Increasing Film Thickness Research Articles

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

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

Low thickness effect on the properties of Mn-doped ZnO thin films synthesized by sol-gel spin coating technique

In this study, 7% manganese-doped zinc oxide (MZO) thin films with varying low thicknesses were synthesized using the spin coating method. The structural, optical, and morphological properties of MZO films with different film thickness, were systematically investigated. The crystallite structure, superficial morphology, and optical characteristics were analyzed using X-ray diffraction (XRD), atomic force microscopy (AFM), scanning electron microscopy (SEM), and ultraviolet–visible spectroscopy (UV-Vis). Structural analysis confirmed that all films exhibit a hexagonal wurtzite phase with a pronounced peak along the c-axis, and slight variation in low thickness significantly affected the structural parameters. The surface morphology demonstrated good uniformity, characterized by rounded grain shapes in the plane, while surface roughness was found to be increased with increasing film thickness. Optical analysis revealed that as the number of coatings increased, both transmittance and band gap energy decreased, accompanied by a redshift in the absorption edge across all samples. This behavior is attributed to light scattering, as well as an increase in the refractive index and dielectric function with visible light energy, influenced by the number of layers and corresponding crystallite size.

Thickness dependent crystallinity, hydrophilicity, and surface microtexture in CaF2 thin films deposited via thermal evaporation method

This study investigates the deposition and characterization of CaF₂ thin films with thicknesses ranging from 40 to 320 nm, fabricated via thermal evaporation onto glass substrates. X-ray diffractometry (XRD) revealed that increased film thickness leads to enhanced crystallinity, with larger crystallite sizes and reduced lattice strain. Wettability analysis demonstrated a transition from hydrophobic behavior (contact angle ∼70° for 40 nm) to hydrophilic behavior (contact angle ∼52° for 320 nm) as film thickness increased. Surface morphology, examined via atomic force microscopy (AFM), showed a significant reduction in surface roughness in thicker films, with smoother, more coalesced surfaces observed for films over 160 nm. Monofractal analysis further confirmed the evolution of surface microtexture, with thicker films exhibiting higher uniformity and reduced surface complexity. These findings provide critical insights into optimizing CaF₂ thin films for applications in optics, electronics, and surface coatings, where improved crystallinity and surface properties are essential.

Investigating the influence of RF power on the surface morphological and optical properties of sputtered TiO2 thin films

Thin films of titanium dioxide (TiO2), with thicknesses ranging from 105 to 231 nm, were deposited on glass substrates using radio-frequency (RF) magnetron sputtering in an argon atmosphere at four distinct RF power levels: 40, 70, 100, and 130 W, with the deposition time kept constant. The crystalline structure, surface morphology and optical and semiconductor properties of the obtained films were analyzed using X-ray diffraction (XRD), Atomic Force Microscopy (AFM) and UV–visible transmittance spectroscopy. These analyses revealed that the crystallinity of the films improves with increasing RF power, corresponding to an increase in film thickness. Consequently, the samples transition from poorly crystalline or amorphous structure to a monocrystalline rutile phase with a (110) texture. However, at the highest RF power studied, this texture is partially disrupted by the formation of nanocrystals with different orientations. The surface roughness exhibited multifractal characteristics, with complexity systematically decreasing and surface stiffness reducing as RF power increased. Refractive indices and optical band gap energies were determined using the Swanepoel and Tauc plot methods, respectively. The films exhibited a notable increase in the refractive index and a decrease in the optical band gap, from 3.81 eV to 3.52 eV, as the RF power was increased. This underscores the influence of RF power on the optical and semiconductor properties of TiO2 films.

Lubrication mechanism analysis of textures in journal bearings using CFD simulations

Purpose This paper aims to study the lubrication mechanism of textured journal bearings. Design/methodology/approach CFD models for textured journal bearings are established. The effect of texture coverage on the pressure distribution is studied to find the proper texture distribution. To enhance the local load-carrying capacity at textures, the micro-hydrodynamic pressure and microflow at different texture depth ratios are captured. The interaction between the texture-induced microflow and the bearing lubrication film is analyzed from the microflow perspective. Findings The bearing performance is on the one hand enhanced by the micro-hydrodynamic pressure generated by textures. On the other hand, the main bearing land and maximum pressure can be interfered by textures, leading to the reduction of load-carrying capacity. To minimize the interference effect, textures are suggested to distribute downstream of the minimum film thickness location. As the lubrication film thickness increases, the corresponding optimum texture depth ratio rises. The vortices influence the local flow rate through the lubrication film at textures and further affect the micro-hydrodynamic pressure and local load-carrying capacity. The texture depth ratio, at which vortices begin to occur, generates the maximum micro-hydrodynamic pressure. Originality/value The proper texture distribution is introduced, which is capable to generate the micro-hydrodynamic pressure without interfering with the primary load-carrying capacity of the bearing. The microflow effect is found to considerably influence the local load-carrying capacity at textures. The necessity of sub-regional optimization in textured journal bearings is pointed out. This study provides the fundamental reference for the design and optimization of textured journal bearings.

Iron Gall Ink Revisited: Visible Light-Induced, Eosin-Mediated Acceleration of Fe2+ Oxidation in Pattern Nanoarchitectonics of Fe3+-Tannic Acid Films.

Inspired by iron gall ink (IGI), the Fe2+ ion is utilized for the continuous formation of Fe3+-tannic acid (TA) films through its in situ oxidation to the Fe3+ ion. Although several IGI-based strategies have been developed to meet different application requirements, there remains a need for the precise kinetic control for Fe2+ oxidation, along with one-step spatial controllability. This work demonstrates a visible light-induced method for oxidizing Fe2+ to Fe3+ ions, achieving the kinetic control over Fe3+-TA film formation. Photoexcitation of eosin Y leads to significantly accelerated film formation in a continuous manner, as shown by an 11-fold increase in film thickness compared with the air oxidation-based IGI method. Mechanistic studies reveal that the process is O2-dependent, and the kinetics of the film-forming process could be easily tuned by changing the light intensity or eosin Y concentration. Furthermore, the spatiotemporal controllability of the photoreaction allows for the pattern generation of Fe3+-TA complexes, proteins, and cells.

Effect of 1,4-Napthaquinone (NQ) and benzophenone (BPH)on the photodegradation and biodegradation of methyl cellulose film

The induced photodegradation of methyl cellulose (MC) films in air was investigated in the absence and presence of aromatic carbonyl compounds(photosenssitizers): 1,4-naphthaquinone (NQ) and benzophenone (BPH) by accelerated weathering tester. The addition of (0.01 wt %) of low molecular weight aromatic carbonyl compounds to cellulose derivatives films(25µm in thickness) enhanced the photodegradation of the polymer films.The photodegradation rate was measured by the increase in carbonyl absorbance. Decreases in solution viscosity and reduction of molecular weight were also observed in the irradiated samples. Changes in the number-average chain scission, the degree of deterioration and in the quantum yield of chain scission values are also observed, and it was concluded that branching or cross-linking has occurred for cellulose derivative with NQ and BPH. Findings from all analytical techniques indicated that the 1,4-naphthaquinone (NQ) photosensitizer enhance the photodegradation of methyl cellulose more than benzophenone (BPH). The effect of the photosensitizer concentration, (ranging from 0.01 to 0.1 %), on the rate of photodegradation was also monitored for MC films. The rates are increased with increasing the photosensitizer concentration. The effect of film thickness is also studied at fixed sensitizer concentration (0.05%), and results show that the rate of cellulose derivative photodegradation decreases with increasing film thickness. The rate constants of the photodegradation of the photosensitizers deduced in cellulose derivatives films, [at concentration of (0.1%)by weight and thickness (25µm)]. Biodegradation of irradiated cellulose derivatives films was conclusively established with bacteria type Pseudomonas aeuroginosa Rb-19 isolated from crude oil. The amount of bacteria growth on MC after 30 days was lower, while there was no growth observed in MC with BPH

Nonlinear optical parameters and electronic properties of plasma polymerized methyl acrylate thin films

Plasma polymerized methyl acrylate (PPMA) thin films were fabricated on a borosilicate glass substrate at a plasma power of 28 W to study nonlinear optical parameters and electronic properties. X-ray Diffraction analysis confirmed the amorphous nature of the PPMA films, while Attenuated total reflectance Fourier transform infrared spectroscopy indicated monomer fragmentation due to plasma polymerization. Field emission scanning electron microscope images of the films display a water wave-like structure. PPMA films demonstrated thermal stability up to approximately 574 K in both N2 and air environments. The values of direct band gap energies increase from 3.30 to 3.41 eV with increasing film thicknesses, whereas the Urbach energy values show in an opposite manner. The Wemple-DiDomenico model was employed to analyze both the oscillator energies ranging from 5.54 to 6.44 eV and the dispersion energies ranging from 10.56 to 12.89 eV. The static linear refractive index showed typical dispersion behavior, with film thickness conforming to Moss's rule. The nonlinear refractive index and 2nd and 3rd order nonlinear susceptibilities decrease with increasing the studied films. The lattice dielectric constant values exceeded the high-frequency dielectric constant, indicating the presence of lattice vibrations and free carriers. Electronic parameters are fluctuating with increasing film thickness. The observed changes in nonlinear optical parameters and electronic properties highlight the potential of PPMA films for applications in photovoltaic and optoelectronics.

Structural, Morphological, and Optoelectronic Properties of RF Sputtered AZO Thin Films on Glass and Polymer Substrates: A Comparative Study

This paper investigates the thickness-dependent structural, morphological, and optoelectronic properties of Al-doped ZnO (AZO) thin films deposited on glass and flexible polyethylene terephthalate (PET) substrates via confocal magnetron sputtering. The film’s thickness ranged from 50 to 130 nm. X-ray diffraction results show that all AZO films on glass have better structural properties than those on PET. Furthermore, the (002) peak intensity and crystallite size on both substrates improved progressively with thickness. Field emission scanning electron microscopy and atomic force microscopy images revealed that the film morphology and surface roughness are dependent on substrate and thickness. According to the UV–vis-NIR measurement results, the air-referenced transmittance spectra of films on PET were slightly lower than those on glass; however, compared to films on glass, the substrate-referenced transmittance of PET films was higher. Moreover, for both substrates, it is found that the bandgap of fabricated thin films decreases with thickness. Photoluminescence spectra show that for glass and PET substrates, the total luminescence of AZO decreases with increasing film thickness and that green and red emissions are absent from AZO films deposited on PET substrates. AZO films deposited on glass substrates exhibit superior electrical and optoelectronic characteristics.

Effect of thin film thickness of ferrofluid on inclined bioconvective flow

This research examines the effect of variable thin film thickness on the bioconvective ferrofluid flow through a rotating sloped surface when a magnetic field (dipole) is present. Similarity transformation is used to standardize the current model's governing equations. By using a finite element method, the normalized nonlinear differential equations are numerically solved. Variable thickness of ferrofluid thin film and bioconvective parameters (bioconvective Lewis number, bioconvective Peclet number, and micro-organism concentration difference) yield the following results: velocity profiles (radial, tangential, and axial), gravity flow (drainage velocity and induced velocity), temperature profile, concentration profile and microorganism profile. In addition, this investigation examines the density of moving microorganisms as well as local heat and mass transport. The temperature, concentration, radial, axial, drainage, induced, and motile microbe velocity are all improved with increasing film thickness. Variable thickness increases local heat transfer whereas increasing Brownian motion and thermophoresis parameters decreases it. This study could be helpful for self-sterilizing applications and biomedical engineering.

Phase composition of sputter deposited tungsten thin films

Sputter deposited tungsten thin films are studied by X-ray diffraction. Two phases can be identified: α-W and β-W based on the observed (110), and (200) and (210) Bragg reflections, respectively. With increasing film thickness (50 to 200 nm), the phase composition shifts from β-W towards α-W. No influence of the base pressure (3 × 10−3 – 3 × 10−5 Pa) on the phase composition is observed. Also the influence of the argon pressure (0.3 to 0.7 Pa) is rather weak. The strongest shift towards α-W composed thin films is obtained by increasing the discharge power (50 to 250 W). This trend is further studied by energy flux measurements using a calorimetric probe. These measurements rule out a strong change of the substrate temperature, and an impact of the energy flux scaled by the deposition rate (total energy per deposited atom). Test particle Monte Carlo simulations reveal the importance of the momentum of the reflected argon neutrals on the phase composition. The maximum energy of these species is mainly defined by the discharge voltage, and is higher than the directional dependent displacement energy of W. Despite the significant correlation between phase composition and the number of displacement per deposited atom, there is a strong scatter of the phase composition. As the deposition conditions were varied in random way, changes of the target erosion profile, and the changing discharge voltage over each series are probably partially responsible for the observed scatter. This scatter is also enhanced by the long term changes in the phase composition towards the more thermodynamic stable α-W phase.

Experimental Performance Evaluation of a Lightweight Additively Manufactured Hydrodynamic Thrust Bearing

In this paper, a lightweight additively manufactured (AM) fixed geometry hydrodynamic thrust bearing fabricated via laser powder bed fusion (LPBF) is experimentally compared to a traditionally manufactured cast aluminum alloy thrust bearing of similar design. The purpose of this study is to evaluate how weight-saving design features in the AM bearing affect active critical hydrodynamic performance parameters to better understand in-service viability. Under various static operating conditions, performance parameters such as hydrodynamic pressure distribution, minimum oil film thickness (MOFT), bearing temperature and increase in oil temperature are measured. Compared to the traditionally manufactured bearing, the AM bearing showed an average increase in minimum oil film thickness of 53%, an average increase in trailing edge hydrodynamic pressure of 116%, while exhibiting an average decrease in bearing temperature of 1%. Experimental results are compared to numerical simulation showing reasonably good agreement.

Breakdown strength and energy storage properties of epitaxial lead-based relaxor-ferroelectric films over a wide range of film thickness

Herein, we report the effect of film-thickness, ranging from 0.1 μm to 7.0 μm, on the energy storage performance of epitaxial Pb0.91La0.09Zr0.7Ti0.3O3 (PLZT) films grown on silicon substrates. As the PLZT film-thickness increases, polarization is enhanced and reaches a maximum value at a film-thickness of 1.0 μm, while the breakdown-strength reaches its maximum value at 0.5 μm. A film-thickness of 1.0 μm achieves an optimal volumetric recoverable energy-storage density (Ur,V) of 114.4 J/cm3 and an energy-efficiency of 87.3% at 4.7 MV/cm. Contrastingly, a film-thickness of 4.0 μm exhibits the largest stored recoverable-energy capacity over surface-area (Ur,A) of 34.2 mJ/cm2 (Ur,V = 85.4 J/cm3 at 4.05 MV/cm). Moreover, a film-thickness of 4.0 μm displays a large Ur,V value of 66.8 J/cm3, good thermal stability and excellent fatigue-endurance even at an operational temperature of 200 °C. These results suggest that thick PLZT films hold promise as high-performance energy-storage capacitors capable of operating effectively in harsh conditions.

Optical and optoelectrical characterizations of Cu2ZnSn3S8: A potential nominee for optoelectronic and photovoltaic applications

A successful trial has been accomplished in synthesizing a stable phase of Cu2ZnSn3S8 (CZTS8). The deposited thin films have been obtained by utilizing the chemical bath deposition (CBD) process. Basic characterizations have been applied to check the formation of our new stable material. The formed CZTS8 films disclose the amorphous nature as presented in the x-ray diffraction (XRD) patterns. Also, an enhancement in film morphology has been obtained by expanding the film thickness. Moreover, optoelectrical and linear/nonlinear optical features have been studied for the as-deposited films. Our material has interesting characteristics to be a promising window sheet for thin film solar cells. It reveals a tendency to be an n-type semiconductor material. Further, it shows high optical absorption as well as high optical conductivity. Moreover, it has a direct optical transition, and its energy gap is varied in the range (3.89 eV - 3.94 eV). Additionally, the dispersion and optoelectrical indices were affected by the variation in both film thickness and film roughness. Furthermore, the nonlinear optical indices χ(1),χ(3) and n2 were improved via the increase in film thickness. A satisfactory correlation has been performed between all of the evaluated parameters. The main goal of this study has been achieved by obtaining n-type material by increasing the Tin and Sulfur contents in the CZTS8 as compared with the known p-type material (Cu2ZnSnS4) CZTS4. The revealed findings acknowledge that CZTS8 could be a promising nominee for either optoelectronic or photovoltaic applications.

Physical properties of La:ZnO thin films prepared at different thicknesses using spray pyrolysis technique

Herein we investigate the impact of film thickness on the physical properties of Lanthanum (La) doped ZnO thin films. The films were fabricated using the spray pyrolysis technique with a consistent La content of 5 weight (wt) % in the initial solution. X-ray diffraction analysis indicated the presence of a hexagonal ZnO phase with preferred orientation along the (002) direction and no other phases were detected. The crystallite sizes were calculated using the Halder-Wagner equation, with a maximum size of 16.1 nm observed for a film thickness of 106 nm. Field-emission scanning electron microscopy (FE-SEM) images revealed the formation of a continuous film with an average grain size that increased as the thickness of the film increased. The grain size ranged from 74.5 to 136 nm as the film thickness varied from 106 to 426 nm. Films with lower thicknesses up to 196 nm exhibited two band gaps at approximately 3.2 and 4 eV, while films with higher thicknesses displayed a single band gap around 3.2 eV. The refractive index dispersion for all films was modeled using the Cauchy model, with parameters showing high dependence on the thickness values.The refractive index at high frequency, as calculated using the Cauchy model, was observed to decrease with increasing film thickness, ranging from 1.87 at 106nm to 1.63 at 426nm. Similar values were obtained by fitting the optical refractive index data with the Wemple-DiDomenico relation. Additionally, the UV sensing performance of the films was evaluated against UV light of a single wavelength (365 nm) at applied voltages of 10, 20, and 30V. The rise and decay times were measured, with the film thickness of 426 nm exhibiting the shortest rise and decay times at a specific applied voltage.

A novel time-varying mesh stiffness model for orthogonal face gear drives considering EHL

PurposeThis study aims to research the time-varying mesh stiffness (TVMS) model for orthogonal face gear drives considering elastohydrodynamic lubrication (EHL) and provide a theoretical basis for understanding the dynamic characteristics of face gear drives.Design/methodology/approachConsidering EHL, a novel model is proposed to calculate the TVMS of orthogonal face gears using the deformation compatibility condition. First, the tooth surface equations of orthogonal face gears are derived according to the tooth surface generation principle. Then, the oil film thickness on the tooth surface of face gears is obtained by solving the governing equations of EHL. Furthermore, the proposed model is used to calculate the TVMS of face gears along the mesh cycle and is verified. Finally, the effects of module, tooth number of shaper cutter and pressure angle on mesh stiffness are analyzed.FindingsThe results indicate that when the contact ratio is greater than 1 and less than or equal to 2, the TVMS of face gears exhibits a phenomenon of double-single tooth alternating meshing where sudden changes occur. As the module increases, the overall mesh stiffness of face gears increases, and the magnitude of the sudden change at the moment of single-double tooth alternating meshing gradually increases. As the tooth number of shaper cutter and pressure angle increase, so does the TVMS of face gears. When the effect of oil film is considered, the calculated TVMS of face gears slightly increases overall and the increase in average oil film thickness leads to a rise in the TVMS. This study provides a theoretical basis for understanding the dynamic characteristics of face gear drives.Originality/valueThis study’s originality and value lie in its comprehensive approach, which includes conducting analysis based on loaded tooth contact, considering the influence of elastohydrodynamic lubrication, proposing a novel analytical–finite–element model, calculating TVMS of face gears, verifying the proposed model and analyzing the effects of typical structural parameters and oil film thickness.

Inverse-proximity effect and 2D superconductivity of Ta/Au bilayer thin films

This study investigated the inverse-proximity effect (IPE) and two-dimensional (2D) superconductivity in α-phase Ta films and Ta/Au bilayers. These bilayers were deposited onto silicon substrates using a direct current (DC) sputtering system. The findings reveal that higher substrate temperatures and increased film thickness facilitate the formation of α-Ta up to a temperature limit of 300°C, resulting in higher Tc around 3.5–3.7 K. The fundamental superconductivity of α-Ta thin films is similar to that of a conventional s-wave BCS superconductor. The IPE in the Ta/Au bilayer films was observed, where the Tc increases and decreases with the Au overlayer thickness. This behavior was quantitatively described by considering a model accounting for the reduced superconducting fluctuations induced by the highly conductive Au layer. Furthermore, the presence of 2D superconductivity in the Ta film and Ta/Au bilayer was examined through critical field analysis, vortex motions, and Berezinskii-Kosterlitz-Thouless (BKT) transition detection. Finally, the results were summarized in an H-T phase diagram illustrating the presence of IPE and 2D superconductivity in a Ta/Au bilayer. This study provides additional insights into 2D superconductivity within normal/superconductor (N/S) bilayers, laying the groundwork for future research to optimize film properties to align more closely with theoretical expectations.

The role of ionic liquid additives in enhancing the tribological performance of plastic-derived oils

Improper disposal of waste plastic contributes significantly to environmental pollution. A promising solution to address this issue involves converting such plastics into valuable lubricating oils. This study investigated the tribological performance of both an aromatic-lean industrial plastic oil (PO) and aromatic-rich lab-scale plastic oils (LPO) using a ball-on-disk setup. The results revealed that PO exhibited considerably higher coefficients of friction (COF) and specific wear rates compared to LPO. To enhance the lubrication performance, a bio-based ionic liquid (IL: trihexyltetradecyl phosphonium saccharinate) with an unsaturated anion was incorporated. The COF and wear rates were further reduced with an IL blend in both PO and LPO. The IL additive promoted increased film thickness, beneficial micelle formation, facilitated adsorption film formation, and provided a phosphorus-rich tribofilm. These mechanisms collectively contributed to the notable improvement in tribological performance. Overall, this research demonstrates the potential of IL additives to enhance the tribological performance of both PO and LPO, thereby mitigating waste plastic pollution, and fostering a sustainable future.

Coupled Discrete Phase and Eulerian Wall Film Models for Drug Deposition Efficacy Analysis in Human Respiratory Airways.

The current study explores the effectiveness of drug particle deposition into human respiratory airways to cure various pulmonary-bound ailments. It has been assumed that drug solutions are inhaled in the form of tiny droplets or mist, which after striking create a thin layer along the inner surface of airways where the virus initially resides to infect the human body. A coupled Eulerian wall film (EWF) and discrete phase model (DPM) based simulation approach is used to capture these dynamics. Here, the Lagrangian DPM technique tracks the dynamics of tiny droplets, while the liquid layer formation after striking is captured using the Eulerian thin film approximations or the EWF model. Previous studies in this field primarily employed only the DPM method, which is inadequate to predict the poststriking dynamics of drug layer deposition and their spread to neutralize the respiratory virus. The drug delivery effectiveness is characterized by three different particle sizes, 1, 5, and 10 μm at the inhalation rates of 15, 30, and 60 L per minute (LPM). It has been found that the size of the drug particles significantly influences drug delivery effectiveness. The film thickness increases monotonically with particle sizes and inhalation rates. However, this increase in averaged film thickness is prominent in the range 5 to 10 μm (≈60%) compared to 1 to 5 μm (≈10%) droplet sizes at generation level 4 (G4). The other deposition parameters, e.g., deposition fraction, deposition density, and area coverage) roughly show similar behavior with the increase in droplet sizes. Therefore, it is recommended to vary the droplet sizes between 5 and 10 μm for better deposition effectiveness. The sizes of more than 10 μm mostly stuck into the oral cavity and cannot reach the targeted generations. In contrast, less than 5 μm may reach much deeper generations than the targeted one.

Investigation of magnetic domain interactions and switching mechanism in sputter deposited Fe–Co–Al thin film

To create a high-density data storage system, a thorough understanding of magnetic domain interactions is essential. In this work, we present a systematic study of magnetic domain state interaction and switching mechanism of Fe–Co–Al films across various thicknesses. Structural analysis confirms the formation of an A2-type disorder structure. Magnetic investigation reveals that all films are soft magnetic in nature, exhibiting a predominant in-plane magnetic anisotropy with a low coercive field that increases from 1.9 mT to 3 mT as the film thickness grows from 5 nm to 25 nm. Analysis of first-order reversal curves reveals the formation of multi-domain (MD) states. An enhancement of magnetic domain interactions occurs as the contour graph shifts along the coercive field direction with an increase in film thickness. Switching field distribution (SFD) analysis reveals broader SFD curves, indicating more inter-grain interactions as magnetostatic interactions between magnetic grains intensify with thickness. Further, magnetic force microscopy analysis confirms the presence of MD structures in all films. Magnetization reversal dynamics elucidates domain wall pinning near to zero field and possesses a large out-of-plane switching field. Simulations are performed to corroborate experimental findings. These findings underscore the critical role of domain state configuration and switching mechanisms for designing spintronic devices using soft magnetic thin films.