Alumina Substrates Research Articles

Adhesive and healable supramolecular comb-polymers

A series of supramolecular comb polymers (SCPs) with adhesive and healable characteristics have been generated through the copolymerisation of methacrylate monomers featuring aromatic amide functionalities with lauryl methacrylate. By varying the amide functionality and loading of the supramolecular monomers, the properties of the resulting SCPs can be tailored, ultimately providing stable films at room temperature. As the loading of the amide-bearing monomer was increased, the phase separation between the hard and soft domains was enhanced, promoting larger hard-domain aggregation, as observed via atomic force microscopy (AFM). The mechanical properties of the SCPs correlated to the loading of the amide-bearing monomers, by increasing the mol% incorporation the resulting SCPs transition from possessing high strain to high ultimate tensile strength (UTS) and Young's modulus (YM). Over several re-adhesion cycles, the SCPs were shown to retain their shear strength when thermally adhered to both glass and aluminium substrates. Additionally, the SCPs exhibited healable properties at elevated temperatures (> 45 °C) allowing for the recovery of mechanical properties post-damage.

Two-axis beamsteering using a wideband Butler matrix and series-fed arrays for millimeter wave frequencies fabricated on metallic-nanowire-membrane platform

This work presents a two-axis beamsteering system designed for WLAN millimeter-wave frequencies. The system comprises a wideband Butler matrix and series-fed arrays. The Butler matrix, implemented with microstrip lines, features a wideband crossover with low phase imbalance, enabling four discrete beamsteering directions on the radiation H-plane. The series-fed arrays enable frequency-dependent beamsteering on the E-plane. The entire system was fabricated on a nanoporous alumina substrate using metallic-nanowire-membrane technology. Measurement results indicate an impedance bandwidth of 17.71%, which accommodates typical requirements for 60 GHz WLAN applications. Additionally, beamsteering in the desired directions was achieved. The presented Butler matrix structure stands out as one of the most compact found in the reviewed literature. The produced device successfully balances wideband behavior, compactness, and fabrication simplicity.

Study on the tribological properties and corrosion resistance of the modified NiZnAl-LDH coating on anodic aluminum surface

The porous structure of anodized aluminum creates an opportunity for corrosive media to contact the aluminum substrate, resulting in diminished corrosion resistance and wear performance under adverse conditions. In this study, ternary hydrotalcite containing Ni, Zn, and Al elements, named NiZnAl-LDH, was synthesized on anodized aluminum surfaces using an in-situ growth method. The corrosion and wear resistance of the aluminum substrate were further enhanced by intercalation modification with sodium molybdate. The impact of synthesis parameters, including pH, reaction temperature, and reaction time, on the corrosion and wear resistance of the coating was investigated. Morphology, structure, and properties of the coating were analyzed. The results confirm the synthesis of NiZnAl-LDH modified with sodium molybdate intercalation. Electrochemical tests revealed that immersing NiZnAl-LDH in a sodium molybdate solution with a pH of 9.5 for 2.5 h at 35 °C resulted in a minimum self-corrosion current density of 4.131 × 10−8 A cm−2, significantly enhancing the corrosion resistance of the coating. Friction tests demonstrated a coating friction coefficient of 0.28, indicating excellent tribological performance. The discussed process parameters in this study provide valuable insights for the synthesis and application of LDH, expanding the application of aluminum alloys in the field of corrosion resistance and wear resistance.

Ultrarapid soldering Cf/Al by inactive solder by ultrasonic assistance

Ultrasonic vibration was applied when soldering carbon fiber-reinforced aluminum composites (Cf/Al) in this work. The effects of ultrasonic action time on joint formation, carbon fiber distribution, and mechanical properties of the joints were studied. Results show that, with the assistance of ultrasonic vibration, inactive solder can wet the carbon fiber within dozens of seconds at low temperature (250 °C). Short ultrasonic action time leads to minor erosion of aluminum substrate, thereby restricting the movement of carbon fibers into joint. Extensive erosion of the aluminum occurs with prolonged ultrasonic action time. A uniform distribution of carbon fibers in joint is achieved at 60 s. Wetting of carbon fiber is characterized by amorphous-nanocrystalline oxides on its surface, which can be attributed to the elevated temperature and pressure induced by the cavitation of the solder. Extending ultrasonic time enhances the hardness and the shear strength of the joint. The failure cracks propagate through the substrate when ultrasonic time exceeds 15 s. This work provides referential value when soldering materials with low surface energies.

Wear of alumina-PTFE against brass and aluminum: Role of interfacial films and tribochemistry

PTFE matrix composites reinforced with α-Al2O3 fillers are considered a gold standard polymeric solid lubricant. α-Al2O3 PTFE exhibits ultra-low wear rates (k ∼10−8 mm3/Nm) when sliding against steel in the presence of water vapor. Mechanochemical interactions involving the breaking of PTFE chains, and subsequent oxidation in the presence of water vapor helps promote growth of interfacial films that are strongly bound to the sliding interface. In the absence of moisture, wear rates of α-Al2O3 PTFE can increase by as much as three orders of magnitude, underscoring its importance to ultra-low wear behavior. A similar increase in wear rates of α-Al2O3 PTFE in humid environments has recently been observed when sliding against brass counter surfaces, though reasons for this increase remain unclear. These findings suggest that mechanisms of ultra-low wear not only rely on ambient humidity but are also strongly dependent on the counter surface chemistry. In the present work, we test the hypothesis that counter surface chemistry drives alumina PTFE wear by systematically investigating the wear of an α-Al2O3 PTFE composite against brass and aluminum substrates within the context of the morphological and mechanochemical evolution of the sliding interface. Wear tests are conducted under reciprocating, dry sliding conditions. Results presented in this work offer insights on mechanochemical mechanisms that drive wear of α-Al2O3 PTFE against brass and aluminum, and provide a framework for developing strategies for controlling wear.

Strong and tough 3D-(SiC–Si3N4)/Al co-continuous composite with enhanced interfaces

Materials with high specific strength and toughness are urgently needed in the fields of electronic packaging, armor, and aerospace. SiC/Al composites show good potential for these applications but the problem of mutual exclusion of strength and toughness still needs to be solved. Herein, we propose a new strategy to simultaneously enhance its strength and toughness from the perspective of structural optimization and interface enhancement. Inspired by the nacre structure, a 3D-(SiC–Si3N4)/Al co-continuous composite was prepared by freeze-casting combined with the pressure infiltration method. During the process, elongated Si3N4 grains were introduced into the ceramic framework to design the internal lamella wall structure and increase the contact area with the aluminum substrate. Moreover, a favorable interfacial bonding was designed between Si3N4 and Al to improve interface wettability. The reliable microstructure of porous 3D-(SiC–Si3N4) preform was tailored through the adjustment of initial solid loading and the α-Si3N4 component. The effects of initial solid loading and the α-Si3N4 component on the microstructure, interfacial wettability, and mechanical properties of the final composites were investigated. The results showed that the SiC–Si3N4/Al composites possess high flexural strength (769 MPa) and fracture toughness (15.1 MPa m1/2), which is superior to data reported in general literature. Numerous elongated β-Si3N4 grains are produced on the ceramic skeleton, forming an interlocking structure with the aluminum matrix, which increases the contact area with the aluminum substrate. A chemical reaction layer was formed at the interface of the composite, greatly improving the interfacial bonding strength. This work provides a promising design guideline for developing and optimizing high-strength and tough composite.

Fabrication of superhydrophobic surface by spraying hydrophobically modified silica nanoparticles on partially cured polyurethane paint

ABSTRACT There is an increasing demand for superhydrophobic surfaces due to their unique properties like self-cleaning, anti-icing, corrosion resistance, etc. The development of polyurethane (PU)-based superhydrophobic coating has garnered significant attention for aircraft applications. Polyurethane (PU) topcoat is widely used in aircraft and is hydrophilic in nature with a water contact angle (WCA) of 75 ± 3°. In the present work, a hydrophilic PU clear coat on aircraft-grade aluminum substrate is transformed to a superhydrophobic (SHP) surface by spraying environmentally friendly hydrophobically modified silica nanoparticles (HSiNps) oonto a PU layer that was partially cured in a hot air oven at 60°C for 1.5 h. The SHP surface exhibited a WCA of 162 ± 3° and a sliding angle (SA) of 8 ± 3°. With the incorporation of HSiNps, micro – nano dual-scale surface roughness is created and the surface roughness of the PU coating is increased from 0.35 to 2.42 µm. The coating exhibits good adhesion (5B) with excellent water repelling property and remains thermally stable and superhydrophobic even after subjecting it to 100°C for one week. Durability of the coatings is studied by immersing the coatings in various liquids. The retention of superhydrophobic property after anti-fogging, water sprinkler, and sand paper abrasion tests further demonstrate the robustness of the coating.

3D Nanostructured Electrodes Based on Anodic Alumina Templates for Stable Pseudocapacitors

This study investigates the preparation of nickel nanostructured electrodes for the enhancement of supercapacitor performance. The nanostructured electrodes are synthesized using nanoporous anodic alumina (NAA) as a template via the pulsed electrodeposition method. Structural properties are examined using field‐emission scanning electron microscopy, while electrochemical characterization is conducted through cyclic voltammetry (CV) and electrochemical impedance spectroscopy. The results reveal that Ni nanorod arrays can be obtained embedded in the NAA matrix and with electrical contact with the aluminum substrate. On average, the rods are spaced 90 nm apart, with a diameter of 70 nm and a length of 2 μm. The Ni@NAA electrode exhibits an enlarged active area and exceptional electrochemical performance, demonstrating remarkable stability over 5000 cycles of CV at a scan rate of 50 mV s−1. Specific capacitance values exceeding 100 mF cm−2 and maximum charging times of less than 10 min are reported, highlighting its suitability for high‐power energy devices requiring pseudo‐supercapacitance. The study underscores the significance of nanostructured electrodes in advancing energy storage technologies and presents promising prospects for practical applications.

Role of Mn Doping in Improving the Hydrophobic Property of ZnO Coating on Aluminum Substrate

Role of Mn Doping in Improving the Hydrophobic Property of ZnO Coating on Aluminum Substrate

Atmospheric plasma treatment effect on shear strength of GFRP-Aluminum adhesively bonded lap joints

The objective of this study is to investigate the effect of air (dielectric barrier discharge) DBD plasma treatment on the bonding strength of adhesively bonded glass fiber-reinforced epoxy composite-aluminum lap joints. The bonding performance of lap joints produced by the plasma treatment was compared with that of untreated and peel-ply surface treatments. Water contact angles of the substrates were measured for untreated, peel-ply, and plasma surface-treated substrates. Experimental results showed that plasma-treated aluminum and GFRP substrates increased the wettability properties and thus shear strength of adhesively bonded GFRP-Al joints increased. After the shear tests, the fracture surfaces of the substrates were visually examined and three different damage modes were observed, including light fiber tear failure, adhesive failure, and thin layer cohesive failure modes.

Gas Permeation through V2O5 Nanoribbons‐Based Membrane

AbstractMembrane separation processes play a crucial role in gas separation applications, with the need for ongoing development to fulfill new needs for today's challenges. For this purpose, novel 2D nanomaterials are progressively showing promise over conventional polymer‐based membrane material, exhibiting excellent molecular transport properties. Beyond the 2D materials already studied in this field, this article presents the first gas separation performances of vanadium pentoxide membrane. Brand new in gas separation topic, 2D van der Waals nanoribbons of V2O5 are successfully synthesized and layered on an anodic aluminum oxide substrate. Gas permeation analysis of He, N2, and CO2 are performed on various membranes made from different quantities of the nanomaterial. Gas permeance results suggest a deviation from an expected Knudsen diffusion mechanism of the V2O5‐based membrane for He separation. The ideal selectivities of He/N2 and He/CO2 are compared to Robeson's upper bound for polymeric membranes. V2O5 membranes, prepared with the highest V2O5 quantity, exceeded the upper bound from 2008 for He/N2 and 2019 (the most recent) for He/CO2, demonstrating the interesting potential of V2O5 2D materials for gas separation.

Electrical detachment of triboelectrically charged bumpy particles from rough surfaces

The detachment of bumpy particles from smooth and rough surfaces through electrostatic fields was studied. The Johnson–Kendall–Roberts (JKR) adhesion model for elastic interface deformations was used to account for the individual bump adhesion, including the electrostatic forces. It was assumed that the elastic deformation of asperities determines the real contact area, and the effect of topographic properties of substrates was included in the analysis. For a fixed charge per unit mass, the Coulomb, the image, the dielectrophoretic, and the polarization forces acting on the particle in the presence of an imposed electric field were evaluated. The electrostatic detachment of bumpy toner particles for various applied electrostatic fields was studied. The triboelectric charges were concentrated on the hemispherical bumps, and the critical electric field strength needed to detach charged particles from surfaces with varying roughness levels was evaluated. It was shown that the particle charge, surface roughness, and the number of bumps significantly affect the removal of particles from surfaces. For higher charges (∼5 × 10−15 C ), decreasing the number of bumps from 22 to 14 and the roughness parameter from 0.83 to 0.77 approximately doubled the detachment field needed to remove 8.3 μ m polystyrene (PSL) particles from the aluminum oxide substrate. The model predictions are compared with the available experimental data, and good agreement was observed. The study’s findings predicting the electric field needed for charged particle removal could lead to more efficient copiers and electrostatic cleaning devices.

Research on Laser Cleaning Technology for Aircraft Skin Surface Paint Layer.

In this study, a pulsed laser operating at a wavelength of 1064 nm and with a pulse width of 100 ns was utilized for the removal of paint from the surface of a 2024 aluminum alloy. The experimental investigation was conducted to analyze the influence of laser parameters on the efficacy of paint layer removal from the aircraft skin's surface and the subsequent evolution in the microstructure of the laser-treated aluminum alloy substrate. The mechanism underlying laser cleaning was explored through simulation. The findings revealed that power density and scanning speed significantly affected the quality of cleaning. Notably, there were discernible damage thresholds and optimal cleaning parameters in repetitive frequency, with a power density of 178.25 MW/cm2, scanning speed of 500 mm/s, and repetitive frequency of 40 kHz identified as the primary optimal settings for achieving the desired cleaning effect. Thermal ablation and thermal vibration were identified as the principal mechanisms of cleaning. Moreover, laser processing induced surface dislocations and concentrated stress, accompanied by grain refinement, on the aluminum substrate.

Can Aluminum Cations Promote Nucleation for THF Hydrate Growth?

Rapid nucleation of tetrahydrofuran (THF) hydrate is essential for developing a THF hydrate-based cold storage technology. Earlier works have hypothesized the role of aluminum complexes in initiating the nucleation of clathrate hydrates using aluminum metal electrodes and substrates. This study investigates if the nucleation promotional effect of hydrate can be achieved using the aluminum salt, AlCl3, due to the formation of aluminum aqua complexes in water. Metal chlorides NaCl and MgCl2 are also utilized to evaluate the effect of cation type in initiating nucleation, i.e., the effect of charge/radius ratio. The induction time is measured in a stirred reactor at various subcoolings and concentrations of 0.05, 0.1, 0.5, 1, and 2 wt %. The nucleation time is studied in two reactor configurations based on the nature of salt introduction in the THF solution, i.e., salt premixed in solution and salt injected inside the solution. The sudden rise in the reactor temperature due to hydrate formation is used as an indicator of hydrate formation. Results indicate that AlCl3 promotes hydrate nucleation as AlCl3 reduces induction time by 92.2% at 0.05 wt % concentration compared with water. Nearly instantaneous nucleation is also achieved by directly injecting AlCl3. MgCl2 and NaCl do not show a similar effect on induction time as AlCl3. The pH and Raman spectra measurements with and without salts are carried out to explain the effect of cations on the THF-water solution.

Enhancing the quality factor of aerosol jet printed RF spiral inductors through gold electroplating

Aerosol jet printing (AJP) outperforms inkjet printing by significantly reducing printed line width, effectively addressing issues such as bulging and surface irregularities. This technology allows for line widths as narrow as 10–100 μm with high aspect ratios, making it well-suited for radio frequency (RF) applications. Consequently, AJP emerges as a valuable tool for direct printing in RF applications. Among conductive inks, silver nanoparticle (Ag-NP) ink is preferred for its straightforward direct printing process and lower sintering temperature requirements. However, the conductivity of printed Ag NP traces falls markedly below that of bulk silver due to significant porosity, limiting its use in RF applications where a high-quality factor is essential. The quality factor of an inductor, indicative of its efficiency in energy storage and release, inversely correlates with its resistance. Our research combines AJP with selective electroplating to reduce the resistance of printed traces, thereby enhancing the inductor’s quality factor for RF applications. We fabricated spiral inductors on alumina substrates using silver NP ink and subsequently applied selective gold electroplating to these traces. This approach led to a significant increase in the inductors’ quality factor, improving it by a factor of 3–5 in the RF frequency range of 100–700 MHz.

Anchoring groups for ordered and highly stable monomolecular films on naturally oxidized aluminum – phosphonate versus carboxylate

Modification of metal oxide surfaces by self-assembled monolayers (SAMs) is attracting growing attention. Carboxylic (CA) and phosphonic (PA) acids are most popular anchoring groups in this context, applied to create hydrophobic coatings, biosensors, and organic field-effect transistors. The efficiency of these devices is crucially affected by the structural quality and stability of the SAM. In this context, we studied the effect of the preparation procedure (solvent, incubation time, and temperature) on the quality of PA SAMs on naturally oxidized aluminum. We demonstrate formation of PA SAMs matching structural quality of archetypical alkanethiols on gold. Next, we compare their stability with analogous CA SAMs. Our data show that PA SAMs not only exhibit much higher hydrolytic stability but are also capable to protect aluminum substrate from oxidation and degradation. Importantly, even small improvement of the PA SAMs quality, translates into enormous increase of their hydrolytic stability crucial for majority of applications. Finally, we demonstrate that the thermal stability of PA on oxidized aluminum is by ∼250 K higher than CA SAMs, and by ∼200 K higher than for thiols on gold, which makes PA SAMs an excellent candidate for organic electronics, where overheating problems and high-temperature fabrication procedures are common issues.

Design of Reversible Adhesives by Using a Triple Function of Ionic Liquids

AbstractReversible adhesives are crucial for a circular economy of composites as they play a key role for rework, repair, and recycling of adhesively bonded components. Herein, electrically debondable adhesives are prepared by introducing ionic liquids in dynamic thiol–epoxy networks. The function of the ionic liquid in the networks is threefold as it accelerates the curing reaction between thiol and epoxy monomers, facilitates electrical debonding, and catalyzes thermoactivated transesterification reactions, required for rebonding at elevated temperature. A library of 1,3‐dibutylimidazolium‐based ionic liquids with varying anions is synthetized and it is found that 1,3‐dibutyl‐1H‐imidazol‐3‐ium dicyanamide (DiButIm─N(CN)2) is superior in accelerating bond‐exchange reactions between hydroxy and ester moieties at elevated temperature. Thus, a thiol–epoxy resin containing 20 wt% of DiButIm─N(CN)2 is used to impregnate glass fiber mats yielding adhesive connections for aluminum substrates with 10.2 MPa pull‐off strength. The adhesive connections are successfully debonded at the metal–adhesive interface by applying 120 V. The samples are then rebonded via the thermoactivated change in the networks’ viscoelastic properties and ≈80% (8.1 MPa) of their original bond strength can be regained. By providing a simple strategy to synthetize reversible adhesives, this approach paves a way toward improved recyclability and repairability of adhesively bonded structures.

Enhanced Pool Boiling Heat Transfer with Porous Ti-6Al-4V-Coatings Produced by Cold Spray Metal Additive Manufacturing

In advancing industrial heat transfer mechanisms, surface coatings offer significant potential. This research elucidates the efficacy of the metal additive manufacturing Cold Spray deposition technique for producing enhanced boiling surfaces, specifically focusing on Ti-6Al-4V (Ti64) coatings on Aluminium substrates. This offers a rapid and low-cost fabrication method for producing lightweight enhanced boiling surfaces. The Cold Spray method is typically used to create dense metal deposits. Here, the process has been specially tuned to create highly inhomogeneous honeycomb-type porous Ti64 coatings. Critical Cold Spray deposition parameters, such as particle velocity, preheat temperature, and deposition rate have been identified to create repeatable porous coatings, with thicknesses of up to 3.0 mm achievable. Following deposition, several samples were subjected to systematic boiling heat transfer tests in a purpose-built pool boiling apparatus. Boiling curves were generated for the augmented Cold Spray surfaces as well as a bare surface, with the latter acting as a baseline to which enhancement levels were assessed. Initial data analysis shows that some of the tested surfaces exhibit a notable increase in boiling heat transfer coefficient and Critical Heat Flux (CHF). This enhancement is potentially attributed to increased surface area, increased nucleation site density, capillary wicking, and mitigation of lateral bubble coalescence, though excessive coating thickness may degrade heat transfer. In summary, the novel Ti64 surface structures developed using the Cold Spray deposition technique exhibits high potential for industries necessitating superior boiling heat transfer performance. Importantly, the manufacturing process is industrially scalable, offering the capacity to rapidly coat large areas at low cost compared with subtractive manufacturing other metal additive manufacturing methods.

Properties and corrosion protection of polypyrrole prepared by electrochemical polymerization on aluminum

AbstractIn a one‐step procedure that did not require any surface preparation, polypyrrole (PPy) films doped with 3‐nitrosalicylic acid (3Nisa) became effectively electropolymerized on the aluminum substrate in aqueous solutions. Fourier transform infrared, scanning electron microscopy, and thermal gravimetric analysis were used to analyze the properties of PPy‐based films. Open circuit potential (OCP), electrochemical impedance spectroscopy, Tafel polarization, and salt spray tests were used to study the corrosion‐resistant efficiency of the coatings. The as‐prepared PPy films performed corrosion resistance on aluminum in the 3% NaCl solution. However, the PPy films prepared in the 0.01 m solution of 3Nisa showed the best protection ability on aluminum. The self‐healing characteristic of the PPy films was recorded by varying the potential in the OCP measurement. The findings indicate the potential of using 3‐nitrosalicylic acid‐doped PPy films for applications as anti‐corrosion coatings for aluminum.

Diffusion Nitride Surface Layers on Aluminum Substrates Produced by Hybrid Method Using Gas Nitriding

While gas nitriding of steel is currently used in industry, nitriding of aluminum alloys remains an open challenge. The main obstacle is aluminum’s high susceptibility to passivation. The oxide film provides an effective barrier to nitrogen diffusion. Attempts to overcome this problem have mainly focused on glow discharge nitriding using cathode sputtering of an oxide layer. The produced AlN layers exhibit no diffusion zone and show limited performance properties. In this work, the effect of hybrid treatment aimed at producing diffusion layers of nitrides other than AlN on aluminum alloys was investigated on the model system of iron nitride–aluminum substrate. Hybrid treatment combines an electrochemical process involving the removal of the aluminum oxide layer from the substrate, its subsequent iron plating, and a further gas nitriding in high-purity ammonia. The obtained results prove that the hybrid treatment allows the production, at 530 °C/10 h, of diffusion layers of Fe3N iron nitrides on aluminum substrates with a nitrogen diffusion zone range in aluminum of ca. 12 µm. In alloys containing magnesium, its unfavorable effect on the nitrogen diffusion and the functional properties of the layers was observed. An interesting direction for further research is hybrid treatment of precipitation-hardened alloys without magnesium.