Film Thickness Research Articles

On the Effect of Randomly Oriented Grain Growth on the Structure of Aluminum Thin Films Deposited via Magnetron Sputtering

The microstructure of aluminum thin films, including the grain morphology and surface roughness, are key parameters for improving the thermal or electrical properties and optical reflectance of films. The first step in optimizing these parameters is a thorough understanding of the grain growth mechanisms and film structure. To investigate these issues, thin aluminum films with thicknesses ranging from 25 to 280 nm were coated on SiOx/Si substrates at ambient temperature under high-vacuum conditions and a low argon pressure of 3 × 10−3 mbar (0.3 Pa) using the radio frequency magnetron sputtering method. Quantitative analyses of the surface roughness and nanograin characteristics were conducted using atomic force microscopy (AFM), transmission electron microscopy (TEM), and X-ray diffraction. Changes in specular reflectance were measured using ultraviolet–visible and near-infrared spectroscopy. The low roughness values obtained from the AFM images resulted in high film reflectivity, even for thicker films. TEM and AFM results indicate monomodal, randomly oriented grain growth without a distinct columnar or spherical morphology. Using TEM cross-sectional images and the dependence of the grain size on the film thickness, we propose a grain growth mechanism based on the diffusion mobility of aluminum atoms through grain boundaries.

Optimization of Superconducting Niobium Nitride Thin Films via High-Power Impulse Magnetron Sputtering

Abstract We report a systematic comparison of niobium nitride thin films deposited on oxidized silicon substrates by reactive DC magnetron sputtering and reactive high-power impulse magnetron sputtering (HiPIMS). After determining the nitrogen gas concentration that produces the highest superconducting critical temperature for each process, we characterize the dependence of the critical temperature on film thickness. The optimal nitrogen concentration is higher for HiPIMS than for DC sputtering, and HiPIMS produces higher critical temperatures for all thicknesses studied. We attribute this to the HiPIMS process enabling the films to get closer to optimal stoichiometry before beginning to form a hexagonal crystal phase that reduces the critical temperature, along with the extra kinetic energy in the HiPIMS process improving crystallinity. We also study the ability to increase the critical temperature of the HiPIMS films through the use of an aluminum nitride buffer layer and substrate heating.

Assessment of Oil Paints for Corrosion Protection of Reinforcing Steel Bars in Concrete

Corrosion becomes a threat to reinforced concrete structural integrity during the service life of the structural member. This situation has become a global concern because of the economic and safety implications. Hence, many corrosion inhibition techniques including coating with materials (organic and inorganic) were used to prevent its devastating effects. The present study used three oil paint brands (mat, red-oxide and gloss Leyland oil paints in Ghana) to variedly coat reinforcing steel bars to ascertain their corrosion protection capacity in concrete. There were zero, one, two and three paint coats of average film thickness, 72 µm, 129 µm and 220 µm respectively explored. An Electrochemical process involved simulated concrete pore solution made of 10% sodium chloride (NaCl) in distilled water with three electrode systems to represent a corrosion medium was used to determine corrosion protection capacity of the paints. The results indicate over 90% corrosion resistance of the paints used. Comparing the corrosion rates of the coated and uncoated reinforcing steel bars, while it would take a one coat steel bar 342.5 years and 237 years respectively for spraying and manual brushing modes to reduce in diameter by 0.616mm, it would take only one year for an uncoated steel bar to reduce by this same 0.616mm. The protection capacity proved better with increasing coats on all corrosion variables for the selected paints used. The implication is that the selected oil paint brands are capable of protecting reinforcing steel bars in concrete against corrosion and therefore recommended for application to reduce maintenance cost. Statistically, no significant difference existed between coating mode, number of coatings, paint type and steel type on the corrosion variables for the coated steel bars. However, a further study about the durability of the coating in the concrete during its service time is recommended.

Optimizing non-toxic (CH3NH3)3Bi2I9 perovskite solar cells by SCAPS-1D

Abstract Low-dimensional bismuth-based perovskite solar cells (PSCs) have demonstrated some benefits over lead-based PSCs for nontoxicity and remarkable stability. These two factors are now the primary concerns in the photovoltaic community. The power conversion efficiency (PCE) of PSCs using the lead Pb-free chemical methylammonium bismuth iodide (CH3NH3)3Bi2I9 is severely limited due to the poor quality of the photoactive material. Herein, the photovoltaic performance of the (CH3NH3)3Bi2I9 PSCs was investigated. The objective of this study was to investigate the intrinsic impacts of (CH3NH3)3Bi2I9 perovskite by using SCAPS-1D (Solar Cell Capacitance Simulator) to simulate the PSCs and the adjustment of relevant physical parameters to closely match experimental results. Moreover, the cells were optimized based on (CH3NH3)3Bi2I9 film thickness, total defect density of (CH3NH3)3Bi2I9, optical bandgap, and interfacial defects. By conducting a comprehensive analysis of the current-voltage (J-V) plots and quantum efficiency feature, the best values of perovskite thickness, bandgap, and defect density were determined to be 100 nm, 1.6 eV, and 1014 cm-3, respectively. Furthermore, defects in the interfaces between the electron-transporting layer (ETL)/(CH3NH3)3Bi2I9 and hole transport layer (HTL)/(CH3NH3)3Bi2I9 were considered, and their influence on performance was also investigated. Accordingly, the optimized cell has realized a record PCE of 9.043% and a high quantum efficiency exceeding 60%, which is comparable to those of some Pb-free perovskite analogues. The operational temperature calucations showed that all parameters remain relatively constant with increasing temperature. Therefore, the results imply that the simulated Pb-free PSCs can be stable in a thermal environment. The proposed structural layout and optimization approach can encourage more study and actual applications for Pb-free organometallic perovskite solar cells.

Fabrication of Ultrathin Ferroelectric Al0.7Sc0.3N Films under Complementary‐Metal‐Oxide‐Semiconductor Compatible Conditions by using HfN0.4 Electrode

AbstractAluminum scandium nitride (AlScN) has emerged as a promising candidate for next‐generation ferroelectric memories, offering a much higher remanent charge density than other materials with a stable ferroelectric phase. However, the inherently high coercive field requires a substantial decrease in film thickness to lower the operating voltage. Significant leakage currents present a severe challenge during the thickness scaling, especially when maintaining compatibility with complementary‐metal‐oxide‐semiconductor (CMOS) fabrication standards. This study adopts a HfN0.4 bottom electrode, which minimizes lattice mismatch with Al0.7Sc0.3N (ASN), forming a coherent bottom interface that effectively reduces leakage currents even at thickness < 5 nm. CMOS‐compatible HfN0.4/ASN/TiN stack, deposited without vacuum break between each layer, demonstrates exceptional scalability, confirming the ferroelectricity of ASN films at thicknesses down to 3 nm. The coercive voltage is decreased to 4.35 V, significantly advancing low‐voltage AlScN devices that align with CMOS standards.

Enhanced energy storage performance of lead-free Sr0.7Bi0.2TiO3 ceramics via tape casting

Abstract The development of pulsed power technology demands high energy storage density dielectric materials. In this study, Sr0.7Bi0.2TiO3 relaxor ferroelectric (rFE) ceramic thick films were prepared using a tape-casting process. The ceramics exhibit a dense structure and typical rFE hysteresis curves, achieving an energy storage density of 4.77 J cm−3 and efficiency of 94.4%, attributed to the high polarization intensity, low remnant polarization, and low hysteresis loss of rFE. Additionally, the material demonstrates good temperature stability. Moreover, the Sr0.7Bi0.2TiO3 ceramic thick films show advantages in charge-discharge performance, capable of discharging within hundreds of nanoseconds and achieving a power density of 137 MW cm−3. Overall, the Sr0.7Bi0.2TiO3 ceramic thick film exhibits a comprehensive performance advantage in terms of energy storage density, efficiency, and power density. Additionally, the material was fabricated using the tape-casting process, which is compatible with subsequent multilayer ceramic capacitor production, indicating potential for further performance enhancement.

Interdependence of Support Wettability ‐ Electrodeposition Rate‐ Sodium Metal Anode and SEI Microstructure

AbstractThis study examines how current collector support chemistry (sodiophilic intermetallic Na2Te vs. sodiophobic baseline Cu) and electrodeposition rate affect microstructure of sodium metal and its solid electrolyte interphase (SEI). Capacity and current (6 mAh cm−2, 0.5–3 mA cm−2) representative of commercially relevant mass loading in anode‐free sodium metal battery (AF‐SMBs) are analyzed. Synchrotron X‐ray nanotomography and grazing‐incidence wide‐angle X‐ray scattering (GIWAXS) are combined with cryogenic ion beam (cryo‐FIB) microscopy. Highlighted are major differences in film morphology, internal porosity, and crystallographic preferred orientation e.g. (110) vs. (100) and (211) with support and deposition rate. Within the SEI, sodium fluoride (NaF) is more prevalent with Te−Cu versus sodium hydride (NaH) and sodium hydroxide (NaOH) with baseline Cu. Due to competitive grain growth the preferred orientation of sodium crystallites depends on film thickness. Mesoscale modeling delineates the role of SEI (ionic conductivity, morphology) on electrodeposit growth and onset of electrochemical instability.

Lithium lanthanum zirconate thin films investigated using spectroscopic and microscopic techniques

ABSTRACT In this work, thin film growth of lithium lanthanum zirconate (LLZO) on p-type Si substrate was carried out using radio frequency (RF) sputtering and was characterized using microscopic and various spectroscopic techniques including X-ray absorption spectroscopy. Films were deposited at a sputtering power of 70 W at a based pressure of 4 × 10−5 Torr. Deposited films were annealed at 700°C for 1 h. The as-deposited films were amorphous and no transition to a crystalline phase was observed after annealing. Although films are amorphous Raman spectroscopic measurements exhibit the bands that are characteristics of LLZO. The thickness of the as-deposited film estimated from Rutherford backscattering spectroscopy (RBS) was 100 nm and remained unchanged after annealing. The thickness of the annealed films as determined from scanning electron microscopy (SEM) was 48 ± 21 nm. The composition of these films determined from RBS is almost analogues to that estimated from SEM-energy-dispersive spectroscopic measurements. However, O K-edge near edge X-ray absorption fine structure spectra showed slight modification with annealing but a drastic change was observed in the spectra measured in total electron yield and total fluorescence yield measurements. This change is due to the difference like the interaction of oxygen ions with its neighbouring atoms on the surface and in the bulk of the films.

Determination of Optical and Structural Parameters of Thin Films with Differently Rough Boundaries

The optical characterization of non-absorbing, homogeneous, isotropic polymer-like thin films with correlated, differently rough boundaries is essential in optimizing their performance in various applications. A central aim of this study is to derive the general formulae necessary for the characterization of such films. The applicability of this theory is illustrated through the characterization of a polymer-like thin film deposited by plasma-enhanced chemical vapor deposition onto a silicon substrate with a randomly rough surface, focusing on the analysis of its rough boundaries over a wide range of spatial frequencies. The method is based on processing experimental data obtained using variable-angle spectroscopic ellipsometry and spectroscopic reflectometry. The transition layer is considered at the lower boundary of the polymer-like thin film. The spectral dependencies of the optical constants of the polymer-like thin film and the transition layer are determined using the Campi–Coriasso dispersion model. The reflectance data are processed using a combination of Rayleigh–Rice theory and scalar diffraction theory in the near-infrared and visible spectral ranges, while scalar diffraction theory is used for the processing of reflectance data within the ultraviolet range. Rayleigh–Rice theory alone is sufficient for the processing of the ellipsometric data across the entire spectral range. We accurately determine the thicknesses of the polymer-like thin film and the transition layer, as well as the roughness parameters of both boundaries, with the root mean square (rms) values cross-validated using atomic force microscopy. Notably, the rms values derived from optical measurements and atomic force microscopy show excellent agreement. These findings confirm the reliability of the optical method for the detailed characterization of thin films with differently rough boundaries, supporting the applicability of the proposed method in high-precision film analysis.

Dielectric and energy storage properties of the g-C3N4/PVDF nanocomposite thick film

Dielectric and energy storage properties of the g-C3N4/PVDF nanocomposite thick film

Achieving Ultra‐High Heat Flux Transfer in Graphene Films via Tunable Gas Escape Channels

AbstractGraphene films have been applied in the thermal management of electronic devices due to their high thermal conductivity. However, the ever‐increasing power and local heat flux density of electronic chips require graphene films with excellent heat flux carrying capacity. Enhancing the heat flux carrying capacity is highly challenging, and the key is to maintain high thermal conductivity while increasing film thickness. Gases released during film assembly and the resulting catastrophic structural destruction should be responsible for the trade‐off between film thickness and thermal conductivity. Herein, the evolution of the pore structure is investigated during the assembly of graphene films and propose the construction of gas escape channels for the preparation of thick graphene films. The process involves using humidification treatment and freeze‐drying GO films to pre‐construct the ordered flat pore structure. The microstructure optimization of graphene films with more order, fewer wrinkles and defects, and larger grain size is achieved. After optimization, graphene films with ultra‐high thermal conductivity (1781 W m−1 K−1) and a thickness over 100 µm are realized. These films exhibit exceptional heat dissipation and cooling capabilities in high heat flux density (≈2000 W cm−2). This finding holds significant potential for guiding the thermal management of high‐power devices.

Interdependence of Support Wettability - Electrodeposition Rate- Sodium Metal Anode and SEI Microstructure.

This study examines how current collector support chemistry (sodiophilic intermetallic Na2Te vs. sodiophobic baseline Cu) and electrodeposition rate affect microstructure of sodium metal and its solid electrolyte interphase (SEI). Capacity and current (6 mAh cm-2, 0.5-3 mA cm-2) representative of commercially relevant mass loading in anode-free sodium metal battery (AF-SMBs) are analyzed. Synchrotron X-ray nanotomography and grazing-incidence wide-angle X-ray scattering (GIWAXS) are combined with cryogenic ion beam (cryo-FIB) microscopy. Highlighted are major differences in film morphology, internal porosity, and crystallographic preferred orientation e.g. (110) vs. (100) and (211) with support and deposition rate. Within the SEI, sodium fluoride (NaF) is more prevalent with Te-Cu versus sodium hydride (NaH) and sodium hydroxide (NaOH) with baseline Cu. Due to competitive grain growth the preferred orientation of sodium crystallites depends on film thickness. Mesoscale modeling delineates the role of SEI (ionic conductivity, morphology) on electrodeposit growth and onset of electrochemical instability.

Indium Oxide Thick-Films Decorated with PdO and PtO2 Particles for Oxygen Detection in Humid Environments

Abstract Thick film indium oxide chemiresistive sensors decorated with PdO and PtO2 particles were investigated for oxygen detection under humid conditions (tested ranging from 20%- 80% RH) across a temperature range of 50 °C to 400 °C. The PtO2-decorated In2O3 sensors demonstrated a significantly higher response to oxygen, showing a 500% increase at 200 °C compared to the PdO-decorated sensors (response values of 41 and 8, respectively). Tests in dry air were conducted to assess the effect of humidity on sensor performance, revealing a maximum response of 74 for PtO2-In2O3 at 400 °C, more than three times higher than the response of 22 for PdO-In2O3. Selectivity tests confirmed that the sensors responded more strongly to oxygen than to interfering gases. The integration of an active carbon cloth (ACC) filter effectively reduced interferences from isobutylene and ethylene, enhancing sensor’s selectivity. A comparison of both sensors demonstrated that PtO2-decorated In2O3 has greater potential as an alternative to existing Pb-based electrochemical oxygen sensors, particularly in humid environments.

On Thermal Reduction Factor for Elastohydrodynamic Film Thickness in Rolling/Sliding Contacts

On Thermal Reduction Factor for Elastohydrodynamic Film Thickness in Rolling/Sliding Contacts

Leakage Control Mechanisms and Strategies for Hydraulically Driven Controllable Rod Seals

Abstract The primary function of rod seals in hydraulic systems is to prevent the leakage of the hydraulic medium, which would otherwise result in environmental pollution and the loss of energy. However, the leakage control performance of conventional rod seals is limited by the level of product design. As a result, the performance of these seals will gradually degrade during the service process. Furthermore, it is not possible to adaptively adjust the performance of these seals in response to changes in operating conditions. Hydraulically controllable rod seals (HCRS) can be driven hydraulically to adjust the internal stress distribution of the seal to regulate the sealing performance. This may be an effective solution, although the leakage control mechanism and strategy remain unclear. This paper employs a thermoelastohydrodynamic mixed lubrication model to comparatively analyze the behaviors and performances of the HCRS with or without a cavity structure. The leakage control mechanism of the HCRS is revealed, namely that it is achieved by increasing the interface contact pressure and reducing the fluid film thickness through external pressurization. Furthermore, the functional relationship between the sealing performance and the regulating variables under different operating conditions is obtained through multivariate regression analysis, thereby forming the quantitative leakage control strategy of the HCRS.

Uncovering bacterial-mammalian cell interactions via single-cell tracking

BackgroundThe interactions between bacterial pathogens and host cells are characterized by a multitude of complexities, leading to a wide range of heterogeneous outcomes. Despite extensive research, we still have a limited understanding of how bacterial motility in complex environments impacts their ability to tolerate antibiotics and adhere to mammalian cell surfaces. The challenge lies in unraveling the complexity of these interactions and developing quantitative microscopy approaches to predict the behavior of bacterial populations.ResultsTo address this challenge, we directed our efforts towards Pseudomonas aeruginosa, a pathogenic bacterium known for producing thick films in the lungs of cystic fibrosis patients, and Escherichia coli, used as a proof of concept to develop and demonstrate our single-cell tracking approaches. Our results revealed that P. aeruginosa exhibits diverse and complex interactions on mammalian cell surfaces, such as adhesion, rotational motion, and swimming, unlike the less interactive behavior of Escherichia coli. Our analysis indicated that P. aeruginosa demonstrated lower mean-squared displacement (MSD) values and greater adherence to mammalian cells compared to E. coli, which showed higher MSD slopes and less frequent adherence. Genetic mutations in membrane proteins of P. aeruginosa resulted in altered displacement patterns and reduced adhesion, with the ΔfliD mutant displaying a more Gaussian displacement distribution and significantly less adherence to mammalian cells. Adhesion and tolerance mechanisms are diverse and complex, potentially involving distinct pathways; however, our findings highlight the therapeutic potential of targeting the fliD gene (encoding a critical flagellum protein), as its deletion not only reduced adherence but also antibiotic tolerance.ConclusionsOverall, our findings underscore the importance of single cell tracking in accurately assessing bacterial behavior over short time periods and highlight its significant potential in guiding effective intervention strategies.

CsPbIBr2 Thick Film With (100)‐Preferred Orientation Enables Highly Sensitive X‐Ray Detector by a Spray‐Coating Method via Dual‐Additive‐Assisted Solution Strategy under Atmospheric Environment

AbstractThe realization of large‐area high‐quality perovskite thick films under an atmospheric environment without humidity control is confronting an urgent challenge for the applications in X‐ray detection and imaging. A spray‐coating method with air as the gas carrier is employed to achieve large‐area perovskite thick films for X‐ray flat‐panel detection applications. To further improve the quality of the thick films, the 10 µm‐thick CsPbIBr2 films with (100)‐preferred orientation, low trap density (7.1 × 1012 cm−3) and high resistivity corresponding to low dark current (3.2 × 10−9 A) are prepared via dual‐additive‐assisted (NH4SCN and L‐α‐phosphatidylcholine (LP)) solution strategy under atmospheric environment with relative humidity of 60% (60% RH). Thus, the metal‐semiconductor‐metal‐structured (Au/CsPbIBr2/Au) transverse X‐ray detection device under 40 KeV X‐ray irradiation possesses a high sensitivity up to 1420 µC Gyair−1 cm−2 under a weak electric field of 18 V mm−1 and a low dose rate of 3.3 µGyair s−1 that is lower than a dose rate of ≈5.5 µGyair s−1 required for routine medical diagnosis. Strikingly, the unencapsulated device maintains 80% (1120 µC Gyair−1 cm−2) of the original sensitivity after 1000 h under the atmospheric environment with 45–55% RH. These results pave the way for the practical applications of perovskite thick films in X‐ray medical detection and imaging.

Vertically Aligned Nanocrystalline Graphite Nanowalls for Flexible Electrodes as Electrochemical Sensors for Anthracene Detection

Plasma-enhanced chemical vapor deposition (PECVD) was used to obtain several graphite nanowall (GNW)-type films at different deposition times on silicon and copper to achieve various thicknesses of carbonic films for the development of electrochemical sensors for the detection of anthracene. The PECVD growth time varied from 15 min to 30 min to 45 min, while scanning electron microscopy (SEM) confirmed the changes in the thickness of the GNW films, revealing a continuous increase in the series. X-ray diffraction (XRD) analysis revealed that the crystallinity of the GNW film samples increased with increasing crystallite size and decreasing dislocation density as the deposition time increased. Electrochemical characterization of the GNW-based electrodes indicated that the electroactive area and heterogeneous electron transfer rate constant were greater for the GNW 45 min film in the carbonic material series. We present the transfer of GNW films on flexible polyethylene substrates for achieving flexible electrochemical sensors for further use in anthracene determination. The flexible GNW-based electrodes were investigated using differential pulse voltammetry (DPV) in the presence of anthracene. The results showed that the highest sensitivity in anthracene detection was provided by the sensor with the GNW film obtained after 45 min of PECVD growth. The optimization of the GNW film thickness for the development of flexible electrochemical sensors on polyethylene substrates represents a successful approach for enhancing the electrochemical performance of carbonic materials.

Ultra‐Sensitive, Self‐powered, CMOS‐Compatible Near‐Infrared Photodetectors for Wide‐Ranging Applications

AbstractSelf‐powered near‐infrared (NIR) photodetectors are essential for surveillance systems, sensing in IoT electronics, facial recognition, health monitoring, optical communication networks, night vision, and biomedical imaging. However, silicon commercial detectors need external power to operate and cooling to suppress large dark currents. This work demonstrates a new class of CMOS‐compatible self‐powered NIR photodetector based on ferroelectric 5‐nm thick ZrO2 films which do not require cooling and therefore have two key advantages over Si, and at the same time have comparable performance metrics. At room‐temperature, under 940 nm wavelength illumination (1.4 mW cm−2 power density, 10 Hz repetition rate), and without any power applied, fast rise and fall times of ≈2 and 4 µs, respectively, are achieved in Al/Si/SiOx/ZrO2/ITO devices, along with responsivity, detectivity and sensitivity values of up to ≈3.4 A W−1, 1.2 × 1010 Jones and 4.2 × 103, respectively, far exceeding all other emerging self‐powered systems. Furthermore, dual‐band NIR detection is shown for different NIR wavelengths, proof‐of‐concept feasibility being demonstrated for the smart identification of NIR targets. Therefore, it is demonstrated, for the first time, that coupling together the pyroelectric effect, the photovoltaic effect, and the ferroelectric effect is a novel method to significantly enhance the performance of CMOS‐compatible ZrO2‐based self‐powered photodetectors in the NIR region.

Two-core photonic quasicrystal fiber - surface plasmon resonance (PQF-SPR) methane sensor comprising the ZnO/Au composite film: design and FEM simulation

A photonic quasicrystal fiber - surface plasmon resonance (PQF-SPR) methane sensor made up of the eight-fold photonic quasicrystal fiber has been designed and analyzed. The PQF is used to construct the double-core D-type structure with air holes forming a hole groove on the D-type surface. The grooves are plated with ZnO and Au films successively, following the deposition of a methane-sensitive film containing Cryptophane-E. The effects of the air hole diameter, materials, and relative thickness of the composite film on the sensing properties are studied by finite element simulation. The results show that the wavelength sensitivity of the sensor with the ZnO-Au and TiO2-Au composite film with the same thickness is significantly higher than that with a single gold film coating in the methane concentration range of 0%–3.5%, confirming that the composite film enhances the SPR effect and improves the sensing properties. The ZnO-Au composite film has the best properties such as maximum and average wavelength sensitivities of 64 nm/% and 40.24 nm/%, respectively. The performance of this sensor is notably superior to that of comparable methane sensors previously documented.