Foil Thickness Research Articles

Enhancing formability in Micro-Incremental sheet forming by a novel stacking method of ultra-thin sheets

Metallic foils areused extensively in the microelectronics and avionics industries. However, forming these foils into complexshapes is challenging, due to size-effect. The foils are susceptible to bending and distortion under self-weight as they lack stiffness and fail early during forming. Processes, like drawing, stamping, etc. have been explored at the micro-scale, but they are suitable for simpler geometry and low aspect ratio parts. Micro-incremental sheet forming (μISF) is a new flexible forming process that can be used for micro-scale deformation of foils into complexgeometries with higher formability. This work attempts to improve the stiffness and formability of 100 μm thick CP-Ti Gr2 foils by proposing a unique ‘stacking of foils’ (SOF) approach in μISF. In SOF, multiple foils are stacked together which increases their stiffness and plastic deformation. Experimental results demonstrate that formability is considerably improved by about 21–27 %, with better geometrical accuracy of the micro-parts.

Finite Element Analysis and Experimental Verification of Thermal Fatigue of W-PFM with Stacked Structure

As the prime candidate for plasma-facing materials (PFM), the response of tungsten (W) to thermal shock loads is an important research topic for future fusion devices. Under heat loads, the surface of tungsten plasma-facing materials (W-PFM) can experience thermal damage, including brittle cracking and fatigue cracks. Therefore, exploring solutions for thermal damage of W-PFM remains one of the current research focuses. We propose a novel approach to mitigate thermal radiation damage in PFM, namely, the stacked structure W-PFM. The surface thermal stress distribution of the stacked structure W-PFM under heat loads was simulated and analyzed by the finite element method. As the foil thickness decreases, both the peak thermal stresses in the normal direction (ND) and rolling direction (RD) decrease. When the thickness decreases to a certain value, the peak thermal stress in the RD decreases to about 1384 MPa and no longer decreases; while the peak thermal stress in the ND approaches 0 MPa and can be neglected. In the range of approximately 5–100 mm, the accumulated equivalent plastic strain decreases sharply as the thickness decreases; in other thickness ranges, it decreases slowly. Thermal fatigue experiments were conducted on the stacked structure W composed of W foils with different thicknesses and bulk W using an electron beam facility. The samples were applied with a power density of 30 MW/m2 for 10,000 and 20,000 pulses. The cracks on the surface of the stacked structure W extended along the ND direction, while on the surface of bulk W, besides the main crack in the ND direction, a crack network also formed. The experimental results were consistent with finite element simulations. When the pulse number was 10,000, as the thickness of the W foil decreased, the number and width of the cracks on the surface of the stacked structure W decreased. Only four small cracks were present on the surface of stacked structure W (0.05 mm). When the pulse number increased to 20,000, the plastic deformation and number of cracks on the surface of all samples increased. However, the stacked structure W (0.05 mm) only added one small crack and had the smallest surface roughness (Ra = 1.536 μm). Quantitative analysis of the fatigue cracks showed that the stacked structure W-PFM (0.05 mm) exhibited superior thermal fatigue performance.

A comprehensive review on advancements in compliant structures of gas foil journal bearings

Gas foil journal bearings (GFJBs) are widely considered technically advanced bearings and a viable alternative to conventional rolling element and oil-lubricated bearings in high-speed rotating machinery. GFJBs offer advantages such as reduced maintenance, improved efficiency, and the ability to operate in challenging environments. A traditional GFJB consists of (i) a smooth top foil for the generation of hydrodynamic pressure, (ii) a compliant corrugated foil beneath the top foil for tailoring stiffness, and (iii) a bearing base to hold the foils together. The shape and geometry of corrugated thin foil are primarily designed for the essential stiffness and load-carrying capacity of the bearings. The thickness of thin foils is in the range of 100–150 μm. The fabrication of complaint thin foils to their desired shapes and sizes is quite challenging. Engineers and researchers around the world have designed and published various advanced design structures of GFJBs to improve their static and dynamic characteristics. The corrugated or compliant structure is the most significant component of GFJBs from design and fabrication point of view. Therefore, a modest attempt is made by the authors to review and report systematically on various foil journal bearings reported in open literature. The study covers four primary categories, which are centered around the design of compliant structures, materials, manufacturing processes, and coatings over the years. By analyzing the state-of-the-art advancements, this review aims to identify key areas for further research, explain technological trends, and underline the pivotal role of GFJBs in various high-speed applications across industries.

Convective boiling heat transfer enhancement via femtosecond laser textured inclined microfeatures

Designing efficient cooling devices is crucial in a multitude of applications. Although cooling technologies have existed for decades, there is a lack of efficient heat dissipation methods, especially for space applications where thermal management devices must dissipate heat in reduced gravity and where convective boiling heat transfer is frequently employed. In this framework, we evaluate the change in bubble production for different types of surface textures produced on 200 µm thick 316L SS foils using a femtosecond laser. The investigated textures include microscale grooves and conical holes with tilted (= 45°) geometry. In addition, we also evaluate the effect of laser-induced periodic surface structures (LIPSS), which are sub-micron scale features fabricated by fs laser processing. The fluid used is PP1, a replacement of 3M™ FC-72 in heat transfer applications.

Study of the irradiation hardening of a Fe9Cr ferritic model alloy by nanoindentations

This paper presents a series of Berkovich indentation results obtained on unirradiated and 7.2 MeV proton irradiated specimens of a Fe9Cr model alloy with an equiaxed ferritic microstructure. Using a energy degrader wheel made of 24 aluminum foils of different thickness, a flat damage profile of about 50 μm resulted from the irradiation, allowing to perform indentations within a volume material that is homogeneously irradiated. The indentation size effect on measured hardness was analyzed with a model based on the disloction-slip distance theory built on the concept of combined spatial frequency of all obstacles to dislocation motion. The effects on hardness of the tip-specimen contact size (or penetration depth), dislocation density and mean distance between irradiation defects were quantified and discussed. The irradiation hardening was characterized by the increase of hardness determined at large penetration depths.

Dynamic response and roughness control of surface materials on TC4 titanium alloy subjected to laser shock wave planishing

Abstract In this study, ABAQUS was used to predict the dynamic response of surface materials on TC4 titanium alloy during laser shock wave planishing (LSWP). The experiments were conducted to evaluate the simulations. The results indicate that during the initial stage of LSWP, the contact status between the contact foil and the micro-protrusion changes from the one-dimensional stress state to the one-dimensional strain state. This causes the high-amplitude tensile residual stress to converge at the center of the flattened micro-protrusion surface. When treating specimens with high surface roughness, the application of a thin contact foil can significantly lower the height of micro-protrusions and lift the bottom of micro-depressions. This improves the plastic flow of micro-protrusions and prevents the convergence of tensile residual stress. Using a thick contact foil can help extend the pressure pulse duration and prevent the overall surface profile subsidence when treating specimens with lower surface roughness. The outcomes of the experiment and the simulation agree rather well. Additionally, a thick contact foil can reduce the build-up of tensile residual stress by reducing the contact pressure.

Improvement of microstructure and mechanical properties of laser welded Al-Si coated 22MnB5 steel joints by austenitic element copper

In this experiment, the effects of different copper foil thicknesses on the morphology, structure, and mechanical properties of laser lap welded 22MnB5 steel joints were studied. The aim was to reduce the damage of Al-Si coating and increase the mechanical properties of welded joints. As the thickness of copper foil increases from 0 to 100μm, there was a gradual decrease in the presence of δ-ferrite in the fusion zone (FZ) and fusion boundary (FB), while the copper-rich content of lath martensite (LM) gradually increased. The reason was that Cu is an austenite element which can expand the γ phase area and play a stabilizing and strengthening role. The result of JmatPro software can support it. It found peritectic reaction (L+δ→γ) range expanded from 1414 to 1422°C to 1436–1453°C which led to more γ phases formed during the solid-state phase transition (δ→γ) at high temperature. Based on this phenomenon, as the copper foil increased (0–100μm), the joint tensile strength increased from 361 MPa to 706 MPa. However, after adding too much copper foil (200μm), the microstructure of FZ varied to a copper-rich phase (ε-Cu) with low hardness and brittleness which adhered to the martensite grain boundaries and reduced the bonding force of the crystal boundaries, so the the mechanical properties of the weld joint seriously reduced (232 MPa). When the copper foil was thin or non-existent (0–30μm), there was still more delta ferrite in FB (low strength and brittle), and the fracture type of the joint mainly appeared as a cleavage fracture. When adding 100μm copper foil, the fracture expressed ductile fracture due to the interfacial fracture due to the lack of δ-ferrite in FB. If the thickness of Cu increased to 200μm, the fracture changed back to FB which expressed a quasi-cleavage fracture.

Wheatstone bridge sensor arrays in foil by robust μ-via technology combining femtosecond-laser drilling and pulsed electrodeposition

Flexible sensor arrays with multilevel circuits typically require complex production cycles leading to high costs and reliability issues. For establishing flexible arrays of strain sensors in Wheatstone bridge configurations structures on different levels within flexible films have to be connected by robust μ-via technology. Usually, dry etching is used to establish via-holes and direct current (DC) electrodeposition is used to fill them with copper. However, dry etching can lead to damages in the underlying electrode or incomplete removal of polymeric material, as inhomogeneities of polymeric foil thicknesses cannot completely be eliminated. This affects the quality of the plating and the reliability of the μ-via connections. It is aggravated by the fact that DC electroplated copper is often weakened by various defects, such as small voids. This article describes a reliable and less complex fabrication process for a Wheatstone bridge sandwich structure consisting of five polymer interlayers separating four metal layers. The femtosecond-laser μ-via drilling proved to be fast, material selective and therefore tolerant to inhomogeneities of polymeric foil thicknesses. Moreover, pulsed current (PC) electrodeposition significantly improved the quality of the copper filling. No voids were found using electron microscopy. Finally, the respiration monitoring sensors produced using this method were subjected to repetitive cycles of bending and relaxation. At a frequency of five cycles per second, reproducible cycles of signal changes were obtained, indicating the usefulness for detecting respiratory cycles of premature infants.

Establishing theoretical foundations for predicting the structural and morphological characteristics of diffusion-welded joints of the beryllium–copper composite

The paper presents the results of theoretical and experimental studies regarding the quality of diffusion welding of the beryllium–copper composite. Numerical investigations of the parameters of heterodiffusion of diffusants and the thickness of the Be–Cu pair welded joint under varying temperature-time conditions were conducted. The analytical examinations revealed that the thickness of the diffusion weld at the Be–Cu joint varies between 26 and 345 µm, with the temperature increasing from 800 to 1000 °C and the holding time ranging from 20 to 120 min. The calculated layer thickness during the diffusion welding of a Be–Cu pair at 800 °C for 2 h is 65 µm, with 15 µm on the beryllium side and 50 µm on the copper side. Notably, a CuBe3 intermetallic compound zone can form in the diffusion weld, which should be considered an adverse factor that reduces the mechanical properties. To theoretically substantiate the modification of the structure and properties of the diffusion zone, a numerical study of welding was carried out using a 10 μm thick nickel foil spacer, which is readily soluble in beryllium. It was demonstrated that after exposure to temperature-time conditions at 900 °C for 20 min, a 50 µm wide diffusion-bonded joint is formed. Its structure includes two single-phase zones of solid solutions based on copper and beryllium, as well as two two-phase regions consisting of solid solutions hardened with intermetallic compounds. Since the weld lacks structural zones consisting solely of intermetallic compounds (unlike when welding the Be–Cu diffusion pair), there are grounds to anticipate a reduction in the embrittling effect on the weld. The results obtained from the analytical studies can serve as the foundation for a theoretical prediction method for assessing the quality of diffusion welding of the beryllium–copper composite.

Comparative dose distribution profiles in a water-filled tube, jet, and tray treated with 1–5 MeV electrons

Accelerated electrons up to 5 MeV energy are relatively low-penetrating, and in the second half of the penetration length, the non-uniformity of energy deposition can increase by 20–50% per 1 mm of material depth. This feature of 1–5 MeV electrons, widely used in technology and research, as well as the high cost of beam power, requires the researcher to have the skills to identify areas of optimal energy deposition and develop measures to reduce energy loss. This work examines the dependence of the average absorbed dose and dose non-uniformity for three modes of electron beam treatment of water, taking into account the beam direction (horizontal or vertical, 1–5 MeV), beam window foil thickness (20–100 μm Al or Ti) and glass wall thickness (0.2–2 mm Pyrex). The dependencies are applicable to clarify, predict and analyze the dose distribution in a liquid irradiated in a tube, jet or tray.

Surface roughness evolution and heterogeneous plastic deformation of austenitic stainless steel during micro deep drawing: Modeling and experiment

The present work involves the numerical simulation and experimental study on the surface roughness evolution and heterogeneous plastic deformation (strain localization and concomitant surface morphology evolution) in grain scale of micro deep drawn parts of austenitic stainless steel (ASS) 304 foils. A three-dimensional modeling framework was used to simulate the micro deep drawing (MDD) process. The simulation involved the development of a Voronoi-based polycrystalline geometry model (VPGM), a multi-stress-strain response model, and a crystal plasticity finite element methods (CPFEM) model. The results indicate that CPFEM model exhibits higher accuracy in the localized stress and strain, thickness distribution fluctuation and surface roughness evolution of the fabricated parts compared to multi-stress-strain response model. Therefore, the plastic deformation heterogeneity in MDD is in-depth discussed based on CPFEM model. The results show that the coarse-grained foils correspond to the intense strain localization, which is the main cause of surface roughening. Considering the average grain size is close to the thickness of ASS foils, mounding features on the rough surface may readily develop further into potentially fractured sites during deformation. On the other hand, crystal orientation influence plastic deformation by affecting the slip behavior of materials. The effect of crystal orientations including {011} 〈211〉 (Brass), {011} 〈100〉 (Goss), and {112} 〈110〉 components on deformation is discussed. The results indicate a strong correlation between the magnitude of the Schmid's factor and the ease of deformation. Additionally, variations in Schmid's factor across different directions result in differences in deformation accumulation, which affects the thickness distribution along the radial direction and the distribution of earrings and wrinkles along the circumferential direction of the fabricated micro parts.

Study on static load performance of FMLs based on ultra-thin stainless-steel foils and cross-ply thin CFRP

The ultra-thin stainless steel/CFRP laminates overcome the limitations in application due to the weight drawbacks of conventional thick cold-rolled stainless steel. By laminating these two high-performance materials, it allows enhanced design flexibility and exceptional formability, rendering them highly promising in various industries such as automotive structures, shipbuilding, and electronics. The existing research on steel/CFRP laminates primarily revolves around locally reinforcing CFRP with cold-rolled plates of typical thickness (≥1 mm). Nonetheless, there remains a dearth of investigations examining the mechanical properties of laminates with varying metal thicknesses under the same volume fraction, particularly for ultra-thin stainless steel below 0.1 mm in thickness. In this study, to investigate the influence of micron-scale thickness ultra-thin stainless-steel foils on the performance of fiber metal laminates (FMLs), the laminates were manufactured and characterized using stainless-steel foils with thicknesses of either 0.05 mm or 0.025 mm. The tension and bearing properties of cross-ply thin CFRP (30 g/m2) laminates were examined both with and without the incorporation of ultra-thin stainless-steel foils. The findings confirmed that a substantial improvement in tensile strength of up to 35 % when ultra-thin stainless-steel foils were incorporated, accompanied by a remarkable increase in modulus by 65 %. Furthermore, the addition of stainless-steel foils to CFRP composites shifted their failure mode from brittle failure to progressive damage during three-point bending tests. Notably, utilizing 0.025 mm thick stainless-steel foils not only enhanced the strength and modulus but also mitigated post-yield stiffness loss compared to FMLs incorporating 0.05 mm thick stainless-steel foils for cross-ply thin CFRP laminates. Further researches revealed that ultra-thin stainless-steel foils with a thickness of 0.025 mm exhibited improved compatibility for deformation with cross-ply thin CFRP as evidenced by both tensile and bending damage behavior.

Li Stripping Behavior of Anode‐Free Solid‐State Batteries Under Intermittent‐Current Discharge Conditions

AbstractAnode‐free manufacturing holds promise to enable high energy densities and lower Lithium (Li)‐metal solid‐state batteries (LMSSBs). Nevertheless, in contrast to thick Li foil (>50 µm), the stripping capacity of in situ‐formed Li (10–30 µm) is limited due to diminished creep flow, resulting in reduced accessible capacity. This study explores the correlation between stripping capacity and surface roughness of garnet Li7La3Zr2O12 (LLZO) solid electrolyte. The results reveal that stripping capacity can be enhanced through the surface modification of solid electrolytes. Additionally, this study scrutinizes the stripping behavior of in situ Li under intermittent‐current discharge conditions, which are more relevant to the operational conditions of electric vehicles (EVs). It is demonstrated that, when compared to constant‐current stripping, intermittent‐current stripping effectively suppresses void formation and enhances the stripping capacity of in situ Li by 40%. It is considered that the intermittent current inhibits the accumulation of Li vacancies, thereby delaying the void formation. These findings provide valuable insights into the development of high‐performance anode‐free LMSSBs for EVs.

The Influence of Machining Conditions on the Orientation of Nanocrystallites and Anisotropy of Physical and Mechanical Properties of Flexible Graphite Foils.

The physical and mechanical properties and structural condition of flexible graphite foils produced by processing natural graphite with nitric acid, hydrolysis, thermal expansion of graphite and subsequent rolling were studied. The processes of obtaining materials and changing their characteristics has been thoroughly described and demonstrated. The structural transformations of graphite in the manufacture of foils were studied by X-ray diffraction analysis (XRD) and transmission electron microscopy (TEM). A decrease in the average size of the coherent scattering regions (CSR) of nanocrystallites was revealed during the transition from natural graphite to thermally expanded graphite from 57.3 nm to 20.5 nm at a temperature of 900 °C. The rolling pressure ranged from 0.05 MPa to 72.5 MPa. The thickness of the flexible graphite foils varied from 0.11 mm to 0.75 mm, the density-from 0.70 to 1.75 g/cm3. It was shown that with an increase in density within these limits, the compressibility of the graphite foil decreased from 65% to 9%, the recoverability increased from 5% to 60%, and the resiliency decreased from 10% to 6%, which is explained by the structural features of nanocrystallites. The properties' anisotropy of graphite foils was studied. The tensile strength increased with increasing density from 3.0 MPa (ρ = 0.7 g/cm3) to 14.0 MPa (ρ = 1.75 g/cm3) both in the rolling direction L and across T. At the same time, the anisotropy of physical and mechanical properties increased with an increase in density along L and T to 12% with absolute values of 14.0 MPa against 12.5 MPa at a thickness of 200 μm. Expressed anisotropy was observed along L and T when studying the misorientation angles of nanocrystallites: at ρ = 0.7 g/cm3, it was from 13.4° to 14.4° (up to 5% at the same thickness); at ρ = 1.3 g/cm3-from 11.0° to 12.8° (up to 7%); at ρ = 1.75 g/cm3-from 10.9° to 12.4° (up to 11%). It was found that in graphite foils, there was an increase in the coherent scattering regions in nanocrystallites with an increase in density from 24.8 nm to 49.6 nm. The observed effect can be explained by the coagulation of nanocrystallites by enhancing the Van der Waals interaction between the surface planes of coaxial nanocrystallites, which is accompanied by an increase in microstrains. The results obtained can help discover the mechanism of deformation of porous graphite foils. The obtained results can help discover the deformation mechanism of porous graphite foils. We assume that this will help predict the material behavior under industrial operating conditions of products based flexible graphite foils.

First Monte Carlo beam model for ultra-high dose rate radiotherapy with a compact electron LINAC.

FLASH radiotherapy based on ultra-high dose rate (UHDR) is actively being studied by the radiotherapy community. Dedicated UHDR electron devices are currently a mainstay for FLASH studies. To present the first Monte Carlo (MC) electron beam model for the UHDR capable Mobetron (FLASH-IQ) as a dose calculation and treatment planning platform for preclinical research and FLASH-radiotherapy (RT) clinical trials. The initial beamline geometry of the Mobetron was provided by the manufacturer, with the first-principal implementation realized in the Geant4-based GAMOS MC toolkit. The geometry and electron source characteristics, such as energy spectrum and beamline parameters, were tuned to match the central-axis percentage depth dose (PDD) and lateral profiles for the pristine beam measured during machine commissioning. The thickness of the small foil in secondary scatter affected the beam model dominantly and was fine tuned to achieve the best agreement with commissioning data. Validation of the MC beam modeling was performed by comparing the calculated PDDs and profiles with EBT-XD radiochromic film measurements for various combinations of applicators and inserts. The nominal 9 MeV electron FLASH beams were best represented by a Gaussian energy spectrum with mean energy of 9.9 MeV and variance (σ) of 0.2 MeV. Good agreement between the MC beam model and commissioning data were demonstrated with maximal discrepancy<3% for PDDs and profiles. Hundred percent gamma pass rate was achieved for all PDDs and profiles with the criteria of 2mm/3%. With the criteria of 2mm/2%, maximum, minimum and mean gamma pass rates were (100.0%, 93.8%, 98.7%) for PDDs and (100.0%, 96.7%, 99.4%) for profiles, respectively. A validated MC beam model for the UHDR capable Mobetron is presented for the first time. The MC model can be utilized for direct dose calculation or to generate beam modeling input required for treatment planning systems for FLASH-RT planning. The beam model presented in this work should facilitate translational and clinical FLASH-RT for trials conducted on the Mobetron FLASH-IQ platform.

Effect of varying stiffness of top foil on the performance of Air foil thrust bearing (AFTB)

Air foil thrust bearings (AFTB) are essential components in various rotating machinery, such as gas turbines and turbochargers, designed to support higher loads while minimizing friction and wear. The project aims to investigate the effect of varying stiffness of the top foil on the performance of air foil thrust bearings. The stiffness of the top foil is a critical parameter that influences the bearing's load-carrying capacity, stability, and overall efficiency. The geometric parameters like foil geometry, sector angle of top foil, initial angle of top foil and thickness of top foil and operating parameters like runner speed, gap between top foil and runner, will affect the load carrying capacity of the thrust bearing. The study involves both static analysis and dynamic analysis to comprehensively evaluate how changes in top foil stiffness affect the bearing's operational characteristics. The geometric parameters like foil geometry, sector angle of top foil, initial angle of top foil and thickness of top foil are considered for the study. The results of these analyses will be used to validate how the varying geometrical parameters impact the stiffness of the Air foil thrust bearing. This will provide practical insights into the real-world performance of air foil thrust bearings with varying top foil stiffness. The findings of this research will have significant implications for the design and optimization of air foil thrust bearings in various industrial applications. By understanding how changes in top foil stiffness affect the bearing's performance, engineers and researchers can enhance the efficiency and reliability of rotating machinery, ultimately contributing to improved energy efficiency and reduced maintenance costs.

Cu-based thin rolled foils: relationship among alloy composition, micromechanical and antiviral properties against SARS-CoV-2

The healthcare-associated infections (HAIs) and pandemics caused by multidrug-resistant (MDR) and new-generation pathogens threaten the whole world community. Cu and its alloys have been attracting widespread interest as anti-contamination materials due to the rapid inactivation of MDR-superbugs and viruses. Applying thin Cu-based foils on pre-existing surfaces in hygiene-sensitive areas represents a quick, simple, cost-effective self-sanitising practice. However, the influence of chemical composition and microstructure should be deeply investigated when evaluating the antimicrobial capability and durability of Cu-based materials. The effect of composition on micromechanical and antiviral properties was investigated by comparing Cu15Zn and Cu18Ni20Zn (foil thickness from 13 to 27 μm) with Phosphorous High-Conductivity (PHC) Cu. The influence of recrystallisation annealing of PHC Cu was also investigated. Microstructural characterisation was carried out by optical (OM) and scanning electron (FEG-SEM) microscopy, Energy-dispersive Spectroscopy (EDS) and Electron-Backscattered Diffraction (EBSD). The micromechanical behaviour was assessed by microhardness, microscale abrasion and scratch tests. Cu-based foils were exposed to SARS-CoV-2 for different time points in quasi-dry conditions (artificial sweat solution), evaluating their antiviral capability by quantitative Reverse-Transcriptase Polymerase Chain Reaction (qRT-PCR). Surface morphology, contact angle measurements and Cu release were measured. All Cu-based surfaces completely inactivated SARS-CoV-2 in 10 min: pure Cu was the best option regarding antiviral efficiency, while Cu15Zn showed the best trade-off between micromechanical and antiviral properties.

Preparation of ultra-thin copper–aluminum composite foils for high-energy–density lithium-ion batteries through synergistic electroless plating and electroplating

Copper-aluminum composite foils have the advantages of excellent electrical and mechanical properties, lightweight, and low cost. However, overcoming the equipment limitations of physical preparation methods to produce ultra-thin copper–aluminum composite foils with outstanding properties has been a challenge. Herein, smooth-faced, dense, and tightly bonded copper–aluminum composite foils are prepared using a combination of electroless plating and electroplating. This process involves the use of tin and nickel as transition layers, followed by electroplating the copper-clad layer. Ultra-thin copper–aluminum composite foils with a copper layer thickness ranging from 0.5 to 7 μm and a minimum square resistance of 4.6 mΩ can be prepared with a mass of 36.7 %-70 % of that of pure copper foils of the same thickness. These foils are expected to be used in a variety of energy storage components that require extreme lightweight.

Optimizing Load Capacity Predictions in Gas Foil Thrust Bearings: A Novel Full-Ramp Model

Gas film thickness significantly influences the performance prediction of Gas Foil Thrust Bearings (GFTB). However, the Classical Model (CM) for GFTBs exhibits inaccuracies in describing gas film thickness. In this paper, we explore the differences in the details of gas film thickness modeling and propose a Parallel Segmentation Model (PSM), which fixes the errors of the CM in describing the gas film thickness in the ramp section, and a Full-Ramp Model (FRM), to which a more realistic description of the gas film in the flat section is also added. Comparative analysis, utilizing a publicly available test dataset based on the open-source GFTB structure, establishes that the FRM surpasses the CM and PSM in accurately predicting load capacity. In-depth analysis shows that the location of the minimum gas film thickness for determining the load capacity is located at the innermost circle of the free end of the top foil, whereas the FRM is subjected to the same load with a larger film thickness at this location, which may be due to the unique geometry of the top foil of the FRM. Subsequently, employing the FRM, a parametric study explores load capacity in GFTB, considering variables such as ramp height, top foil thickness, bump foil stiffness, ramp section extent, and top foil area. The results demonstrate that GFTB load capacity exhibits a linear increase with the expansion of the top foil area. Moreover, the load capacity increases with augmented top foil thickness and bump foil stiffness, albeit at a decreasing rate. Additionally, an increase in ramp section extent initially enhances load capacity, reaching a maximum value before declining. Similarly, an increase in ramp height initially augments load capacity, attaining a maximum before subsequent diminution.

High-energy electron measurements with thin Si detectors

A technique for measuring high-energy electrons using Si detectors of various thicknesses that are much smaller than the range of the examined electrons is presented. The advantages of the method are discussed on the basis of electron–positron pair creation recently studied in deuteron–deuteron fusion reactions at very low energies. Careful Geant4 Monte Carlo simulations enabled to identify the main spectral contributions of emitted electrons and positrons resulting from the energy loss mechanisms and scattering processes within the target, detector and their holders. Significant changes in the intensity of the detected electrons, depending on the detector thickness and the thicknesses of absorption foils placed in the front of the detector could be observed. The corresponding correction factors have been calculated and can be used for different applications in basic and applied research.