Low Melting Point Alloy Research Articles

A latchable high-pressure thermohydraulic valve actuator

This work presents a latchable thermohydraulic microactuator for use in high-pressure valves, e.g. for oceanic sampling in missions of long duration. Mounted on a miniature submersible, it can be used in confined spaces to explore previously unreachable environments. However, the device can be used in any high-pressure application where long duration open and/or closed valve states are required, and power consumption is an issue. The actuator is fabricated using standard batch-processes as photochemical machining, wet etching and photolithography. The actuation and latching mechanisms are both thermohydraulic, using solid-to-liquid phase transition of paraffin for actuation and of a low melting point alloy for latching. Focus of this work is on the endurance of the actuator to facilitate a bistable valve. The actuator managed to keep a deflected position for almost 50h at the load equivalent to 1.8MPa applied pressure, after which the experiment was aborted. No pressure dependence was discovered in the latching losses, i.e. the difference in deflection before and after the actuator is powered off. Furthermore, the effect of intermixing of paraffin and the low melting point alloy was evaluated.

Effects of modification on microstructure and properties of ultrahigh carbon (1.9 wt.% C) steel

Abstract The effects of a modifier that contains Rare Earths (RE), low melting point alloy (Al–Bi–Sb) and Ca–Si alloy on an ultrahigh carbon steel containing 1.9 wt.% C were studied. Microstructure characterization was carried out with optical microscopy (OM) and scanning electronic microscopy (SEM) combined with energy-dispersive spectrometry (EDS). Upon modification, the continuous eutectic carbide network structure was broken up and changed to a partly isolated and finer blocky structure in the as-cast alloy. Differential scanning calorimetry (DSC) revealed that the eutectoid temperature increased and the eutectic temperature decreased for the modified alloy. Modification also improved the impact toughness of the tempered steel, with a significant increase from 6.5 to 12.6 J cm −2 , despite the hardness remaining around 66 HRC. Furthermore, in pure sliding under loads of 20, 60 and 100 N for 600 s against a zirconia ball, the modified alloy shows slightly higher friction coefficient at all loads than the non-modified one. In addition, the friction coefficient for the steel specimen decreased with load from 20 N to 100 N attributing to a reduction in metallic wear and the formation of a thicker oxide film on the surfaces.

Hot Deformation Behavior and Fracture of As-Extruded 7075 Aluminum Alloy

Based on the isothermal compression experiment under constant strain rate, the deformation behavior and flow stress of as-extruded 7075 aluminum alloy at high temperature was studied. Then the fracture behavior and mechanism of 7075 aluminum alloy were investigated, the results showed that longitudinal cracking was easy to occur at a high temperature due to additional tensile stress and low melting point alloy in grain boundaries melting. Through analysis and comparing of C&L and Oyane fracture criteria, it was proved that C&L fracture criterion was more reasonable to predict fracture in 7075 aluminum alloy hot deforming, and the critical damage factor in a forming temperature range(300~450°C) for 7075 aluminum alloy was obtained.

Nanostructural CoSnC anode prepared by CoSnO 3 with improved cyclability for high-performance Li-ion batteries

Stannate, CoSnO 3, which mixes the elements Co and Sn evenly at the atomic level, was used as precursor to prepare CoSnC by a modified carbothermal reduction method. The synthesis process was characterized by differential thermal analysis (DTA) and X-ray diffraction (XRD). The particle feature was evaluated by transmission electron microscopy (TEM). The results indicated the as-prepared composite has a well-coated carbon layer that effectively prevents the encapsulated, low melting point alloy from out-flowing in a high-temperature treatment process. In addition, this structure, CoSn x grains surrounded by carbon, prevents aggregation and pulverization of nanosized, tin-based alloy particles during charge/discharge cycling and improves the cycling stability of the alloy. The synthesized CoSnC integrates the merits of intermetallic compounds and nanosized anode materials and delivers a reversible capacity of 450 mA h g −1 with a capacity retention of 72% after 50 cycles.

Lead–gold eutectic: An alternative liquid target material candidate for high power spallation neutron sources

One of the main technical concerns of Megawatt-class spallation neutron sources is the removal of the heat deposited in the target station. A way to overcome it is to use targets consisting of flowing liquid metals, but the already tested materials – mercury and lead–bismuth eutectic (LBE) – are not unproblematic. We show here that another eutectic alloy containing lead and gold (LGE) could be a suitable alternative. Besides a chemical toxicity lower than mercury, this low melting-point alloy has the advantage of being solid at RT. Moreover, it combines a neutron production similar to mercury and LBE with smaller amounts of alpha-emitting nuclides, relieving safety and environmental requirements. Further advantages are a reduced decay heat a few weeks after stopping operation and density variations in the solid state significantly smaller than LBE. Steel corrosion appears to be more important than expected but if it remains manageable, the current research suggests that LGE could be a valuable alternative to LBE and mercury.

Inherently aligned microfluidic electrodes composed of liquid metal

This paper describes the fabrication and characterization of microelectrodes that are inherently aligned with microfluidic channels and in direct contact with the fluid in the channels. Injecting low melting point alloys, such as eutectic gallium indium (EGaIn), into microchannels at room temperature (or just above room temperature) offers a simple way to fabricate microelectrodes. The channels that define the shape and position of the microelectrodes are fabricated simultaneously with other microfluidic channels (i.e., those used to manipulate fluids) in a single step; consequently, all of the components are inherently aligned. In contrast, conventional techniques require multiple fabrication steps and registration (i.e., alignment of the electrodes with the microfluidic channels), which are technically challenging. The distinguishing characteristic of this work is that the electrodes are in direct contact with the fluid in the microfluidic channel, which is useful for a number of applications such as electrophoresis. Periodic posts between the microelectrodes and the microfluidic channel prevent the liquid metal from entering the microfluidic channel during injection. A thin oxide skin that forms rapidly and spontaneously on the surface of the metal stabilizes mechanically the otherwise low viscosity, high surface tension fluid within the channel. Moreover, the injected electrodes vertically span the sidewalls of the channel, which allows for the application of uniform electric field lines throughout the height of the channel and perpendicular to the direction of flow. The electrodes are mechanically stable over operating conditions commonly used in microfluidic applications; the mechanical stability depends on the magnitude of the applied bias, the nature of the bias (DC vs. AC), and the conductivity of the solutions in the microfluidic channel. Electrodes formed using alloys with melting points above room temperature ensure mechanical stability over all of the conditions explored. As a demonstration of their utility, the fluidic electrodes are used for electrohydrodynamic mixing, which requires extremely high electric fields (~10(5) V m(-1)).

A modified carbothermal reduction method for preparation of high-performance nano-scale core/shell Cu 6Sn 5 alloy anodes in Li-ion batteries

Core–shell structured, carbon-coated, nano-scale Cu 6Sn 5 has been prepared by a modified carbothermal reduction method using polymer coated mixed oxides of CuO and SnO 2 as precursors. On heat treatment, the mixture oxides were converted into Cu 6Sn 5 alloy by carbothermal reduction. Simultaneously, the remnants carbon was coated on the surface of the Cu 6Sn 5 particles to form a core–shell structure. Transmission electron microscope (TEM) images demonstrate that the well-coated carbon layer effectively prevents the encapsulated, low melting point alloy from out flowing in a high-temperature treatment process. Core–shell structured, carbon coated Cu 6Sn 5 delivers a reversible capacity of 420 mAh g −1 with capacity retention of 80% after 50 cycles. The improvement in the cycling ability can be attributed to the fact that the carbon-shell prevents aggregation and pulverization of nano-sized tin-based alloy particles during charge/discharge cycling.

Nosing thin-walled tubes into axisymmetric seamless reservoirs using recyclable mandrels

This paper is focused on novel utilizations of raw materials and technologies for manufacturing lightweight metallic reservoirs. The objective is to develop an environmental friendly technology for producing gas and liquid storage reservoirs that ensures a more efficient utilization of raw materials and a better end-of-life management of products than other technologies currently used to fabricate metallic reservoirs. The proposed technology utilizes previously engineered single-stage nosing of thin-walled tubes using sacrificial (expendable) mandrels to develop a multi-stage process that makes use of recyclable mandrels for producing lightweight, axisymmetric, seamless reservoirs. Recyclable mandrels are cast from low melting point alloys, possess the ability to continuously adapt its shape to that of the preforms and are easily removed by melting, while leaving the reservoir intact, at the end of the process. The prospects for eliminating the welding routes commonly used in the fabrication of reservoirs and for remelting and recycling the mandrels, results in significant economic and time savings and offers potential for opening new markets for the production of low-cost seamless reservoirs. The presentation is supported by experimentation and numerical modelling based on independently determined mechanical properties of the materials with the purpose of understanding the deformation mechanics and identifying the major operating parameters of the proposed technology.

Development of a Range of Anatomically Realistic Renal Artery Flow Phantoms

Computer-aided modelling techniques were used to generate a range of anatomically realistic phantoms of the renal artery from medical images of a 64-slice CT data set acquired from a healthy volunteer. From these data, models of a normal healthy renal artery and diseased renal arteries with 30%, 50%, 70% and 85% stenoses were generated. Investment casting techniques and a low melting point alloy were used to create the vessels with varying degrees of stenosis. The use of novel inserts significantly reduced the time, materials and cost required in the fabrication of these anatomically realistic phantoms. To prevent residual metal remaining in the final phantom lumens a technique employing clingfilm was used to remove all molten metal from the lumen. These novel flow phantoms developed using efficient methods for producing vessels with various degrees of stenosis can provide a means of evaluation of current and emerging ultrasound technology. (E-mail: king.deirdre@mayo.edu)

Fabrication of low-melting-point alloy microelectrode and monolithic spray tip for integration of glass chip with electrospray ionization mass spectrometry

In this paper, a glass microchip-based emitter with a low-melting-point alloy (LMA) microelectrode and a monolithic tip for electrospray ionization mass spectrometry (ESI-MS) was described. So far, the fabrication of metal microelectrode achieving direct electrical contact in the microchannel of glass chip is still a challenge. A novel fabrication approach for LMA microelectrode in the glass chip was developed to achieve direct electrode-solution electrical contact in the microchannel. An electrode channel and a sample channel were firstly fabricated on a glass chip with a micropore connecting the two channels. The melted LMA was filled into the electrode channel under a pressure of ca. 100kPa, forming a stable and nicely fitted interface at the micropore between the sample and the electrode channels due to surface tension effect. The melted LMA filled in the electrode channel was then allowed to solidify at room temperature. The channel geometries including the distance between the sample and the electrode channels on the mask and the turning angle of the electrode channel were optimized for fabricating the LMA electrode. In this work, an improved fabrication approach for monolithic emitter tip based on pyramid-shaped tip configuration and stepped grinding method was also developed to fabricate well-defined sharp tips with a smallest tip end size of ca. 15microm x 50microm. Two types of emitter tip end including puncher-shaped tip and fork-shaped tip were produced. The emitter with the fork-shaped tip showed better working stability (4.4% RSD, TIC) at nanoliter-scale flow rate of 50nL/min. The fabrication approaches for the LMA microelectrode and emitter tip are simple and robust, and could be carried out in most of routine laboratories without the need of complicated and expensive instruments. The performance of the emitter was evaluated in the analysis of reserpine, angiotensin II and myoglobin. A continuous experiment over 6h demonstrated good stability of the present system in long-term analysis.

Characteristics of Isotropically Conductive Adhesive (ICA) Filled with Carbon Nanotubes (CNTs) and Low-Melting-Point Alloy Fillers

A new class of isotropic conductive adhesive (ICA) using a carbon nanotubes (CNTs) and a low-melting-point alloy (LMPA) fillers has been developed. We investigated the fundamental materials characteristics including curing behavior and temperature-dependant viscous property of ICA. In addition, the morphology of conduction paths in each ICA was investigated using X-ray inspection systems and an optical microscope. Mechanical and electrical characteristics of formulated ICAs were determined and compared with those of three kinds of conventional ICAs filled with Ag flakes. The CNT-filled solderable ICA formed good metallurgical interconnection between upper and corresponding lower electrode. In addition, the results indicated that the CNT-filled ICA exhibit lower electrical resistance and higher mechanical strength, as compared with those of conventional ICAs.

Monte Carlo simulation of a multi-leaf collimator design for telecobalt machine using BEAMnrc code.

This investigation aims to design a practical multi-leaf collimator (MLC) system for the cobalt teletherapy machine and check its radiation properties using the Monte Carlo (MC) method. The cobalt machine was modeled using the BEAMnrc Omega-Beam MC system, which could be freely downloaded from the website of the National Research Council (NRC), Canada. Comparison with standard depth dose data tables and the theoretically modeled beam showed good agreement within 2%. An MLC design with low melting point alloy (LMPA) was tested for leakage properties of leaves. The LMPA leaves with a width of 7 mm and height of 6 cm, with tongue and groove of size 2 mm wide by 4 cm height, produced only 4% extra leakage compared to 10 cm height tungsten leaves. With finite 60Co source size, the interleaf leakage was insignificant. This analysis helped to design a prototype MLC as an accessory mount on a cobalt machine. The complete details of the simulation process and analysis of results are discussed.

Effects of novel carboxylic acid-based reductants on the wetting characteristics of anisotropic conductive adhesive with low melting point alloy filler

A low viscosity epoxy resin with carboxylic acid-based novel reductants was introduced to improve the process ability and reliability of an anisotropic conductive adhesive (ACA) resin with a low melting point alloy (LMPA) filler system. The curing degree of the ACA resin and the melting of the LMPA filler were investigated using differential scanning calorimetry (DSC) conducted in the dynamic mode in order to control the curing conditions such as the reaction temperature and a melting temperature of solder. The temperature-dependent viscosity characteristics of the ACA resin were investigated using a rheometer. The compatibility between the viscosity of a polymer matrix and a melting temperature of solder was characterized to optimize the processing cycle. Three different types of carboxyl acid-based reductants were added to remove the oxide layer on the surfaces of the filler particles and the conductive pad. Good wetting properties were achieved between the LMPA filler and the Cu pad in the epoxy resin using these carboxylic acid-based reductants.

Matching extended‐SSD electron beams to multileaf collimated photon beams in the treatment of head and neck cancer

Matching the penumbra of a 6 MeV electron beam to the penumbra of a 6 MV photon beam is a dose optimization challenge, especially when the electron beam is applied from an extended source-to-surface distance (SSD), as in the case of some head and neck treatments. Traditionally low melting point alloy blocks have been used to define the photon beam shielding over the spinal cord region. However, these are inherently time consuming to construct and employ in the clinical situation. Multileaf collimators (MLCs) provide a fast and reproducible shielding option but generate geometrically nonconformal approximations to the desired beam edge definition. The effects of substituting Cerrobend for the MLC shielding mode in the context of beam matching with extended-SSD electron beams are the subject of this investigation. Relative dose beam data from a Varian EX 2100 linear accelerator were acquired in a water tank under the 6 MeV electron beam at both standard and extended-SSD and under the 6 MV photon beam defined by Cerrobend and a number of MLC stepping regimes. The effect of increasing the electron beam SSD on the beam penumbra was assessed. MLC stepping was also assessed in terms of the effects on both the mean photon beam penumbra and the intraleaf dose-profile nonuniformity relative to the MLC midleaf. Computational techniques were used to combine the beam data so as to simulate composite relative dosimetry in the water tank, allowing fine control of beam abutment gap variation. Idealized volumetric dosimetry was generated based on the percentage depth-dose data for the beam modes and the abutment geometries involved. Comparison was made between each composite dosimetry dataset and the relevant ideal dosimetry dataset by way of subtraction. Weighted dose-difference volume histograms (DDVHs) were produced, and these, in turn, summed to provide an overall dosimetry score for each abutment and shielding type/angle combination. Increasing the electron beam SSD increased the penumbra width (defined as the lateral distance of the 80% and 20% isodose contours) by 8-10 mm at the depths of 10-20 mm. Mean photon beam penumbra width increased with increased MLC stepping, and the mean MLC penumbra was approximately 1.5 times greater than that across the corresponding Cerrobend shielding. Intraleaf dose discrepancy in the direction orthogonal to the beam edge also increased with MLC stepping. The weighted DDVH comparison techniques allowed the composite dosimetry resulting from the interplay of the abovementioned variables to be ranked. The MLC dosimetry ranked as good or better than that resulting from beam matching with Cerrobend for all except large field overlaps (-2.5 mm gap). The results for the linear-weighted DDVH comparison suggest that optimal MLC abutment dosimetry results from an optical surface gap of around 1 +/- 0.5 mm. Furthermore, this appears reasonably lenient to abutment gap variation, such as that arising from uncertainty in beam markup or other setup errors.

2A2-B02 全方向包み込み式なじみグリッパ : 把持応答性向上を目指した各種方法

This paper describes the morphing omnidirectional gripper which is able to grasp various objects with low melting point alloy. The deformable part of the gripper changes its shape by covering all directionof objects and makes the contacting area higher. In order to keep the high grasping force, proposed gripper does not need any additional energy thanks to the solid state of the deformable part including low melting point alloy. The design of the actual prototype model with cooling mechanism is shown and built. In addition, the usage of functional fluids for the morphing part is proposed. The basic performance of the blended material of low melting point alloy and magnetic fluid has been observed.

Hybrid Interconnection Process Using Solderable ICAs (Isotropic Conductive Adhesives) with Low-Melting-Point Alloy Fillers

In order to overcome several crucial limitations to the traditional electrically conductive adhesive bonding used in the electronics field, a novel low-melting-point alloy (LMPA)-filled ICA (Isotropic Conductive Adhesive) was synthesized. Also, a hybrid interconnection process using it was developed, which can be achieved by melting-coalescence-wetting behavior of LMPA fillers in ICA. In order to ensure excellent coalescence and wetting characteristics of the LMPA filler particles, the fluxing capability of the resin should have been sufficient to remove the oxide layer on the surfaces of the filler particles and the electrode materials. The effect of reductant on the hybrid interconnection formation was examined. ICAs with and without reductant were formulated with a 40% volume fraction of filler. The QFP chip had a size of 14 � 14 � 2:7 mm and a 1 mm lead pitch. The test board had a 18 mm thick Cu daisy-chained pattern. Thermal characteristic of the ICA was observed by differential scanning calorimetry (DSC), and the temperature-dependant viscosity characteristic of the polymer matrix was observed by torsional parallel rheometer. Based on the results, the reflow profile of the interconnection process was determined. The dipping interconnection method was applied in the QFP bonding process. After the QFP bonding process, the electrical characteristic of ICA was measured with a multimeter. The wetting, bondability, coalescence characteristics of the LMPA filler particles and the morphology of the conduction path were observed by microfocus X-ray inspection systems and optical microscopy. As a result, the LMPA-filled ICAs with reductant had stable contact resistance, forming the metallurgical interconnection. A good electrical conduction path was achieved with the coalescence and wetting characteristics of the molten solder particles in the ICA. [doi:10.2320/matertrans.M2009109]

Self-Organized Interconnection Process Using Solderable ACA (Anisotropic Conductive Adhesive)

In this paper, we discuss our design of a new class of low-melting-point alloy (LMPA)-filled anisotropically conductive adhesives (ACA) and a self-organized interconnection process for using these adhesives, and we demonstrate a good electrical conduction for the process. Flow, melting, coalescence, and wetting characteristics of LMPA fillers in the ACA facilitate this process. In order to exploit good coalescence and wetting characteristics of LMPA fillers, the polymer matrix has a sufficient fluxing capability against oxide films of both LMPA fillers and electrode materials. Furthermore, it is essential that the polymer have a low viscosity level around the melting point of the incorporated LMPA to achieve a good electrical conduction path. In order to study coalescence and wetting characteristics, we formulated two types of ACA with different volume fractions of LMPA filler (10 vol% and 40 vol%). Our test board had an 18-mm thick Cu line-type pattern (10 mm � 0:1 mm) and an area array-type pattern (square type: 0:1 mm � 0:1 mm, circle type: ’, 0.1 mm) with five different pitches (50 mm to 250 mm). We measured thermal properties of the ACA by differential scanning calorimetry (DSC), and we determined a temperature profile for the interconnection process. We then monitored coalescence and wetting characteristics of LMPA fillers and morphology of conduction path in ACA by using a microfocusing X-ray inspection system and an optical microscope. We determined that the developed LMPA-filled ACA have good coalescence and wetting characteristics regardless of pattern types. In addition, we were able to achieve a good electrical conduction path because of the coalescence and wetting characteristics of the LMPA fillers in the ACA. [doi:10.2320/matertrans.MF200918]

Simple technique for fabrication of shielding blocks for total body irradiation at extended treatment distances

Techniques are being standardized in our department for total body irradiation (TBI) with six MV photons in linear accelerator for preconditioning to bone marrow transplantation (BMT). Individualized shields with low melting point alloy are to be fabricated for shielding critical organs such as lungs, kidneys etc. A method to mount diminished dimension of shields in a tray at 3.75m is designed in the department for a teletreatment distance of four meters with magna field with A simulator image taken with the patient's midplane (MP) at one meter distance is used to mark the dimensions of lung, scaled down by a factor of 3.75/4.0. These lung dimensions are reprinted from the digital simulator image for making the shield. The methodology of the technique using digitized minification in radiography is the first of its kind to be used for shield cutting in magna field radiotherapy.

Numerical Analysis of Coalescence Characteristics of Low Melting Point Alloy Fillers Using a Non-Equilibrium Phase Field Model

A non-equilibrium phase field model (NPFM) is proposed to examine the three-dimensional coalescence characteristics of low melting point alloy (LMPA) fillers, widely used for self-organized interconnection applications. This model sufficiently considers the non-equilibrium process during phase transitions, resulting in accurate prediction of interfaces between two different phases with a high density ratio. The preliminary simulation is carried out for validation of the present model and numerical predictions are in good agreement with analytical solutions for a one-dimensional solidification problem. The proposed NPFM successfully predicts the phase transition, the heat transfer from solid to liquid, and the coalescence behaviors of LMPA fillers, whereas the conventional enthalpy method fails to describe the non-equilibrium phase transition. Moreover, the results show that there exists grid dependency in the mush zone, suggesting that special care should be taken of the mush zone for better prediction of interfaces between different phases.

J0406-3-1 超音波法による鋳造金型および凝固材料の温度分布モニタリングの基礎的検討(超音波計測・解析法の新展開(3))

An ultrasonic method has been applied to internal temperature measurements of heated materials during casting process. The principle of the method is based on the temperature dependence of the velocity of ultrasonic wave propagating through a material. An inverse analysis coupled with a finite difference calculation is used to determine a one-dimensional temperature distribution. In this work, an attempt to monitor both temperatures of a solidifying alloy and a die during casting process has been made. A low melting-point alloy is employed as the melt. Ultrasonic pulse-echo measurements are performed and the changes in the transit times of the reflected echoes through the die and the alloy are continuously acquired, and then the temperature distributions inside the die and the alloy have been estimated during the casting process.