shows measurements at wavelengths 634.0
and 700.5 nm made over the cathode and its surrounding
plasma at z= 1.5 mm. As the distance from the arc axis
decreasesa sudden increase in the measured radiation flux
appears as a result of the passagefrom the arc to the cath-
ode (a=90”). There is then a slower increase in F, owing
to a continued increase in the radiation reflected by the
cathode surface with decrease in the distance from the arc
axis. This reflected radiation has a maximum for a=O.
At the edges of the cathode (a =90”), it is thus possi-
ble to neglect the reflected light flux, leaving only the ra-
diation emitted from the cathode. Under these conditions,
the energy flux emitted from the cathode surface element
FIG. 4. Side-on integrated intensity of the emission from the plasma and
the cathode at the wavelengths 634.0 and 700.5 n m at z= 1.5 m m (same
conditions as in Fig. 2).
of area S(x,r,a) at an axial position z from its tip, at a
temperature T, in a direction having an angle a with the
normal to this surface, can be expressed as”
F,kwW) =S(x,T,a)eia,a,T)Lc(x,a,a,T), (4)
where e(a,il,T) represents the emissivity of the cathode,
L,(x,a,A,T) the blackbody radiation, delined as
L,(x,a,il,T)=E(a,il,T)C1A-5(e~‘~T-1)-’, (5)
and C,=3.7415~10-I6 W m2 and C,= 1.4388~ low2
m K are the constants of the blackbody radiation formula.
The continuous variation in time of the cathode sur-
face morphology and the dependence of this morphology
on the arc parameters and in particular on the oxygen
concentration in the gas provided to the arc make it very
difficult to perform monochromatic measurements of the
cathode surface temperature. The emissivity-related prob-
lems can, however, be minimized by using a two-
wavelength pyrometry technique. If l ( a,;1i, T) and
E((Y,&,T) are the emissivities corresponding to the wave-
lengths ill and il,, respectively, then the ratio of the energy
fluxes emitted from the cathode at those wavelengths be-
comes
F,(x,a,dl,T) E(a,/Zl,T) /2, 5 1 -ec2”zT
(6)
R”2”F,(x,a,Az,T)‘~(a,~~,T) (z 1
1 _ eC,//llT *
In general terms, the spectral emissivity is not well
known;“*” It depends on many parameters including the
surface roughness and temperature, direction of emission,
and wavelength. l2 Because no analytical formula can be
obtained for the dependence on wavelength and tempera-
ture, experimental data for this emissivity correction are
used.i3 The dependence on the direction of emission can
also be simplified through the use of the cathode mono-
chromatic hemispherical emissivity E(/Z,T), defined as the
ratio of the monochromatic emissive power to the mono-
chromatic blackbody emissive power, l4

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 S%I~S~~OIF,(X,a,/Z,T)/S]sin 2a da dc$
E(asT)=]
Because of the cylindrical symmetry of the arc and its
cathode the surface. temperature is assumed to be indepen-
dent of a. A scan over the cathode surface at a given axial
position is equivalent to a scan over one location of that
surface from different angles (Fig. 1). If S represents the
cathode surface element characterized by (a,r,z) then
F,(x,a,A,T)/S represents the emitted flux per unit area
from that surface in a direction having an angle a with the
normal to S. It follows that a complete set of measure-
ments of F,(x,a,A,T)/S for a given axial position of the
cathode can be written in terms of the monochromatic
hemispherical emissivity of the cathode surface at that
temperature and the ratio of two sets of such measure-
ments at /2i and /2, becomes
S~~OIF,(x,a,ill,T)/S]sin 2a da
J~~o[F,(x,a,/Zz,T)/S]sin 2a da
This equation provides a quantitative relation between the
real cathode emissivity and its emissivity in a given direc-
tion.
This general treatment can be simplified in some cases
where the angular dependence can be separated from the
spectral dependence. In this case the ratio RI,, of the fluxes
measured for the two wavelengths d, and & should be
independent of a for a given axial position over the cylin-
drical part of the cathode (where the emission from the
plasma is negligible). For the tungsten-based cathodes we
have used in this investigation this is seen to be the case.
In the analysis of the measurements presented in this
article we, therefore, assume the emissivity to be of the
form
dd,T) =dakiW),
which simplifies the emissivities ratio in Eq. (6) to
e(,li,T)/e(&T) and permits a determination of the sur-
face temperature T once the radiation fluxes emitted from
the cathode at wavelengths ;1i and & are measured. For
tungsten-based cathodes experimental data taken from
Ref. 13 are used for the emissivity correction.
IV. DISCUSSION
The main potential sources of error in this measure-
ment technique are the influence of the modified Abel-
inversion transformation, the arc radiation reflected by the
cathode, the variation of the cathode emissivity with time,
and the asymmetry in the arc during measurement.
The first two of these error sources concern the tech-
niques proposed to overcome the influence of the plasma
radiation. As discussed above, the reflected radiation is
considered to be minimized at the edges of the cathode and
the modified Abel-inversion transformation is designed to
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*
(7)
a” 0.25
500
QJ
z, 0
50 100
‘rime (minutes)
FIG. 5. Variation in time of the radiation emitted from the cathode at the
wavelength 634.0 nm (same conditions as in Fig. 2).
remove the plasma component of the measured radiation
signal. The effectiveness of our approaches to these prob-
lems associated with the plasma radiation has been verified
by measuring the cathode temperature immediately after
the arc has been rapidly switched off.
(8) A switch connected in parallel to the arc is used to
divert the arc current in less than 100 ns and the plasma
radiation is observed to decay with a short time constant
( < 100 ps) compared with that of the cathode radiation
( > 5 ms). Accordingly, for times z 100 ps after switching
off the arc, the cathode temperature can be determined by
conventional means since the cathode radiation is effec-
tively unchanged but the plasma radiation has essentially
disappeared.
The radiation flux is measured at two wavelengths at
times > 100 ps after switching off the arc and averaged
over 512 switching events. The ratio of these two fluxes is
used to determine the cathode temperature by conven-
tional two-wavelength pyrometry. Electrode temperatures
measured after the arc has been switched off are found to
agree with those measured using the technique described in
this paper while the arc is operating. For example, for
(9)
measurements made near the edges of the cathode at a
surface temperature of 3400 K, the two techniques agree to
within 50 K providing verification of the procedures used
to handle the plasma component of the measured radiation
flux. However, if measurements are made away from these
edges (where reflected radiation is no longer minimized)
the temperatures measured using the two-wavelength tech-
nique are seen to be as much as 1000 K higher than those
obtained when the arc is momentarily switched off.
Any mathematical error resulting from the Abel-
inversion procedure is minimized by taking measurements
at a large number of positions during a radial scan at each
axial position.
Concerning the emissivity problem, the scanning time
was optimized to about 1 min to minimize emissivity vari-
ation associated with changes of the surface morphology.
Local rapid emissivity variations may occur as a result of
local melting. Figure 5 shows an example of measured ra-
diation intensity from a spot located a few mm from the tip
of the cathode as a function of the time. The curve indi-
Free-burning erc 545

I I --...I-__
fro; the tathoie tip7(mmy
FIG. 6. Temperature profiles for a thoriated tungsten cathode measured
at three different times after the start of the arc; surface temperature vs
distance from the cathode cone. Arc current is 300 A, gas flow is 5 &in
argon, arc length is 5 mm, cathode of thoriated tungsten 60”cone and 3.2
m m diameter.
cates that the variation of the emission flux from the cath-
ode in a time interval equivalent to the scanning time of
about 1 min is negligible. Cylindrical symmetry of the
plasma is a critical factor for this technique and consider-
able care is taken in the cathode alignment (both relative
to the anode and within the gas nozzle) and in achieving
uniform gas flow. The precision of the measurements is
estimated to be better than a few percent.
Figure 6 shows an example of the measurement repro-
ducibility for the case of a 3.2-mm-diam, 30”conical angle,
thoriated tungsten cathode operating with a 300 A arc
burning in argon at atmospheric pressure. The continuum
wavelengths used to perform the cathode surface temper-
ature measurements are 634.0 and 700.5 nm. Similar mea-
surements, made using other wavelengths chosen from the
continuum of the arc spectrum (533.5 and 572.5 nm, 538.0
and 595.5 nm, 572.5 and 627.8 nm, 595.5 and 658.7 nm,
615.5 and 700.5 nm, 627.8 and 672.2 nm), have shown the
measured temperature to be independent of the wave-
lengths chosen within the measurement’s uncertainties.
V. RESULTS
In this section we present an example of temperature
measurements for pure and thoriated tungsten electrodes.
The emissivity correction in the case of thoriated tungsten
cathodes (2% thoria by mass) is assumed to be the same
as that for pure tungsten. Experiments indicate that at
the same surface temperature, equal fluxes are emitted
from pure and thoria-doped tungsten, supporting this hy-
pothesis. ’ has been partially supported by BHP Ltd. Australia under
Temperature profiles of pure and thoriated tungsten
cathodes operating with 100 A arc current are compared in
Fig. 7. The tip temperature of the pure tungsten cathode
exceeds that of thoriated tungsten by about 1000 K.
This difference highlights an apparent contradiction in
the understanding of the operation of pure and thoriated
tungsten cathodes. For a high-current free-burning arc, the
energy delivered from the arc to the cathode consists
mainly of heating by ions issued from the plasma.15-17Be-
cause the plasma temperature near the cathode tip is
546 Rev. Sci. Instrum., Vol. 64, No. 2, February 1993
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4500
2
Ef 3500
3
E
:
a
2 2500
--a --’
-a- -* -_
*--. -- <_
1500 oLl , I L-1. ---L . ..__1
Axial &ance3 fro: the ZathodRe t.ip7(mm~
FIG. 7. Surface temperature profiles for thoriated tungsten and pure
tungsten cathodes. Arc current is tC0 A, gas flow is 5 Nmin argon, arc
length is 5 mm, cathode of thoriated tungsten 60” cone and 3.2 m m
diameter.
higher for thoriated tungsten cathodes” this energy is ex-
pected to be higher for thoriated tungsten cathodes than
for pure tungsten cathodes. Cooling of the cathode by ther-
mionic emission of electrons from its surface is generally
considered to be the main cooling process of the cathode
tip. “-I7 The power lost by the cathode due to this process
is equal to 14, where I is the arc current and 4 is the
cathode surface work function. The work function of tho-
riated tungsten (3.5 eV) is lower than that for the pure
tungsten (4.5 eV). For the same arc current, thermionic
cooling of the cathode is, therefore, expected to be lower
for the thoriated tungsten cathode. It follows that the sur-
face temperatures should be higher for the thoriated tung-
sten cathode, which is in disagreement with the measure-
ments shown in Fig. 7.
Discussion of the causes of this disagreement involved
studying the various aspects of difference between pure and
thoriated tungsten cathodes and is beyond the purpose of
this paper. W e have made cathode surface temperature
measurements and plasma temperature measurements for
both cathodes with various arc conditions and these mea-
surements suggest that the origin of the differences between
the temperatures of the two cathodes materials is in their
electrical and thermal properties rather than in the plasma
interactions with the cathode.‘*
ACKNOWLEDGMENTS
W e would like to express our appreciation to Dr. G. N.
Haddad and J. J. Lowke for their valuable suggestions and
discussions during the progress of this work. This study
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