Hot Substrate Research Articles

Combined thermal and particle shape effects on powder spreading in additive manufacturing via discrete element simulations

The thermal and mechanical behaviors of powders are crucial for additive manufacturing. In powder bed fusion, capturing temperature profiles and packing structures before melting is challenging due to diverse heat transfer pathways and powder properties. This study tackles this challenge with a discrete element model simulating non-spherical particles with thermal properties during powder spreading. Thermal conduction and radiation are integrated into a multisphere particle formulation to model heat transfer among irregular-shaped powders with temperature-dependent elastic properties. The model is utilized to simulate the spreading of pre-heated PA12 powder over a hot substrate representing the part under manufacturing. Variances in temperature profiles are observed in the spreading cases based on particle shapes, spreading speed, and temperature-dependent elastic modulus. Particle temperature beneath the spreading blade is influenced by the kinematics of the particle heap and temperature-dependent properties.

Efficient Fabrication of High‐Density Ensembles of Color Centers via Ion Implantation on a Hot Diamond Substrate

AbstractNitrogen‐vacancy (NV) centers in diamonds are one of the most promising systems for quantum technologies, including quantum metrology and sensing. A promising strategy for the achievement of high sensitivity to external fields relies on the exploitation of large ensembles of NV centers, whose fabrication by ion implantation is upper limited by the amount of radiation damage introduced in the diamond lattice. In this work an approach is demonstrated to increase the density of NV centers upon the high‐fluence implantation of MeV N2+ ions on a hot target substrate (>550 °C). The results show that with respect to room‐temperature implantation, the high‐temperature process increases the vacancy density threshold required for the irreversible conversion of diamond to a graphitic phase, thus enabling to achieve higher density ensembles. Furthermore, the formation efficiency of color centers is investigated on diamond substrates implanted at varying temperatures with MeV N2+ and Mg+ ions revealing that the formation efficiency of both NV centers and magnesium‐vacancy (MgV) centers increases with the implantation temperature.

The system of automatic control of the substrate temperature in the installation for the production of film material spray pyrolysis method

A system of automatic control of the substrate temperature is proposed, which ensures the required accuracy of temperature maintenance and its minimum gradient over the surface when obtaining transparent conductive coatings by spray pyrolysis. During pyrolysis, aerosol droplets are transferred to a heated substrate; at the right temperature, they decompose, and then synthesize or melt on a hot substrate. The ideal temperature regime for evaporation of aerosol droplets will be the mode when a drop appears at the substrate immediately after evaporation of the solvent from it. Precise control of the substrate temperature and temperature gradient ensures this mode. The functional scheme of the proposed automatic control system consists of an automatic temperature controller, a power regulator, an infrared heater on halogen lamps, and a temperature sensor. The variational problem of minimizing power consumption when the infrared heater is turned on has been solved. This activation eliminates current emissions and thereby increases the service life of the heater. It is proposed to connect the heater to a current source in order to eliminate current emissions, thereby ensuring the optimal switching mode. The synthesis and analysis of the specified automatic control system has been performed, its time and frequency parameters have been calculated. Acceptable performance, zero static control error and zero overshoot, a significant margin of stability in phase and amplitude have been confirmed. The use of such an automatic temperature control system contributes to the creation of an optimal mode of evaporation of aerosol droplets, allows you to stabilize the substrate temperature and temperature gradient, thereby ensuring the stability of the characteristics of the resulting films. The investigated transparent conductive coatings are part of glasses with adjustable transparency, and are also used as layers of solar cells.

Extralong hot-spots sensor for SERS sensitive detection of phthalate plasticizers in biological tear and serum fluids.

Phthalate plasticizers (PAEs) illegally used in food pose a great threat to human health. A new and efficient sensing platform for the sensitive detection of the PAE residues in biological fluids needs to be designed and developed. Here, we report a simple and reliable surface-enhanced Raman spectroscopy (SERS) active platform with extralong hot spots of Au nanobipyramids@Ag nanorods (Au NBPs@Ag NRs) for the rapid and sensitive detection of PAEs in biological fluids. To achieve high activity, Au NBPs@Ag NRs with different shell lengths were fabricated by controlling the synthesis conditions, and the corresponding SERS properties were investigated by using crystal violet (CryV) and butyl benzyl phthalate (BBP). The experimental results showed that a longer shell length correlated to greater Raman activity, which was confirmed by finite-difference time-domain (FDTD) electromagnetic simulation. More importantly, the extralong hot spots of the Au NBPs@Ag NR SERS-active substrate showed excellent homogeneity and reproducibility for the CryV probe molecules (6.21%), and the detection limit was 10-9M for both BBP and diethylhexyl phthalate (DEHP). Furthermore, through the standard addition method, an extralong hot spots SERS substrate could achieve highly sensitive detection of BBP and DEHP in serum and tears fluids, and the detection limit was as low as 3.52 10-8M and 2.82 10-8M. Therefore, the Au NBPs@Ag NR substrate with an extraordinarily long surface is efficient and versatile, and can potentially be used for high-efficiency sensing analysis in complex biological fluids.

Micrometer‐Thin Nanocellulose Foils for 3D Organic Electronics

AbstractCellulose is a natural polymer with great properties such as high optical transparency and mechanical strength, flexibility, and biodegradability. Hence, cellulose‐based foils are suitable for the replacement of synthetic polymers as substrate materials in organic electronics. This article reports the fabrication of ultrathin, free‐standing cellulose foils by spraying aqueous 2,2,6,6‐tetramethylpiperidine‐1‐oxyl‐nanocellulose (TEMPO) fibrils ink layer‐by‐layer on a hot substrate using a movable spray nozzle. The resulting foils are only 2 ± 1 µm in thickness with an average basis weight of 1.9 g m−2, which ranges in the same scale as the world's thinnest paper. The suitability of these ultra‐thin nanocellulose foils as a sustainable substrate material for organic electronic applications is demonstrated by testing the foils resistance against organic solvents. Furthermore, silver nanowires (AgNWs) and the blend poly(3,4‐ethylenedioxythiophene):polystyrene sulfonate (PEDOT:PSS) are integrated into the foils, and the foils are molded into 3D paper structures in order to create conductive, paper‐based building blocks for organic electronics.

Numerical investigation of droplet impact and heat transfer on hot substrates under an electric field

In this study, the effects of the electric field on the impact dynamics and heat transfer of a single droplet impinging on hot substrates in the film evaporation regime were numerically investigated with phase-field method. According to the simulation results, many fancy impact behaviors of the droplets under a vertical electric field were observed. A strong electric field was found to induce upward pinch-off or even tiny jet phenomena on the hydrophilic substrates. In contrast, the bouncing droplet on hydrophobic substrate would be vertically stretched before leaving the substrates. The maximum spreading ratio of impacting droplets was always inversely proportional to the applied electric field intensity. Correlations of the maximum spreading for the charged condition were proposed by considering the effects of the electric force. In addition, the total heat transfer from hot substrates to the impacting droplet was verified as closely related to the maximum spreading area, spreading time, and instantaneous local heat flux. However, the broken droplets from the induced tiny jet would eventually fall back to disturb the sessile droplet, enhancing the droplet cooling efficiency. The modified heat transfer model of impacting droplets under the effect of an electric field on hydrophilic substrates was established. Finally, the surface charge distribution and electric force loading of the impacting droplets were also discussed. This work delved deep into the underlings of droplet spreading heat transfer under an electric field, and the main findings promised to advance high-efficiency cooling technology.

Comparison of Softening Behavior and Abrasive Wear Resistance between Conventionally and Additively Manufactured Tool Steels

Directed energy deposition (DED) is a powerful method for hard‐facing the existing tool components. Herein, three tool steel grades including a newly developed maraging steel (NMS), a cold work tool steel (V4E), and a high boron steel (HBS) are cladded on a hot work tool steel substrate. After tempering, the cladded tool steels are exposed to high temperatures at 600, 700, and 800 °C for 3 h to evaluate their softening resistance. The results show that all three tool steel grades have a significant hardness drop when the softening temperature reaches 700 °C. The investigated NMS has the lowest initial hardness in the tempered state but the best softening resistance. In contrast, HBS has the highest initial hardness but the worst softening resistance among the three steel grades. V4E tool steel has a moderate softening resistance compared to the other two steel grades. The factors contributing to the softening resistance have been discussed. Corresponding conventional tool steels are also adapted as references for comparison. Except for the NMS, the additive manufacturing tool steel samples have a better softening resistance than the conventional counterparts owing to more alloying elements trapped in the matrix. The abrasive wear resistance of the tempered and softened tool steels manufactured by DED and conventional methods is also evaluated and the wear mechanism is discussed. Besides the hardness, the free spacing λ between coarse hard particles is one of the major factors influencing the abrasive wear resistance.

Nanocrystalline Cubic Phase Scandium-Stabilized Zirconia Thin Films.

The cubic zirconia (ZrO2) is attractive for a broad range of applications. However, at room temperature, the cubic phase needs to be stabilized. The most studied stabilization method is the addition of the oxides of trivalent metals, such as Sc2O3. Another method is the stabilization of the cubic phase in nanostructures-nanopowders or nanocrystallites of pure zirconia. We studied the relationship between the size factor and the dopant concentration range for the formation and stabilization of the cubic phase in scandium-stabilized zirconia (ScSZ) films. The thin films of (ZrO2)1-x(Sc2O3)x, with x from 0 to 0.2, were deposited on room-temperature substrates by reactive direct current magnetron co-sputtering. The crystal structure of films with an average crystallite size of 85 Å was cubic at Sc2O3 content from 6.5 to 17.5 mol%, which is much broader than the range of 8-12 mol.% of the conventional deposition methods. The sputtering of ScSZ films on hot substrates resulted in a doubling of crystallite size and a decrease in the cubic phase range to 7.4-11 mol% of Sc2O3 content. This confirmed that the size of crystallites is one of the determining factors for expanding the concentration range for forming and stabilizing the cubic phase of ScSZ films.

Machine Learning Classification of Self-Organized Surface Structures in Ultrashort-Pulse Laser Processing Based on Light Microscopic Images.

In ultrashort-pulsed laser processing, surface modification is subject to complex laser and scanning parameter studies. In addition, quality assurance systems for monitoring surface modification are still lacking. Automated laser processing routines featuring machine learning (ML) can help overcome these limitations, but they are largely absent in the literature and still lack practical applications. This paper presents a new methodology for machine learning classification of self-organized surface structures based on light microscopic images. For this purpose, three application-relevant types of self-organized surface structures are fabricated using a 300 fs laser system on hot working tool steel and stainless-steel substrates. Optical images of the hot working tool steel substrates were used to learn a classification algorithm based on the open-source tool Teachable Machine from Google. The trained classification algorithm achieved very high accuracy in distinguishing the surface types for the hot working steel substrate learned on, as well as for surface structures on the stainless-steel substrate. In addition, the algorithm also achieved very high accuracy in classifying the images of a specific structure class captured at different optical magnifications. Thus, the methodology proposed represents a simple and robust automated classification of surface structures that can be used as a basis for further development of quality assurance systems, automated process parameter recommendation, and inline laser parameter control.

Comparative study of Cu2XSnS4 (X = Ni, Co, Mn or Fe) films synthesized by spray pyrolysis under air atmosphere, as suitable absorber layers for photovoltaic applications

The present work deals with the synthesis of an absorber Cu2XSnS4 sulfide (X = Ni, Fe, Co or Mn) thin films by a spray pyrolysis method on hot substrate and under air atmosphere for low cost solar cell. Chemical composition analyzes by energy-dispersive X-ray spectroscopy (EDS) revealed the presence of all the chemical elements (Cu, Sn, S and Co, Ni, Mn or Fe) with a composition close to the stoichiometry of the layers of Cu2NiSnS4 (CNTS), Cu2CoSnS4 (CCTS) and far from the stoichiometry for the layers of Cu2MnSnS4 (CMTS) and Cu2FeSnS4 (CFTS). The X-ray diffraction (XRD) analyzes showed the crystallization of the desired phase such as the cubic phase of CNTS with a preferential orientation (111) and the stannite phase of CCTS and CMTS with a preferential orientation (112), except for the CFTS film which is poorly crystallized. SEM analyzes show that CNTS, CCTS and CMTS layers exhibit a rather homogeneous and compact surface with nodule distribution. The CFTS layer surface shows excrescences separated by voids leading to a porous and diffusing surface. The optical analyzes indicated a high absorption coefficient of the order of 104 cm−1 in the visible range for all the layers and an optical band gap of 1.62, 1.58 and 1.64 eV for the layers CNTS, CCTS and CMTS respectively, whereas the direct band gap of CFTS film is higher (∼ 2.23 eV). The comparison of CXTS films synthesized in the same conditions demonstrates that the CNTS and CCTS films have the most suitable features (optical, electrical, mechanical and oxidation resistance) to be used as absorbing layer in low cost solar cell.

Linear stability of thermocapillary flow in a droplet attached to a hot or cold substrate

Linear stability of thermocapillary flow in a droplet attached to a hot or cold substrate

Impact of sputtering gas on the microstructural, mechanical and wetting properties of vanadium nitride coatings

Vanadium nitride (VN) coatings were deposited via reactive DC magnetron sputtering technique on a hot substrate (400 °C) with varying partial pressure of N2. The impact of nitrogen partial pressure on the crystal structure, microstructure, elemental composition, surface topography, mechanical and wetting properties of VN coatings was investigated using grazing incidence X-ray diffraction (GIXRD), Raman spectroscopy, field emission scanning electron microscope (FESEM), energy dispersive spectroscopy (EDS), atomic force microscope (AFM), nano-indentation, and drop shape analyzer (DSA). The variation in the N2 partial pressure leads the significant changes in the microstructure, mechanical and wetting properties of the coatings. The GIXRD spectra reveals the formation of crystalline FCC phase in the deposited VN coatings. However, at 100% N2 partial pressure, the preferred orientation of crystal planes changes from (200) to (220). The FESEM image reveals that at low N2 partial pressure, the coating exhibits well-separated grains with clearly visible grain boundaries. As the N2 partial pressure increases, the agglomeration of grains becomes more pronounced, and the grain boundaries become less discernible. However, at 100% N2 partial pressure, the structure transforms into triangular nanoflake-like prismatic structures with voids. The VN coatings with 60% N2 partial pressure exhibits the highest mechanical properties whereas at 100% N2 partial pressure, the VN coatings reveal super-hydrophilic character.

Evaporation of Leidenfrost droplets on microtextured substrates

A thin thermally insulating vapor layer beneath a levitating Leidenfrost droplet adversely affects the heat transfer from the underlying hot substrate during cooling applications. In this work, we present a theoretical model to determine the total heat transfer to a Leidenfrost droplet on microtextured substrates, taking into account the curved shape of the liquid-vapor interface. The profile of the vapor gap and vapor flow field beneath a Leidenfrost droplet on a microtextured surface is shown to be dependent on the substrate morphology. The shape of the liquid-vapor interface beneath the Leidenfrost droplet, in turn, influences the rate of evaporation on a microtextured substrate. We determine the variation of the minimum and maximum vapor gap over micro-pillared surfaces with different substrate permeability for various droplet volumes and wall superheat. The heat transferred to the droplet is via conduction across the vapor gap beneath the droplet and convection from the ambient air around the droplet. We determine the total evaporation time of a Leidenfrost droplet over a micro-textured substrate using the curved interface model and the conventional flat vapor gap interface model and compare with that obtained from experiments. The overprediction of the average rate of evaporation of a Leidenfrost droplet by the flat interface model ranges from ∼59 % for tall and sparse pillars (marked by high substrate permeability) to ∼ 29 % for short pillars (with low substrate permeability). We show that the average rate of evaporation of the LF droplet obtained using the curved interface model agrees reasonably (within 9%–23 %) with that observed in the experiments.

Investigation of electrohydrodynamic effects on sessile droplet evaporation using the lattice Boltzmann method

Droplet evaporation on hot substrates within an electric field plays an essential role during the electrospray cooling process. However, there is only a vague understanding of electrohydrodynamic (EHD) effects on droplet evaporation. In this paper, the coupled set of governing equations, including the Poisson equations, the energy equations, and the Navier-Stokes equations, is implemented within the lattice Boltzmann (LB) framework to examine the evaporation of leaky dielectric droplets. The contact angle hysteresis (CAH) as well as the influences of fluid-solid conjugate heat transfer are taken into consideration in this model. The method’s accuracy is validated quantitatively by using three basic cases. The results suggest that the sessile droplet could be elongated or flattened under EHD effects. When the droplet is elongated, the acceleration of the rate of evaporation is controlled by the interrelationship between thermal conduction and electric-induced convection in the droplet, i.e., the average Peclet number (Pe) value. As Pe is less than 1.0, the interior of the droplets is controlled by thermal conduction, and the applied electric field would prolong the droplet evaporation time. As Pe is greater than 2.0, the electric convection promotes evaporation compared to neutral droplets. In the case that the droplets are compressed inside the electric field, the evaporation time progressively decreases as the intensity of the electric field increases. These insights help us understand how EHD affects sessile droplet evaporation and illustrate the huge potential of electric fields for thermo-fluid manipulation.

Modelling of drop and spray impact in the transitional boiling regime

Spray cooling of hot substrates is a technology that can provide uniform and intense cooling of surfaces of complex geometry. It is applicable to a wide range of surface temperatures associated with different applications, from cryogenic cooling to steel quenching. The performance of spray cooling is determined by surface temperature, spray parameters such as drop diameter, impact velocity, number flux and the thermal properties of the liquid and substrate. These parameters also determine different regimes of drop wall interactions such as drop deposition, nucleate boiling, drop dancing, thermal atomization and film boiling with drop rebound.The present experimental and theoretical study focuses on the transitional boiling regime, which is currently the least studied regime due to its complexity. The residence time of a single drop is modelled, taking into account the development of a thermal boundary layer in the substrate, the expansion of the vapour phase due to boiling in the drop, and the percolation of the vapour channels on the substrate. Moreover, the model allows to predict the heat flux during spray cooling in the transitional boiling regime. The model agrees well with the experimentally measured heat flux of sprays with low number flux.

Experimental investigation on boiling regime transformation when the binary-droplet impact on the superheated surface

This experimental study focuses on the phenomena induced by thermal effects after a two-component droplet of propylene glycol water impinges on a hot substrate. The visualization experiment revealed that this phenomenon is characterized by a shift in the boiling regime of the droplets, which exhibits different transformation patterns with changes in surface temperature and propanediol concentration. On the basis of high-speed camera sequence images, a temperature-concentration regime map is created. Qualitative analysis is performed on the causes of the boiling transformation, as well as the wall temperatures and concentration intervals at which it might occur. The time at which the boiling regime transformation occurs can be determined by analyzing the secondary droplets. In addition, the effects of various boiling regimes and propylene glycol concentrations on the size and velocity distribution of secondary droplets are briefly investigated.

Numerical investigation of impacting heat transfer of binary droplets on superhydrophobic substrates

The droplet impacting on a substrate is widely encountered in daily life and industrial applications. In this paper, the impact dynamics and heat transfer are numerically simulated for both single droplet and binary droplets on a hot superhydrophobic substrate. The dimensionless numerical model is built up through the transient 2D axisymmetric model with a volume of fluid (VOF) model. The effect of the Weber number, Reynolds number, size ratio, contact angle on the spreading dynamics and heat transfer is investigated in details. It is found that the spreading factor and contact time increase with the increasing Weber number. Besides, the maximum spreading factor and contact time of binary droplets are larger than those of a single droplet under the same Reynolds and Weber numbers. The transient heat transfer rate of a single droplet is larger than that of binary droplets impingement due to larger spreading surface area-to-volume. The total input heat of a single droplet is generally larger than that of binary droplets except at large Weber numbers, and the equal-sized binary droplets have the larger total input heat than un-equal-sized binary droplets. For binary droplets impact on a hot superhydrophobic surface, the hot substrate can promote the spreading and retard the receding due to thermo-capillary effect, and thus will enhance heat transfer between the droplet and the hot substrate. These findings may be helpful in gaining insights into the dynamics and heat transfer of binary droplets impact on the hot substrate.

Spray impact onto a hot solid substrate: Film boiling suppression by lubricant addition

Spray cooling of solid substrates is one of the methods used in various industrial processes such as forging, quenching or other metallurgical applications, electronics, pharmaceutical industry, medicine, or for cooling of powerful electrical devices. Spray cooling is governed by various hydrodynamic and thermodynamic processes, like drop impact, heat conduction in the substrate and convection in the spreading drops, and different regimes of boiling. The problem of modeling spray cooling becomes even more challenging if the liquid is multicomponent. The presence of components with various physicochemical properties (surfactants, binders, dispersed particles, etc.) can significantly affect the entire process of spray impact, as well as the outcome of the known cooling regimes and could lead to a formation of a thin deposited layer on the substrate. In this experimental study, spray impact onto a substrate, initially heated to temperatures significantly exceeding the liquid saturation point, is visualized using a high-speed video system. The heat transfer associated with spray impact is characterized using an array of thermocouples installed in a thick metal target. As a working fluid, a mixture of a distilled water and industrial white lubricant was used. It is observed that the presence of very small concentrations of lubricant augments the heat flux dramatically, particularly at high wall temperatures, at which usually film boiling is observed for spray cooling by using distilled water. Three main mechanisms lead to the increase of heat flux and shift of the Leidenfrost point. They are caused by the significant viscosity increase of the evaporating lubricant solutions, by an increase of the substrate wettability and by the emergence of stable liquid sheets between bubbles, preventing their coalescence and percolation of the vapor channels.

Abandoned disposable masks become hot substrates for plastisphere, whether in soil, atmosphere or water

A large number of surgical masks (SMs) to be discarded indiscriminately during the spread of COVID-19. The relationship between the changes of masks entering the environment and the succession of the microorganisms on them is not yet clear. The natural aging process of SMs in different environments (water, soil, and atmosphere) was simulated, the changes and succession of the microbial community on SMs with aging time were explored. The results showed that the SMs in water environment had the highest aging degree, followed by atmospheric environment, and SMs in soil had the lowest aging degree. The results of high-throughput sequencing demonstrated the load capacity of SMs for microorganisms, showed the important role of environment in determining microbial species on SMs. According to the relative abundance of microorganisms, it is found that compared with the water environment, the microbial community on SMs in water is dominated by rare species. While in soil, in addition to rare species, there are a lot of swinging strains on the SMs. Uncovering the ageing of SMs in the environment and its association with the colonization of microorganisms will help us understand the potential of microorganisms, especially pathogenic bacteria, to survive and migrate on SMs.

Heat flux during a drop train impact in the drop rebound regime

The focus of this study is on the heat flux during cooling of a hot substrate by an impacting monodisperse drop train. Such a drop train is used for achieving high heat flux densities over small surfaces. The temperature inside the substrate is measured with high temporal and spatial resolution using thermocouples. Furthermore, a new analytical model has been developed to describe and predict the transient cooling and temperature of a semi-infinite body by the impacting drop train, assuming a single point heat sink on the surface. The experimental data agree very well with the theoretical predictions for various drop train frequencies.