High Deposition Rate Research Articles

A Macroeconomic Model of Central Bank Digital Currency

We develop a quantitative New Keynesian DSGE model to study the introduction of a central bank digital currency (CBDC): government-backed digital money available to retail consumers. At the heart of our model are monopolistic banks with market power in deposit and loan markets. When a CBDC is introduced, households benefit from an expansion of liquidity services and higher deposit rates as bank deposit market power is curtailed. However, deposits also flow out of the banking system and bank lending contracts. We assess this welfare trade-off for a wide range of economies that differ in their level of interest rates. We find substantial welfare gains from introducing a CBDC with an optimal interest rate that can be approximated by a simple rule of thumb: the maximum between 0% and the policy rate minus 1%.

The Impact of Indoor Air Humidity on the Infiltration of Ambient Particles

Ambient particles contribute to occupant exposure as they infiltrate indoor environments through building envelope cracks, impacting indoor air quality. This study investigates the impact of indoor air humidity on the infiltration of ambient particles, highlighting humidity’s crucial role in influencing particle dynamics in indoor environments. Employing a controlled chamber system, we conducted experiments to quantify the infiltration of size-resolved particles under varying relative humidity (RH) conditions. Both the total number and the mass concentration of particles increased with RH in the experimental chamber. The smallest particles (0.3–0.4 μm) experienced reduced infiltration at higher RH levels due to hygroscopic growth, while intermediate-sized particles showed increased infiltration, resulted from coagulation effects. Large particles (>1.0 μm) demonstrated reduced infiltration factors, caused by lower penetration and higher deposition rates, with minimal impact from RH changes. Our findings reveal that RH influences particle hygroscopic growth, deposition rate, and coagulation process, thereby affecting indoor particle size distribution and concentration.

P–i–n photodetector with active GePb layer grown by sputtering epitaxy

In this paper, single-crystal GePb films were obtained by magnetron sputtering with high substrate temperature and rapid deposition rate. The GePb films have high crystalline qualities and smooth surface. The Pb content reached 1.29% and no segregation was observed. Based on this, a GePb based p–i–n photodetector was successfully prepared. The device showed a RT dark current density of 5.83 mA cm−2 at −1.0 V and a cutoff wavelength of 1990 nm, which covers all communication windows. At the wavelength of 1625 nm, responsivity of the photodetector reached 0.132 A W−1 at −1.0 V. The device demonstrates potential application in optical communications.

Effect of substrate bias on the formation of nanotwin and properties in Cu thin films for advanced packaging technology

Materials with nanotwinned structures have drawn much attention due to their unique properties. The high-density nanotwinned Cu films are generally deposited at room temperature with high deposition rate. In this study, we report nanotwins can be formed in the Cu films at 150 °C with the aid of the ion bombardment effect caused by applied substrate bias. Cu thin films were deposited on Si (100) substrate by the unbalanced magnetron sputtering system using different applied substrate biases ranging from 0 V to −160 V. The results show that, with a suitable applied substrate bias of −120 V, the twinning density of the Cu films can reach over 80 % and exhibit a high hardness of 3.1 GPa. This study provides a concept to tailor the microstructure of the sputtered Cu films by tuning applied substrate biases and realizing the mechanism of substrate bias on the twin formation during deposition.

Millisecond X-ray reflectometry and neural network analysis: unveiling fast processes in spin coating.

X-ray reflectometry (XRR) is a powerful tool for probing the structural characteristics of nanoscale films and layered structures, which is an important field of nanotechnology and is often used in semiconductor and optics manufacturing. This study introduces a novel approach for conducting quantitative high-resolution millisecond monochromatic XRR measurements. This is an order of magnitude faster than in previously published work. Quick XRR (qXRR) enables real time and in situ monitoring of nanoscale processes such as thin film formation during spin coating. A record qXRR acquisition time of 1.4 ms is demonstrated for a static gold thin film on a silicon sample. As a second example of this novel approach, dynamic in situ measurements are performed during PMMA spin coating onto silicon wafers and fast fitting of XRR curves using machine learning is demonstrated. This investigation primarily focuses on the evolution of film structure and surface morphology, resolving for the first time with qXRR the initial film thinning via mass transport and also shedding light on later thinning via solvent evaporation. This innovative millisecond qXRR technique is of significance for in situ studies of thin film deposition. It addresses the challenge of following intrinsically fast processes, such as thin film growth of high deposition rate or spin coating. Beyond thin film growth processes, millisecond XRR has implications for resolving fast structural changes such as photostriction or diffusion processes.

The Effects of Processing Parameters during the Wire Arc Additive Manufacturing of 308L Stainless Steel on the Formation of a Thin-Walled Structure.

Wire arc additive manufacturing (WAAM) excels in producing medium to large components with a high deposition rate. Process optimization is crucial for uniform, defect-free components. This research employs orthogonal experimental design and response surface methodology (RSM) to control TIG WAAM-ed 308L stainless steel components. Varied parameters, including tungsten electrode angle, welding current, and speed, target weld bead attributes. Analysis of variance (ANOVA) evaluates multi-processing parameter influence on weld bead formation. Comparison with experimental results confirms accurate modeling of the relationship between parameters and bead attributes. The study optimizes process parameters and swing to enhance dimensional accuracy in single-layer and multi-layer components, improving precision, quality, and accuracy in thin-walled structures.

Fabrication of pH-Responsive PDPAEMA Thin Film Using a One-Step Environmentally Friendly Plasma Enhanced Chemical Vapor Deposition

In recent years, there has been growing interest in pH-responsive polymers. Polymers with ionizable tertiary amine groups, which have the potential to be used in many critical application areas due to their pKa values, have an important place in pH-responsive polymers. In this study, poly(2-Diisopropyl aminoethyl methacrylate) (PDPAEMA) thin films were coated on various substrates such as glass, fabric, and silicon wafer using a one-step environmentally friendly plasma enhanced chemical vapor deposition (PECVD) method. The effects of typical PECVD plasma processing parameters such as substrate temperature, plasma power, and reactor pressure on the deposition rate were studied. The highest deposition rate was obtained at a substrate temperature of 40 °C, a reactor pressure of 300 mtorr, and a plasma power of 60 W. The apparent activation energy was found to be 17.56 kJ/mol. Based on the results of this study, uniform film thickness and surface roughness were observed in a large area. The PDPAEMA thin film was exposed to successive acid/base cycles. The results showed that the pH sensitivity of the thin film produced by the PECVD method is permanent and reversible.

Advances in Additive Friction Extrusion Deposition (AFED): Process and Tool Design

Additive friction extrusion deposition (AFED) is a recently developed additive manufacturing technique that promises high deposition rates at low forces. Due to the novelty of the process, the underlying phenomena and their interactions are not fully understood, and in particular, the processing strategy and tool design are still in their infancy. This work contributes to the state-of-the-art of AFED through a comprehensive analysis of its working principles and an experimental program, including a representative sample component. The working principle and process mechanics of AFED are broken down into their individual components. The forces and their origins and effects on the process are described, and measures of process efficiency and theoretical minimum energy consumption are derived. Three geometrical features of the extrusion die were identified as most relevant to the active material flow, process forces, and deposition quality: the topography of the inner and outer circular surfaces and the geometry of its extrusion channels. Based on this, the experimental program investigated seven different tool designs in terms of efficiency, force reduction, and throughput. The experiments using AA 6061-T6 as feedstock show that AFED is capable of both high material throughput (close to 550 mm3/s) and reduced substrate forces, for example, the forces for a run at 100 mm3/s remained continuously below 500 N and for a run at 400 mm3/s below 3500 N. The material flow and microstructure of AFED were assessed from macro-sections. Significant differences were found between the advancing and retracting sides for both process effects and material flow. Banded structures in the microstructure show strong similarities to other solid-state processes. The manufacturing of the sample components demonstrates that AFED is already capable of producing industrial-grade components. In mechanical tests, interlayer bonding defects resulted in more brittle failure behavior in the build direction of the structure, whereas in the horizontal direction, mechanical properties corresponding to a T4 temper were achieved.

Additive friction stir deposition of super duplex stainless steel: Microstructure and mechanical properties

Additive Friction Stir Deposition (AFSD) is an emerging solid-state metal additive manufacturing (AM) process that offers several key benefits, including high deposition rates and wrought-equivalent mechanical properties even in the as-deposited condition. The work presented is the first study to report on the development of microstructure and mechanical properties of AFSD-processed duplex stainless steel (DSS2507). The banded microstructure of the starting material was remarkably affected by AFSD processing; the austenite grains exhibited a refined and equiaxed morphology, while the ferrite grains appeared slightly larger and elongated. Microstructural observations revealed that the potential mechanism of microstructure evolution in austenite was discontinuous dynamic recrystallization (DDRX), while in ferrite, it was continuous dynamic recrystallization (CDRX). The occurrence of multiple thermal cycles during the AFSD process resulted in σ phase precipitation, which in turn led to considerable variation in mechanical properties with respect to the build direction. The top region of the as-built part with an insignificant σ phase fraction showed improved tensile strength and ductility combination compared to the as-received DSS2507 as well as other AM-processed DSS2507 alloys.

Impact of incorporating FeNbC into weld flux on the abrasive wear resistance of coatings produced by SAW in a microalloyed steel

Owing to the global shortage of raw materials and an increase in their prices, there is a growing demand for engineering solutions to increase the lifespan and durability of equipment and components. Therefore, this study aims to combine surface engineering and welding engineering to produce a niobium-rich coating using submerged arc welding (SAW) deposition. SAW is a cost-effective technique that allows high deposition rates and technical simplicity, which can enhance mechanical properties and resistance to abrasive wear of components. This research involves the addition of a FeNbC powder alloy in percentages of 5, 10, and 15 wt% to a neutral commercial SAW flux, as an alternative to adding Nb to the microstructure of the deposited coating. The coating was characterized by optical microscopy to analyze the microstructure, such as the presence of phases; microhardness through a Vickers micro-durometer, and resistance to abrasive wear through the loss of mass using a rubber wheel-type abrasometer. The wear mechanisms were evaluated using scanning electron microscopy. The results showed that a Nb-rich coating can be deposited via SAW, and the coatings successfully increased microhardness by up to 110% and resistance to abrasive wear to values higher than the base metal used (microalloyed steel). The microstructure formed was rich in Fe2Nb and NbC, proving the formation of Nb-rich phases. Additionally, the mechanism of abrasive wear was predominantly plastic for the base metal and changed to micro-cutting and micro-plowing after the addition of up to 15% of FeNbC.

Cold spray deposition and microstructure characterization of CuNi, CuSn, and CuNiSiCr coatings

Cold spray is a coating deposition technique that enables to produce a large variety of metallic coatings using supersonic powder particles. Pure copper (Cu) has been used as a model material for cold spray due to its high deposition rate. Nevertheless, many Cu alloys that are broadly used in engineering applications, including Cu-10wt%Ni (CuNi), Cu-10wt%Sn (CuSn) and Cu-7wt%Ni-2wt%Si-0.9wt%Cr (MoldMAX V® High Strength Cu), have not been fully investigated in the cold spray process. Thus, there is still a lack of understanding of their deposition process, microstructure evolution and mechanical properties in these Cu-alloy coatings made by cold spray. In this study, we study the deposition efficiencies, porosities, microstructures and hardness of the cold sprayed Cu alloys and elucidate their deformation mechanisms. Our results show that all the coatings have high densities above 99 % and deposition efficiencies ranging from 73 % (CuSn), 80 % (CuNi) to 99.9 % (HS Cu). The average Vickers hardness of the CuNi, CuSn, and HS Cu coating samples are about 130 HV, 160 HV, and 190 HV, respectively, with HS Cu showing the highest work hardening rate. We find that these Cu coatings, particularly CuNi, exhibit heterogeneous microstructures with relatively large grains in the particle interiors and fine grains at the particle-particle interfaces, which are due to serve plastic deformation at the interfacial regions. Nanoindentation maps also show that the local nanohardness distributions are correlated to the heterogeneous microstructure observed.

Bead geometry prediction and optimization for corner structures in directed energy deposition using machine learning

Wire Arc Additive Manufacturing as a Directed Energy Deposition technology has disruptive potential for modern manufacturing. The technology comes with the flexibility and material efficiency of additive manufacturing processes while mitigating the disadvantages through high material deposition rates and high energy efficiency. However, the prevalence of the technology is inhibited by its geometrical inaccuracy and the large induced residual stresses. This work tackles the former problem by capturing the process parameter-geometry relationship using Machine Learning. To do so, multiple mild steel welding beads with varying shape features like corner angles are printed using a Metal Inert Gas welding machine attached to an industrial robot. The cross-sectional profile of the printed beads is measured using a point laser sensor and correlated through a Multilayer Perceptron to input features such as travel speed, wire feed speed, and shape features. By incorporating varying corner angles, a holistic model, not limited to geometry prediction of straight beads only, is trained. Using the model, excess material at the inner angle of corners determined by the overlapping regions of the two adjacent beads can be predicted. By generating a database of possible bead shapes an inverse algorithm that suggests welding parameter combinations that yield a smooth bead shape at the corner is created, thus enabling improvement of the overall accuracy of the Wire Arc Additive Manufacturing process.

Stabilizing Perovskite Pb(Mg0.33Nb0.67)O3-PbTiO3 Thin Films by Fast Deposition and Tensile Mismatched Growth Template.

Because of its low hysteresis, high dielectric constant, and strong piezoelectric response, Pb(Mg1/3Nb2/3)O3-PbTiO3 (PMN-PT) thin films have attracted considerable attention for the application in PiezoMEMS, field-effect transistors, and energy harvesting and storage devices. However, it remains a great challenge to fabricate phase-pure, pyrochlore-free PMN-PT thin films. In this study, we demonstrate that a high deposition rate, combined with a tensile mismatched template layer can stabilize the perovskite phase of PMN-PT films and prevent the nucleation of passive pyrochlore phases. We observed that an accelerated deposition rate promoted mixing of the B-site cation and facilitated relaxation of the compressively strained PMN-PT on the SrTiO3 (STO) substrate in the initial growth layer, which apparently suppressed the initial formation of pyrochlore phases. By employing La-doped-BaSnO3 (LBSO) as the tensile mismatched buffer layer, 750 nm thick phase-pure perovskite PMN-PT films were synthesized. The resulting PMN-PT films exhibited excellent crystalline quality close to that of the STO substrate.

Demonstration of Excellent Crystalline Silicon Surface Passivation (S < 1.27 cm s−1) by High‐Rate DC‐Sputtered Hydrogenated Amorphous Silicon

The surface passivation quality of intrinsic hydrogenated amorphous silicon (i‐a‐Si:H) layers deposited by constant DC power‐facing target sputtering (FTS) technology is investigated. An n‐type crystalline silicon wafer passivated with a 42 nm‐thick i‐a‐Si:H shows an effective carrier lifetime of 11 ms, which corresponds to a low upper limit effective surface recombination velocity Seff of 1.27 cm s−1. An ultrathin 5 nm‐thick i‐a‐Si:H film achieves an implied open‐circuit voltage (iVoc) of 730 mV at a high deposition rate of 31 nm min−1. It is found that constant DC‐FTS does not cause sputtering damage under high deposition rate conditions. This work demonstrates that i‐a‐Si:H deposited by constant DC‐FTS can achieve the same passivation quality as i‐a‐Si:H deposited by plasma‐enhanced chemical vapor deposition or catalytic chemical vapor deposition, paving the way for the fabrication of silicon heterojunction solar cells without the use of explosive and toxic gases.

Wire Based Directed Energy Deposition of JBK-75

Applications and adoption of metal additive manufacturing (AM) are increasing for fabrication of low volume, complex components with novel materials, as well as replacement parts. While the use of powder bed fusion-based processes have been widely used to build complex components with fine feature resolution, there is a volume limitation. Expanding the application of metal AM will rely on other processes that remove this build size constraint. These processes are referred to as Directed Energy Deposition (DED) and can use either powder or wire feedstock. Wire based DED provides the highest deposition rates which shortens the fabrication time making it attractive for fabrication of large parts replacing traditional wrought billets or castings. In this study, an iron-based austenitic superalloy (JBK-75) was deposited using an arc-based, wire-fed (AW)-DED process. The material was metallographically characterized and quasi-static mechanical properties were obtained. The resulting microstructure and mechanical properties are compared with conventional wrought and cast forms of JBK-75 subjected to the same heat treatments. As compared to wrought material, the AW-DED grain size was larger after the heat treatment, although the strengths were similar. Improved homogenization was observed after heat treatment in the AW-DED specimens as compared to the cast specimens.

Effects of Laser Defocusing on Bead Geometry in Coaxial Titanium Wire-Based Laser Metal Deposition.

Coaxial wire-based laser metal deposition is a versatile and efficient additive process that can achieve a high deposition rate in the manufacturing of complex structures. In this paper, a three-beam coaxial wire system is studied, with particular attention to the effects of deposition height and laser defocusing on the resulting bead geometry. As the deposition standoff distance changes, so does the workpiece illumination proportion, which describes the ratio of energy going directly into the feedstock wire and into the substrate. Single titanium beads are deposited at varying defocus levels and deposition rates and the bead aspect ratio is measured and analyzed. Over the experimental settings, the defocusing level and deposition rate were found to have a significant effect on the resulting bead aspect ratio. As the defocusing level is increased away from the beam convergence plane, the spot size increases and the deposited track is wider and flatter. Process parameters can be used to tune the deposited material to a desired aspect ratio. In coaxial wire deposition, defocusing provides an adjustment mechanism to the distribution of heat between the wire and substrate and has an important impact on the resulting deposit.

Explore the growth mechanism of high-quality diamond under high average power density in the MPCVD reactor

Investigating the mechanism behind the high-efficiency deposition of high-quality diamond has always been a prominent topic in related research. This paper investigates the CH4-H2 plasma characteristics and related chemical reaction kinetics in the average power density range of 18–100 W·cm−3, which is a typical range for large-area diamond film deposition. The number densities of H, CH3 and C2H2 increase linearly with the average power density. C2H2 is the main hydrocarbon in the discharge, and CH3 is the main single-carbon hydrocarbon. The number density and radial uniformity of CH3 and C2H2 increase with the average power density, which is necessary for the high rate and uniform deposition of diamond films. The plasma's optical emission spectra indicate an acceleration in the C2 production rate at high power density. The diamond film deposition experiment demonstrates the efficacy of high average power density in achieving high-quality diamond deposition at a high growth rate.

Effect of welding mode on selected properties of additively manufactured AA5087 aluminium alloy parts

Wire and arc additive manufacturing (WAAM) is a popular direct energy deposition (DED) method for producing large-scale metallic components. The main advantages of the technique are a high deposition rate and low cost. Furthermore, the utilization of the WAAM is prevalent in the aerospace industry. The AA5087 aluminium alloy with 4.5 wt.% of magnesium has been investigated because of its excellent properties. The present research deals with the study of thermal cycles and fields developed in the alloy during additive manufacturing with two different Cold metal transfer (CMT) modes, namely conventional (CMT) and cycle-step (CMT-CS). The welding system was equipped with a Fronius TransPulse Synergic 3200 CMT power source, a Fanuc Arc Mate 1000iC 6-axes robot with an R 30iA control unit, a welding torch, and a 1-axis positioner. The AA5087 aluminium alloy welding wire with a diameter of 1.2 mm was deposited onto the AA5083 aluminium alloy plate with dimensions of 70 mm x 200 mm x 3 mm during the experiment. The thermal cycles were documented using an Ahlborn Almemo 5690-2 measuring station equipped with K-type thermocouples. The thermal fields were monitored with a FLIR E95 thermography camera. The results showed the evident influence of arc mode on the temperatures developed in manufactured aluminium alloy parts during the process of WAAM.

Potential–Dependent BDAC Adsorption on Zinc Enabling Selective Suppression of Zinc Corrosion for Energy Storage Applications

Utility-scale zinc (Zn) batteries are a promising solution to address the problem of intermittency of renewable energy sources; however, Zn-metal anodes in these batteries suffer from capacity loss due to spontaneous corrosion of the Zn especially when high-surface area anode configurations are employed. Additionally, Zn dendrites are known to form during battery charging limiting the cycle-life of these batteries. Electrolyte additives have been explored that prevent aforementioned issues, but these too come at a cost, i.e., surface-blocking additives polarize the electrode surface leading to loss in the voltaic and energy efficiencies of the battery. In this contribution, a novel electrolyte additive, benzyldimethylhexadecylammonium chloride (BDAC), is investigated for its ability to suppresses corrosion of Zn in an acidic (pH = 3) electrolyte. An attribute of BDAC distinct from previously studied additives is that it selectively suppresses electrochemical activity when the Zn electrode is at its corrosion potential; however, during high-rate Zn deposition (charging) or stripping (discharging), BDAC is essentially deactivated and thus it does not appreciably polarize the electrode surface, thus minimizing voltaic efficiency losses. This selective corrosion suppression behavior is explored using slow-scan voltammetry, which reveals hysteresis implying a potential- or current-dependent BDAC adsorption mechanism in which BDAC reaches higher surface coverages when the partial currents at the Zn surface are low (e.g., at or near the corrosion potential), but BDAC coverage is reduced considerably when the Zn deposition or stripping rates are increased. Numerical simulations of the BDAC diffusion-adsorption process corroborate this mechanism. Ramifications of our approach to the selective suppression of Zn dendrites are discussed.

Statistical Analysis of Morphological Characteristics of Inconel 718 Formed by High Deposition Rate and High Laser Power Laser Cladding.

Laser cladding is one of the emerging additive manufacturing technologies and has been adopted in various industrial fields. In this study, the morphological characteristics of a single clad of Inconel 718 manufactured by coaxial laser cladding with high laser power from 4200 W to 5400 W, powder feeding rate from 25 g/min to 50 g/min, and cladding speed from 20 mm/s to 50 mm/s are studied. The cross-section of the melt pool is analyzed and classified by type into three types: shallow dilution, flat dilution, and fluctuating dilution. Nine parameters are designed to describe the morphological characteristics of the clad, and the corresponding linear regression models are developed to establish a quantitative relationship between the combined process parameters and morphological characteristics. The results indicate that the total area of the cross-section A, the clad area above the substrate Ac, the area of the molten substrate Am, the total height of the cross-section H, the height of the clad above the substrate hc, the penetration depth hm, the clad width W, the dilution ratio D, and the wetting angle θ are determined by complex coupling of energy input and mass accumulation, and they are proportional to PF0.4/V, P0.5F/V, P/F0.2/V0.4, P2F0.6/V, PF0.7/V, P2/F/V0.3, P/V0.8, P/FV0.2, and PF7/V0.8, respectively. The large linear regression coefficients and the analysis residuals indicate the high reliability of the statistical linear regression models. This work aims to provide a comprehensive understanding of the influence of the main processing parameters on the morphological characteristics of the clad, which is of great value in providing a reference and laying a basis for the practical application of laser cladding technology at a high deposition rate.