Scaling and laws of DC discharges as pointers for HiPIMS plasmas

Abstract

Scaling or smiliarity laws of plasmas are of interest if lab size plasma sources are to be scaled for industrial processes. In the case of direct current (DC) magnetron sputtering the scales can range from few centimeters in the lab to several meters if one takes the flat glass industry as one example. Ideally, the discharge parameters of the scaled plasmas are predictable and the fundamental physical processes are unaltered. Naturally, there are limitations and ranges of validity. Scaling laws for direct current glow discharges are well known. If a well diagnosed discharge is scaled, the field strength in the positive column, the gas amplification and the normal current density can easily be estimated. For non-stationary high power discharges like high power impulse magnetron sputtering (HiPIMS) plasmas, scaling is not as straight forward. Here, one deals with a non-stationary complex system with strong changes in plasma chemistry and symmetry breaks during the pulses. Because of the huge parameter space no good parameters are available to define these kind of discharges unambiguous at the moment. In this contribution we will discuss the scaling laws for DC glow discharges briefly and present experimental results for a discharge with copper electrodes and helium as plasma forming gas. This discharge was operated in a pressure range from 200 to 1600 hPa with three different electrode diameters (D = 2.1, 3.0 and 4.3 mm). Results from breakdown voltage measurements indicate that the pressure and electrode distance cannot be varied independently. Also limitations of the theoretical Paschen curves will be adressed. Effects of the scaling on the reduced normal current density, the reduced normal electric field in the positive column and discharge temperature will be discussed and limitations highlighted. Compared with these results the added complexity of HiPIMS plasmas will be described. Suggestions in the community how to obtain experimental finger prints of the plasmas will be reviewed and implications from the experiences with DC discharges on the development of similarity laws for HiPIMS plasmas will be discussed.