High Deposition Rate Research Articles

Gas Flow Sputtering of Pt/C Films and their Performance in Electrocatalytic Hydrogen Evolution Reaction.

A single step deposition technique of Pt/C films for electrocatalytic applications is presented. The hollow cathode gas flow sputtering (GFS) method allows a catalyst production within few minutes without further steps. The herein presented films consist of small Pt nanocrystals (2-5 nm) deposited in a matrix of nanocrystalline carbon. The films show a low and stable overpotential under acidic conditions in the hydrogen evolution reaction (HER). Relatively low Pt-mass activity (<1 mA/μgPt ) is attributed to the yet too high Pt-content in the films. Another issue discovered in this work is a non-graphitic state of carbon resulting in its high resistivity. Still, the GFS deposition technique providing by nature high deposition rates and a substance-to-material yield of 80-90 % is advantageous than other sputtering techniques and especially chemical methods in that sense. This technique is scalable to areas in the range of square meters and thus represents an attractive way to efficiently produce large-scale cathode coatings for industrial electrolysers.

Assessment of additive and subtractive sustainable manufacturing of Inconel 625

This study assesses the sustainable subtractive manufacturing of Wire Arc Additive Manufactured (WAAMed) Inconel 625 (IN625). Compared to other additive manufacturing techniques, WAAM is economically efficient and has a higher deposition rate. However, post-subtractive manufacturing operations are often required for additive manufactured (AMed) parts to make them ready for industrial applications. Drilling trials were conducted on AMed and wrought IN625 under three environments: dry, flood and cryogenic. Their machinability was evaluated in terms of cutting forces, torque, power consumption as well as surface roughness. Also, the surface morphology of drill tools, drilled holes and machined chips were analysed and compared. Results show that the cryogenic environment enhances tool life and surface integrity for drilling of WAAMed parts, whereas flood environment emerged as a better cooling/lubricating condition for machining wrought specimens.

On the Influence of Heat Input on Ni-WC GMAW Hardfaced Coating Properties.

Hardfacing is one of the techniques used for part lifecycle elongation. Despite being used for over 100 years, there still is much to discover, as modern metallurgy provides more and more sophisticated alloys, which then have to be studied to find the best technological parameters in order to fully utilize complex material properties. One of the most efficient and versatile hardfacing approaches is Gas Metal Arc Welding technology (GMAW) and its cored-wire equivalent, known as FCAW (Flux-Cored/Cored Arc Welding). In this paper, the authors study the influence of heat input on the geometrical properties and hardness of stringer weld beads fabricated from cored wire consisting of macrocrystalline tungsten carbides in a nickel matrix. The aim is to establish a set of parameters which allow to manufacture wear-resistant overlays with high deposition rates, preserving all possible benefits of this heterogenic material. This study shows, that for a given diameter of the Ni-WC wire, there exists an upper limit of heat input beyond which the tungsten carbide crystals may exhibit undesired segregation at the root.

Unraveling the failure mechanism of wire arc additive manufactured low carbon steel under tensile and high cycle fatigue loading

Wire arc additive manufacturing (WAAM) is one of the common additive manufacturing processes for efficiently building large components due to its high deposition rate and higher catchment efficiency with an easy and relatively simpler arrangement. However, WAAM components often observe defects that adversely affect some mechanical properties. The present work employs a two-camera digital image correlation (DIC)-based technique for simultaneous strain measurements on two mutually orthogonal surfaces to capture the strain accumulation due to defects and subsequent failure behavior under uniaxial tensile loading of WAAM deposited ER70S-6 low carbon steel samples. The elastic cyclic loading tests are also performed at different stress amplitudes, and their fracture surfaces are analyzed with scanning electron microscopy. Due to the weak interlayer consolidation, multiple delaminations and strain accumulation sites are observed. Propagation of delamination contributed towards the failure, and dimples as well as intergranular fractures are observed on failure surfaces. Premature failure with a reduced number of cycles to failure is observed during high cycle fatigue tests due to catastrophic fast failure in the neighborhood of the internal defects. While the fatigue crack initiation and propagation are distinctly observed on fracture surfaces, transition regions from fatigue fracture and fast fracture are mostly obscure.

P-type nickel oxide deposited by reactive hollow cathode gas flow sputtering for the potential usage in thin-film transistors

Thin Nickel Oxide film were deposited by reactive pulsed-direct current hollow cathode gas flow sputtering. This unique technique allows for sputtering magnetic target materials with very high rates without magnetron. Deposition was carried out from a nickel target at room temperature. The influence of process parameters on optical, electrical, and structural film properties are investigated. High deposition rates of 6 nm/s and 2 nm/s are achieved for both direct current and pulsed-direct current power supply. All films are highly resistive and show p-type conduction that is tunable with oxygen flow. The films exhibit optical band gap around 3,8 eV depending on process parameters like oxygen flow and pulsing parameter. Secondary electron microscopy shows pillar-like growth perpendicular to the surface, while grazing incidence X-ray diffraction reveals smaller, randomly oriented crystals. Electrical properties of the films were tested by Hall measurements, revealing mobilities in the range of 1 cm2Vs. The nano crystalline thin films were tested in staggered bottom gate Thin-Film Transistor structures for potential use as channel layer.

Impact of spray angle and particle velocity in cold sprayed IN718 coatings

Cold spray (CS) deposition has potential applications in repair technology or additive manufacturing due to its ability to operate at low temperatures, achieve high deposition rates, and produce thick, dense coatings. For adoption of CS in repair applications, it is crucial to evaluate the influence of spray angles since geometry of repair zones are typically complex and non-flat. In this work, we investigated the influence of spray angles and particle velocities on the cold spray deposition of Inconel 718 (IN718) powder particles using N2 as propellant gas. Three oblique spray angles including 50, 60 and 70° were compared with the 90° normal spray angle for cold spray deposition of IN718 powders on Al6061 substrate. Three sets of cold spray parameters at each spray angle, giving particle velocities from 820 to 920 m/s were employed to study their effect on the coating properties. Particle velocity was found to have greater impact on coating porosity compared to spray angle. Coating with lowest porosity and lowest surface roughness but highest compressive surface residual stress was achieved with deposition at lowest spray angle (50°) and highest particle velocity (920 m/s). Changing the spray angle has greater influence on the deposition efficiency, with thickest coating observed at normal spray angle of 90° across all three cold spray conditions. Finite element method (FEM) simulations were also performed to understand the influence of powder and substrate temperatures on critical angles for bonding. The simulation results suggest that elevating the powder temperature is likely to cause a slight increase in the critical bonding angle.

Study on crystal growth of Ge/Si quantum dots at different Ge deposition by using magnetron sputtering technique

We investigated the growth and evolution of Si-based Ge quantum dots (Ge/Si QDs) under low Ge deposition (1.2–4.4 nm thick) using magnetron sputtering. The morphology and structure of QDs were analyzed with the help of an atomic force microscope (AFM), scanning electron microscope, transmission electron microscope, Raman, surface energy theory and dynamics theory, the photoelectric properties of QDs were characterized by photoluminescence (PL) spectra. The results showed that the growth mechanism of QDs conformed to Stranski–Krastanow mode, but the typical thickness of the wetting layer was nearly three times higher than those derived from conventional technologies such as molecular beam epitaxy, chemical vapor deposition, solid phase epitaxy and so on. Meanwhile, the shape evolution of QDs was very different from existing reports. The specific internal causes of these novel phenomena were analyzed and confirmed and reported in this paper. In addition, the AFM, Raman, and PL tests all indicated that the QDs grown when 3.4 nm Ge was deposited have the most excellent morphology, structure, and optoelectronic performance. Our work lays a foundation for further exploration of the controllable growth of QDs at high deposition rates, which is a new way to realize the industrialization of QDs used for future devices.

Computational fluid-particle dynamics modeling of ultrafine to coarse particles deposition in the human respiratory system, down to the terminal bronchiole

Background and objectivesSuspended respirable airborne particles are associated with human health risks and especially particles within the range of ultrafine (< 0.1 μm) or fine (< 2.5 μm) have a high possibility of penetrating the lung region, which is concerned to be closely related to the bronchial or alveoli tissue dosimetry. Nature complex structure of the respiratory system requires much effort to explore and comprehend the flow and the inhaled particle dynamics for precise health risk assessment. Therefore, this study applied the computational fluid-particle dynamics (CFPD) method to elucidate the deposition characteristics of ultrafine-to-coarse particles in the human respiratory tract from nostrils to the 16th generation of terminal bronchi. MethodsThe realistic bronchi up to the 8th generation are precisely and perfectly generated from computed tomography (CT) images, and an artificial model compensates for the 9th-16th bronchioles. Herein, the steady airflow is simulated at constant breathing flow rates of 7.5, 15, and 30 L/min, reproducing human resting-intense activity. Then, trajectories of the particle size ranging from 0.002 – 10 μm are tracked using a discrete phase model. ResultsHere, we report reliable results of airflow patterns and particle deposition efficiency in the human respiratory system validated against experimental data. The individual-related focal point of ultrafine and fine particles deposition rates was actualized at the 8th generation; whilst the hot-spot of the deposited coarse particles was found in the 6th generation. Lobar deposition characterizes the dominance of coarse particles deposited in the right lower lobe, whereas the left upper-lower and right lower lobes simultaneously occupy high deposition rates for ultrafine particles. Finally, the results indicate a higher deposition in the right lung compared to its counterpart. ConclusionsFrom the results, the developed realistic human respiratory system down to the terminal bronchiole in this study, in coupling with the CFPD method, delivers the accurate prediction of a wide range of particles in terms of particle dosimetry and visualization of site-specific in the consecutive respiratory system. In addition, the series of CFPD analyses and their results are to offer in-depth information on particle behavior in human bronchioles, which may benefit health risk assessment or drug delivery studies

Measurements of deposition rate and droplet temperature in GMAW of aluminum alloys

This article explores the reason behind the higher deposition rate in Mg-containing aluminum alloys in gas metal arc welding (GMAW). Experiments performed on ER1100 (Mg-free alloy) and ER5183 (high Mg alloys) measured current, wire feed speed, and droplet temperature. A non-linear analysis of Joule heating at the electrode extension and an analysis of the power needed to heat the consumable to the droplet temperature were performed. Analysis revealed that Joule heating is two orders of magnitude smaller than what was necessary for the higher wire feed speed. The droplet temperature measurements were done for the first time for both consumables under identical conditions, which revealed that ER5183 had a lower droplet temperature than ER1100 by almost 350 K.

Comparison of Weld Built-up by FCAW and MIG Welding on Damaged Low Cr-Mo Alloy Steel Tube in Boiler Application

In boiler application low Cr-Mo tubes are being used and in manufacturing or working these tubes are getting damaged. ASTM and ASME BPVC (Boiler Pressure vessel code is allowing wall thinning of tubes by 10%. Any damage more than 10% of wall thickness is causing rejection of Tube. As ASTM and ASME has provision for weld build-up on defected or damaged portion of Boiler Tubes, hence I am going to compare two welding process for the weld built-up on low Cr-Mo alloy steel tubes. In current practice the damaged tubes are being scrapped in boiler manufacturing as well as in running boilers. After this demonstration we can compare mechanical Properties of reworked tubes with original one. The Two methods adopted are MIG Welding and FCAW. Metal Inert Gas (MIG) welding is known for high deposition welding technique will minimum defect possibility. Flux Cored Arc Welding also has high weld deposition rate with minimum defect possibility.

Angular distribution of titanium ions and neutrals in high-power impulse magnetron sputtering discharges

The angular dependence of the deposition rates due to ions and neutrals in high-power impulse magnetron sputtering (HiPIMS) discharges with a titanium target were determined experimentally using a magnetically shielded and charge-selective quartz crystal microbalance (or ionmeter). These rates have been established as a function of the argon working gas pressure, the peak discharge current density, and the pulse length. For all explored cases, the total deposition rate exhibits a heart-shaped profile and the ionized flux fraction peaks on the discharge axis normal to the cathode target surface. This heart-shaped pattern is found to be amplified at increasing current densities and reduced at increased working gas pressures. Furthermore, it is confirmed that a low working gas pressure is beneficial for achieving high deposition rates and high ionized flux fractions in HiPIMS operation.

Suppression of humping bead defects in high-speed triple-wire gas indirect arc welding through compensation gas

Triple-wire gas indirect arc welding (TW-GIA) has significant advantages of high deposition rate and low heat input. However, the humping bead defects in high-speed TW-GIA welding limits the improvement of welding speed. In this article, the feasibility of compensation gas to suppress the humping bead in TW-GIA was explored, and the influence on molten pool flow and arc stability was revealed. The results show that the compensation gas with jet angle of 90 °has the ability to suppress the humping bead and reduces the oxygen content of the weld. When the compensation gas flow rate is less than 30 L/min, the decrease of arc pressure leads to the decrease of reverse flow velocity of liquid metal. And the vertical downward impact force caused by compensation gas can directly inhibit the uplift of the liquid metal, which is beneficial to suppress the humping bead. In addition, the compensation gas carry in high ionization energy gas, which reduces the welding current and increases the range of conductive channel. The low gas flow rate with the jet angle of 90° has little effect on the arc stability, but the flow rate exceeding 30 L/min significantly increases the degree of arc disorder.

High deposition rate wire-arc directed energy deposition of 316L and 316LSi: Process exploration and modelling

A parameter design of experiments was undertaken to study the impact of Si content in the wire feedstock, weld speed, and interpass temperature on the microstructure and mechanical properties of high deposition rate Wire-Arc Directed Energy Deposition (WA-DED) of 316L stainless steel. Small-scale, representative builds were constructed using a high deposition rate pulsed spray transfer mode. Across conditions, WA-DED 316L builds exceeded American Society of Mechanical Engineers (ASME) SA-240 minimum values for yield strength, elongation, and tensile strength at room temperature, tested both parallel and perpendicular to the build direction. It was found that 316LSi samples (higher Si content version of 316L) displayed significantly higher strengths and ductilities than samples produced with 316L, while the impact of weld speed and interpass temperature were less significant. A heat transfer model of the WA-DED process was created to allow for microstructure predictions. An infrared thermal camera system was used to calibrate this model by taking temperature measurements at fixed points during the deposition of several layers. Solidification models were developed to allow for predictions of microstructural features in the as-built condition. Predictions of dendrite spacings and growth morphologies show good agreement with experiments, demonstrating the potential for modeling the influences of the WA-DED parameters for process optimization. Based on microstructural analysis, it was concluded that the increase in strength and ductility in 316LSi compared to 316L is due to effects of composition on solid solution strengthening and stacking fault energy, suggesting opportunities for developing new stainless steel alloys for WA-DED with improved mechanical performance.

CMAS deposition rate and sequence effects on cyclic life in gradient testing

Thermal barrier coating (TBC) resistance to varied CMAS deposition rates was experimentally assessed using a temperature gradient rig using a CMAS precursor spray. TBCs were composed of EB-PVD YSZ. Five different deposition rates were tested quantifying life versus deposition rate. A high deposition rate and low deposition rate were selected from those tests for sequence testing. For sequence effect testing CMAS deposition occurred at the initial rate until the expected half-life and then switched to the other rate until failure, in the order of high deposition rate first followed by low deposition rate and vice versa. The results suggest that the order of deposition rates can affect ultimate failure behavior. Specifically applying the CMAS at the low deposition rate extended the life of the sample by a nearly a factor of 2 compared to a virgin sample. At the high deposition rate, the CMAS infiltrated all the way to the bond coat past the estimated freeze line. Data showing the coating life versus CMAS deposition rate and the existence of sequence effects in CMAS dosing are fundamentally important to coating life prediction.

Manufacturing of Gallium Nitride Thin Films in a Multi-Wafer MOCVD Reactor

Abstract Gallium nitride (GaN) thin films have attracted considerable attention for manufacturing optical and electronic devices. They have wide bandgap and superb performance in these applications. The reliability and durability of optoelectronic devices depend on the quality of the GaN thin films. The metal-organic chemical vapor deposition (MOCVD) process is a common manufacturing technique for fabricating high-quality thin films. By manipulating the operating conditions and the reactor design, one can control the deposition rate and the uniformity of the thin film. In this paper, the manufacturing process for GaN thin films in a multi-wafer MOCVD reactor is simulated based on the three-dimensional computational model of an experimental system which provides data for validation as well as realistic design parameters. The reactor pressure and the flow rate of the precursor, trimethyl-gallium (TMG), significantly affect the deposition rate and film uniformity. The incursion of impurities in the deposition can be reduced by increasing the volumetric ratio of NH3 to TMG (V/III) and reducing the reactor pressure. The deposition rate and quality of the thin film are enhanced using an appropriate mixture of H2 and N2 as the carrier gas. The design of the inlet can also be varied to improve the utilization of metal-organic precursors and increase the deposition rate. This paper presents and discusses results on these aspects for this important manufacturing process. Thus, it leads to a better understanding of the basic mechanisms involved and provides guidelines for obtaining high deposition rates with high film quality in practical chemical vapor deposition reactors.

Ultra high-rate composite deposition system on track to beat lay-up target by 75%

Mark Bowering, NCC's chief engineer for civil air structures describes how a new deposition system could reduce production costs and improve operation flexibility.

New understanding and exploration direction of hydrocarbon accumulation in Termit Basin, Niger

Based on the seismic and drilling data, casting thin sections, geochemical analysis of oil and rock samples, and hydrocarbon generation history simulation, the hydrocarbon accumulation characteristics and exploration direction of Termit superimposed marine—continental rift basin are discussed. The Termit basin is superimposed with two-phase rifts (Early Cretaceous and Paleogene). The subsidence curves from two wells on the Trakes slope in the east of the basin show high subsidence rate in the Late Cretaceous, which is believed to be high deposition rate influenced by transgression. However, a weak rift may also be developed. The depositional sequences in the Termit basin were controlled by the Late Cretaceous marine transgression cycle and the Paleogene lacustrine transgression cycle, giving rise to two types of superimposed marine—continental “source-sink” deposits. The marine and continental mixed source rocks developed universally in the whole basinduring the marine transgression period, and are overlaid by the Paleogene Sokor 1 reservoir rocks and Sokor 2 caprocks developed during the lacustrine transgression period, forming the unique superimposed marine—continental basin in WCARS. The early low geothermal gradient in the Termit basin resulted in the late hydrocarbon generated by the source rock of Upper Cretaceous Yogou in Paleogene. Mature source rock of Upper Cretaceous Donga developed in the Trakes slope, so that the double-source-supply hydrocarbon and accumulation models are proposed for the Trakes slope in which formed the oil fields. Due to virtue of the newly proposed hydrocarbon accumulation model and the exploration activities in recent years in the Termit superimposed marine—continental rift basin, an additional effective exploration area of about 2500 km2 has been confirmed in the east of the basin. It is believed that potential domains such as Sokor 1, Donga and Upper Cretaceous lithologic traps in the southeast of the basin are key expected targets for exploration and frontier evaluation in future.

Hierarchical Structures Formed in an Atmospheric Pressure Plasma Jet by Polymerization from an Aerosol of Oxalic Acid Stabilized WO3–x Nanosheet Colloids: Toward High-Performance Electrochemical Devices and Sensors

The development of microstructures which combine high total surface area and high porosity is crucial for technologies such as electrocatalysis, electrochromics, and sensors. High deposition rate, composition control of deposition, and low processing temperature to retain active compositions are also desirable. To this end, this study describes combining colloidal sol chemistry with a nonthermal atmospheric pressure dielectric barrier discharge plasma jet to print hybrid inorganic/organic tungsten trioxide/oxalic acid (WO3–x/OA) microspheres. Injection of an aerosol of oxalic acid stabilized colloidal tungstic acid into an atmospheric pressure plasma jet results in the deposition of spherical structures in which the colloid is trapped within a plasma-polymerized organic shell. Subsequent low-temperature sintering produces hierarchical spherical shell-like structures comprising tungsten oxide nanosheets. Alteration of the gas flow rate changes the composition of the deposited material. The method has promise for the general preparation from colloidal precursors of porous materials of controlled morphology and composition with hierarchical microstructures, such as are required for applications in electrochemical devices and sensors which need a high ratio of surface area to volume and connectivity throughout the structure, yet also need a microstructure which is open for rapid exchange of reactants.

Rapid post processing of cold sprayed Inconel 625 by induction heating

Cold spray is a solid-state metal deposition technology. One of the major advantages of cold spray over other additive manufacturing technologies is the high deposition rate. Heat treatments are usually conducted for cold sprayed deposit to improve its ductility; however, the long duration of conventional furnace heating would compromise the advantage of fast deposition. The current work explored the use of induction heating to accelerate the heat treatment process. A post-process heat treatment of cold sprayed Inconel 625 by induction heating was carried out at 900 °C for 10 min. Microstructure, hardness, ductility, and adhesion strength of the cold sprayed Inconel 625 deposits were systematically studied before and after the induction heating. For comparison, the conventional furnace heat treatment was also conducted with the same heating temperature and duration. Compared with furnace heating, induction heat treatment yielded larger grain size and larger δ precipitates due to enhanced atomic diffusion promoted by the eddy current. There was a significant improvement of ductility of the Inconel 625 deposit after induction heat treatment, and this can be attributed to enhanced inter-splat bonding. In contrast, the improvement of ductility by furnace heating was limited. The adhesion strength was found to increase more significantly by induction heating when the thickness was within the penetration depth of the eddy current. The results show that rapid post processing of cold sprayed Inconel 625 can be achieved by induction heating.

Identification of two vibration regimes of underwater fibre optic cables by distributed acoustic sensing

SUMMARYDistributed acoustic sensing (DAS) enables data acquisition for underwater Earth Science with unprecedented spatial resolution. Submarine fibre optic cables traverse sea bottom features that can lead to suspended or decoupled cable portions, and are exposed to the ocean dynamics and to high rates of marine erosion or sediment deposition, which may induce temporal variations of the cable’s mechanical coupling to the ocean floor. Although these spatio-temporal fluctuations of the mechanical coupling affect the quality of the data recorded by DAS, and determine whether a cable section is useful or not for geophysical purposes, the detection of unsuitable cable portions has not been investigated in detail. Here, we report on DAS observations of two distinct vibration regimes of seafloor fibre optic cables: a high-frequency (&amp;gt;2 Hz) regime we associate to cable segments pinned between seafloor features, and a low-frequency (&amp;lt;1 Hz) regime we associate to suspended cable sections. While the low-frequency oscillations are driven by deep ocean currents, the high-frequency oscillations are triggered by the passage of earthquake seismic waves. Using Proper Orthogonal Decomposition, we demonstrate that high-frequency oscillations excite normal modes comparable to those of a finite 1-D wave propagation structure. We further identify trapped waves propagating along cable portions featuring high-frequency oscillations. Their wave speed is consistent with that of longitudinal waves propagating across the steel armouring of the cable. The DAS data on cable sections featuring such cable waves are dominated by highly monochromatic noise. Our results suggest that the spatio-temporal evolution of the mechanical coupling between fibre optic cables exposed to the ocean dynamics and the seafloor can be monitored through the combined analysis of the two vibration regimes presented here, which provides a DAS-based method to identify underwater cable sections unsuitable for the analysis of seismic waves.