Metal Wire Research Articles

Review of Carbon Nanotube Wire-to-Metal Connection Methods: Techniques, Challenges, and Prospects

This paper reviews the connection technologies between carbon nanotube (CNT) wires and metal materials, analyzes the technical principles, advantages, limitations and application prospects of different connection methods. It mainly focuses on the electrical contact issues of CNT wires in the field of microelectronics, and how to achieve a high-performance, reliable combination of metal and CNT wires through emerging material processing and connection technologies. The article also discusses the challenges these technologies face in overcoming interface resistance, improving mechanical connection performance, and maintaining the characteristics of CNT wires.

Mechanics behaviors and electrical conductivity of beryllium bronze alloy entangled metallic wire material: Experimental study and theoretical modeling

In the present work, a novel entangled metallic wire material (EMWM) with good mechanical properties and electrical conductivity was developed by using beryllium bronze alloy wire as raw material. A series of thermal-mechanical-electrical coupling tests were carried out to investigate the mechanical properties (average stiffness, loss factor) and electrical conductivity of beryllium bronze alloy entangled metallic wire material (QBe2-EMWM) and austenitic stainless steel entangled metallic wire material (304-EMWM). The effect of the density and ambient temperature on mechanical performances and resistance properties of EMWM were analyzed in detail. It is found that the mechanical properties of QBe2-EMWM are similar to those of austenitic stainless steel entangled metallic wire material (304-EMWM). The electrical resistance of EMWM decreases with the increase of density. Moreover, the electrical resistance of QBe2-EMWM is significantly lower than 304-EMWM and is only 5 % of 304-EMWM. In the aspect of theoretical modeling, based on a cube unit-cell approach, a simplified electrical resistor network was derived from modeling low-frequency current flow through the EMWM. Considering the influence of ambient temperature, the simplified resistor network model was modified by referring to the temperature term of the Johnson-Cook model, and then the conductivity model considering temperature effect for EMWM was established. The accuracy of the theoretical electrical model of EMWM was verified by comparing the calculated results with the experimental data. The results show that the proposed model can adequately predict the electrical conductivity characteristics of EMWM under different temperatures.

On-Chip Modification of Titanium Electrothermal Characteristics by Joule Heating: Application to Terahertz Microbolometer.

This study demonstrates the conversion of metallic titanium (Ti) to titanium oxide just by conducting electrical current through Ti thin film in vacuum and increasing the temperature by Joule heating. This led to the improvement of electrical and thermal properties of a microbolometer. A microbolometer with an integrated Ti thermistor and heater width of 2.7 µm and a length of 50 µm was fabricated for the current study. Constant-voltage stresses were applied to the thermistor wire to observe the effect of the Joule heating on its properties. Thermistor resistance ~14 times the initial resistance was observed owing to the heating. A negative large temperature coefficient of resistance (TCR) of -0.32%/K was also observed owing to the treatment, leading to an improved responsivity of ~4.5 times from devices with untreated Ti thermistors. However, this does not improve the noise equivalent power (NEP), due to the increased flicker noise. Microstructural analyses with transmission electron microscopy (TEM), transmission electron diffraction (TED) and energy dispersive X-ray (EDX) confirm the formation of a titanium oxide (TiOx) semiconducting phase on the Ti phase (~85% purity) deposited initially, further to the heating. Formation of TiOx during annealing could minimize the narrow width effect, which we reported previously in thin metal wires, leading to enhancement of responsivity.

Design and integration of textile-based temperature sensors for smart textile applications

Wearable technology is now frequently utilized to check people’s health. Body temperature measurements needed for telemedicine and real-time health monitoring applications can be taken with wearable temperature sensors. The goal of this work was to create thermocouples made of textiles for use in smart textile applications, particularly temperature monitoring in outfield uniforms. The thermocouples were created using metal wire and conductive yarns; however, metal-based thermocouples were only created for reference. In these studies, three junction levels and three distinct materials were used, and the Seebeck coefficient for these samples was examined. A four-probe heating system coupled with a multimeter was used to calculate the Seebeck coef-ficient. Results show that the cotton-based conductive yarn thermo-couple with stainless steel yarn (C + SS2) junction performed well with the best Seebeck coefficient value. The thermocouple values with one, five, and ten junctions were sequentially 167.56 µv °C−1, 227.30 µv °C−1, and 267.54 µv °C−1. After the integration, ten junction thermocouples of C + SS2 showed the best Seebeck coefficient values.

Study on the synergy inhibition of ultrafine water mist and metal wire mesh on the syngas explosion

Synergy inhibition of wire mesh and spray mist on syngas explosion was researched. The correspondence between the explosion parameters under success and failure conditions were analyzed, and its influence regular and inhibition mechanism were revealed. An evident difference appeared in the correspondence at different synergy results. Compared with the failure, the pressure of lower end only experienced an acceleration rise under the success condition although the propagation velocity of flame was slightly increased as it approached wire mesh. Corresponding pressure was also reduced. After passing through wire mesh, flame propagation was evidently accelerated due to the turbulence disturbance caused by wire mesh despite the strong endothermic effect of mist. The corresponding explosion reaction rate was also increased. Pressures of two ends did not appear obvious change under the success condition, but the pressure of upper end was evidently reduced compared with the failure. Due to the combined effect of wire mesh disturbance and mist heat absorption, the velocity history showed a change of increasing firstly and then decreasing as the spray time increased after passing through wire mesh. The synergy inhibition was attributed to the combined physical and chemical effects, and was related to the syngas concentration and spray amount.

Mechanically processed, vacuum- and etch-free fabrication of metal-wire-embedded microtrenches interconnected by semiconductor nanowires for flexible bending-sensitive optoelectronic sensors

Abstract We demonstrate the facile fabrication of metal-wire-embedded microtrenches interconnected with semiconducting ZnO nanowires (ZNWs) through the continuous mechanical machining of micrograting trenches, the mechanical embedding of solution-processable metal wires therein, and the metal-mediated hydrothermal growth of ZNWs selectively thereto. The entire process can be performed at room or a very low temperature without resorting to vacuum, lithography, and etching steps, thereby enabling the use of flexible polymer substrates of scalable sizes. We optimize the fabrication procedure and resulting structural characteristics of this nanowire-interconnected flexible trench-embedded electrode (NIFTEE) architecture. Specifically, we carefully sequence the coating, baking, and doctor-blading of an ionic metal solution for the embedding of clean metal wires, and control the temperature and time of the hydrothermal ZNW growth process for faithful interconnections of such trench-embedded metal wires via high-density ZNWs. The NIFTEE structure can function as a bending-sensitive optoelectronic sensor, as the number of ZNWs interconnecting the neighboring metal wires changes upon mechanical bending. It may benefit further potential applications in diverse fields such as wearable technology, structural health monitoring, and soft robotics, where bending-sensitive devices are in high demand.

Investigation of tensile and fatigue properties of an austenitic stainless steel part fabricated by WAAM

Austenitic stainless steels are used in many industrial applications and the use of components produced from this material by the wire arc additive manufacturing (WAAM) method has gained interest. Since damage of metallic parts generally occurs due to fatigue, it is necessary to understand their fatigue properties. This study focused on the determination of tensile and fatigue properties of an austenitic stainless steel structure produced by WAAM. For this purpose, a medium-sized part was fabricated using 308LSi metallic wire and gas metal arc welding (GMAW) technique. Hardness tests and microstructure examinations were also performed on the part. In the tensile tests, it was found that the strength and ductility of the vertical and horizontal samples were different. However, the fatigue test results of horizontal and vertical specimens were very similar. The average fatigue limit was found to be 195 MPa, and the fatigue life of the sample reached 107 without any macro damage. As a result of the hardness tests, the average hardness was calculated as 197 HV0.5. In the microstructure studies, different ferrite formations were observed in the austenite matrix on the bottom, middle and upper zones. The changes in microstructure were mostly attributed to the exposure of multiple layers to different heating and cooling rates during WAAM.

Effect of Cu content on the wear resistant behavior of arc-sprayed laminated-structured Cu–TiN/TiO2 composite coating

The wear and corrosion effects in marine or coastal environments are critical issues that seriously deteriorate the service performance of marine infrastructure. Thus, development of an effective and long-lasting wear-resistant and corrosion-resistant protective coating is highly desirable. By controlling the diameter ratio of different heterogeneous metal wires during the supersonic arc spraying process, a laminated-structured Cu-TiN/TiO2 metal-ceramic composite coating with a Cu content of 8.3 % -66.6 % was fabricated. The effects of Cu loading on the microstructure, morphology, mechanical properties, and wear resistance of composite coating were analyzed. The results of scanning electron microscopy and nanoindentation tests indicated that the composite coating exhibited a dense microstructure, with tight interlayer bonding, and a gradient change in hardness and Young's modulus with Cu loading. The friction and wear tests under different loads and wear environments shown that the composite coating had excellent wear resistance. The composite coating with 8.3 % Cu loading had stronger resistance to plastic deformation and abrasive wear under dry sliding friction with 5 N and 10 N loads. The composite coating with 35.8 % Cu loading shown the most significant lubrication and friction reduction effect of Cu under dry sliding friction at a larger load of 20 N, showing the best wear resistance. The wear test under 10 N load with 3.5 wt% NaCl corrosion solution shown that the composite coating with 8.3 % Cu load had a more prominent role in resisting corrosion wear. These results may guide the preparation of high hardness, wear and corrosion resistant Cu-TiN/TiO2 metal-ceramic composite coating with appropriate Cu loading capacity through simple and effective preparation methods and easily customized raw materials, according to different wear and corrosion conditions.

Computational Design and Fabrication Strategy for Topology Optimization of Spiral Staircase Using Metal Wire Arc Additive Manufacturing

The study presents the integration of Topology Optimization (TO) as a design strategy and Wire Arc Additive Manufacturing (WAAM) as a fabrication strategy. Although TO is well-known in the discipline, a gap in implementing this technique in architectural design due to fabrication limitations remains. In this research, an integrated framework is proposed to obtain a design where both TO and WAAM printing are implemented simultaneously. This framework is divided into five main phases, (1) checking suitability, (2) preprocessing, (3) processing, (4) post-processing, and (5) printing. The framework is then applied to the design of a topology-optimized spiral staircase and studied for fabrication using WAAM metal 3D printing. The results conclude that avoiding the usual standardization of design can be realized by implementing a framework that takes the fabrication strategies into consideration throughout the design process.

Experimental demonstration of scalability in a cavity-free planar silicon-integrated thermoelectric device

We demonstrate the scalability of cavity-free planar integrated thermoelectric (TE) devices using silicon nanowires (Si-NWs), where miniaturizing the thermoelement by shortening the Si-NWs improves the areal power density. Shortening the Si-NW length decreases the temperature difference between the Si-NW ends and the open-circuit voltage. Meanwhile, the integrated number density of the thermoelement is increased by shortening the Si-NW length, thereby preserving the total electrical resistance. Bileg devices comprising both n- and p-type Si-NWs exhibited superior performance compared to unileg devices comprising only n-type Si-NWs. In unileg devices, the hot and cold electrodes in the adjacent thermoelements are interconnected through metal wiring, which leaks heat, resulting in a lowering of the temperature difference between the Si-NW ends. This study yields structural design guidelines for planar-integrated TE devices using Si-NWs.

Electrochemical and Tribological Performance of Ti–Al with xNb Addition Synthesized via Laser In situ Alloying

Additive manufacturing is a growing technique of producing 3D parts directly using metal powders or wires melted with a high-powered intensity beam or laser. It is still a challenging process as to how laser processing parameters such as gas flow rate and powder flow rate can profitably be adopted to significantly produce Ti–Al-based materials from elemental powders to synthesize alloys that are defect-free and have good mechanical properties. The density of titanium aluminide (Ti–Al) intermetallic alloys makes it gain lots of interests due to its potential ability to substitute nickel-based superalloys in gas turbine engines. This work aims to investigate the effects of Niobium (Nb) additions on Ti–Al–xNb ternary alloys created via the use of 3D printing technology, specifically looking at microstructural evolution, microhardness, electrochemical behavior, and tribological properties. Ti–Al–Nb alloy was synthesized at scan speed of 26 in/min and laser power of 450 W. The structural morphology of the alloys produced was investigated using scanning electron microscopy equipped with energy dispersive spectroscopy and the electrochemical studies of the in situ alloyed Ti–Al–xNb were studied using potentiodynamic techniques. Using an Emco microhardness tester, the microhardness characteristics of the produced TiAl–xNb alloys were examined. From the results obtained, it was observed that the microstructure showed not much substantial cracking or crack initiation. The micrographs are evident of refined microstructure associated to increase in Nb feed rate with α-Ti3Al, γ-TiAl and precipitates of β-TiAl phases as the distinctively identified in the microstructure. The highest recorded microhardness value of 679.1 HV0.5 was achieved at Nb feed of 0.5 rpm and gas carrier of 2 L/min. The fabricated Ti–Al–Nb alloys showed good corrosion resistance behavior in HCl and appreciable wear characteristics with coefficient of friction of 0.412, 0.401, and 0.414 µ at B1, B3, and B5, respectively.

Experimental study and simulation analysis of transmission characteristics of terahertz metal wire waveguides

Terahertz waves are between microwave and infrared, and currently, terahertz waves are mainly transmitted in free space. Metal wire waveguides have been widely studied due to their outstanding transmission characteristics such as low loss and low dispersion. In this study, copper wires are selected as the research samples based on the skin depth of terahertz waves on different metal wire surfaces. An adjustable metal wire waveguide transmission characteristic testing optical path is studied based on the terahertz time-domain spectroscopy system. The time-domain signals transmitted through single/double copper wires with different radii, lengths, and port states are collected. Then, the finite element method is used to analyze the transmission characteristics of single/double copper wires with different radii, lengths, and port states, and the transmission characteristics of single/double copper wires with different degrees of deformation in the air domain are simulated. The experimental results indicate that the transmission loss increases with copper wire length increasing, and the thinner the metal wire, the slower the transmission speed is. The influence of port shape on transmission characteristics is not so significant as that of length variation. The thicker the bimetallic wire, the faster the transmission speed is. The simulation results show that when terahertz waves are transmitted on a single metal wire, the electric field is mainly distributed on the surface of the metal wire, and the finer the metal wire, the smaller the mode field area of the surface plasmon is. When the metal line becomes elliptical, the mode field is mainly distributed on both ends of the major axis; When terahertz waves are transmitted in bimetallic wires, the mode field is mainly distributed between the two wires, and the farther the distance, the smaller the mode field area is. In this work, the terahertz transmission characteristics of single wires and bimetallic wires are studied by combining experimental method and simulation analysis, providing a reference for the subsequent development of efficient terahertz metal waveguides.

A continuous flow electrochemical reactor using readily available metal wires and carbon fibers as electrodes: environmentally benign halogenations of alkenes, alkynes, and aromatics

We have developed a new continuous-flow electrochemical reactor using readily available metal wires and carbon fibers as electrodes. Environmentally benign halogenations were used as a proof of concept.

Analogy between a moving line source illuminating a metallic wire and Compton scattering experiment

AbstractThis paper presents an electromagnetic analysis of a moving infinitely long line source illuminating an infinitely long metallic wire at rest. The study uses the full‐wave numerical finite difference time domain (FDTD) method, which is based on the spatial and temporal discretization of Maxwell's equations. Movement is computed within the FDTD technique by varying the position of the line source at each time loop. An analogy is proposed between the wavelength spectrum of the simulated electromagnetic field and the Compton scattering experiment. A good agreement is obtained between theoretical analysis, numerical results, and Compton experimental data.

Non-equilibrium defect chemistry in oxygen-rich zinc oxide nano-tetrapods synthesized using atmospheric pressure microplasma

We demonstrate the synthesis of zinc oxide (ZnO) nanoscale tetrapods (nTPs) using an atmospheric pressure microplasma with a metal wire as a sacrificial electrode.

Design and structural analysis for a camber-morphing wing with deformable truss

A camber-morphing wing based on a deformable truss is proposed in this paper. And then the structural analysis of the proposed camber-morphing wing is achieved. Compared with the existing concept of camber-morphing wings, the deformation mode of this wing is easier to manufacture and implement in engineering. Due to the fact that the wing is driven by multiple motors, it has the characteristic of multiple degrees of freedom in camber-morphing, which can achieve various deformation controls. Establishing corresponding finite element models, the deformation ability under different driving conditions is simulated. The results indicate that compared with driving short metal wires, driving long metal wires results in a greater degree of trailing edge deflection due to a greater driving force. Based on finite element analysis of deformation capability, the camber-morphing wing exhibits satisfactory deformation capability. Furthermore, based on the analysis of load-bearing capacity, it is indicated that the camber-morphing wing has sufficient load-bearing capacity.

Enhancing stability in thin-walled part production with L-DED wire using an adaptive controller

Laser-based direct energy deposition (L-DED) with metal wire is an efficient additive manufacturing process known for its cleanliness, user-friendliness, and cost-effectiveness. Nonetheless, heat build-up, especially in thin-walled parts, leads to geometric deviations and process instabilities due to limited heat dissipation. Closed-loop control of deposition height and local temperature addresses this issue. However, traditional controllers like PID controllers with fixed dynamics cannot adequately handle the long-term drifts inherent in the system dynamics. This study introduces an adaptive controller that dynamically adjusts the parameters for effective L-DED control using optical coherence tomography for the measurement of the deposition height and a coaxial camera for the determination of the temperature from thermal radiation. The control variables include the feed speed of the wire for material input and the laser power to control the deposition height and temperature. Our approach reduces deviations of the wall’s height by a factor of 10 and enables defect-free fabrication of thin-walled parts. This underscores the efficacy of our control system in enhancing L-DED.

Conceptual review of Clear Aligner Therapy (CAT)

Patients seeking orthodontic treatment often prioritize aesthetics, and aesthetics play a significant role in orthodontic care. Researchers have developed a range of options, such as ceramic or composite braces, lingual orthodontics, and transparent aligners, to meet the growing demand for alternatives to traditional braces. Clear aligner therapy, which consists of a series of transparent dental appliances designed to fit the shape of a patient's teeth, is one such alternative. Clear aligners, like traditional braces, use a progressive force to control tooth movement, but they do so without metal brackets or wires. This review will highlight the increasing popularity of clear aligners by summarizing a few commonly used systems today. It will also discuss the therapeutic outcomes of this approach, including its scope, limitations, effectiveness, and stability. Additionally, the review will evaluate the potential negative effects of clear aligner therapy.

Beam-Beam Long Range Compensator Mechanical Demonstrator

Beam-Beam Long-Range Compensators employing current-carrying wires are considered as valuable options in hadron colliders to increase dynamic aperture at small crossing angles. This paper presents a simple design proposal for application at CERN LHC. The preliminary design allows for a certain scalability of the number of modules, current flowing in the wire, and dimensions. It complies with two key requirements: (a) the use of a thin, bare metal wire that allows for movement as near to the beam as necessary while minimizing interactions with beam particles and meeting the specified DC current target; and (b) a wire support that is both an electrical insulator and a thermal conductor (ceramic). A molybdenum wire, vacuum brazed on an aluminium nitride support, is proposed, and the design is conceptually proved through the realization and extensive test of a demonstrator device. The wire brazing validation, as well as the system’s heat management, which are the most critical aspects, are given particular regard.

Исследование режимов термосиловой обработки напыленных модифицированных слоев

The paper presents the findings of a study investigating the properties of sprayed coatings with subsequent electrothermally treated within the context of the Ministry of Internal Affairs of the Republic of Kazakhstan grant project AR19680421. This study considers the peculiarities of electric current flow through the sprayed coating or pre-formed powder layer. The properties of 40X13 steel coatings obtained by hypersonic metallization followed by electrothermosilic treatment are investigated. A method for obtaining a wear-resistant coating is proposed, including the formation of a jet of sprayed particles of two metal wires melted in an electric arc, their deposition as a layer on a pre-prepared surface of the part and subsequent electrothermosilic treatment of the layer. It is proposed to choose martensitic steel as the material of one wire, nickel–chromium or iron-chromium alloy with high electrical resistivity as the material of the other, and the diameter of the wire made of this alloy should be determined depending on the diameter of the steel wire.