Difference In Thermal Expansion Coefficients Research Articles

Direct laser active brazing of 316Ti to alumina

AbstractThis work addresses the challenges in brazing thermohydraulic sealings involving dissimilar materials, specifically 316Ti stainless steel and alumina, which have significantly different coefficients of thermal expansion (CTEs) and elastic constants. Traditional brazing methods require complex interlayers or extensive metallization steps, leading to issues such as dimensional changes, braze voids, and inadequate corrosion resistance due to prolonged high‐temperature exposure. A novel laser‐based brazing technique utilizing a diode laser is introduced to create high‐quality, localized joints while preserving the integrity of the parent materials. The study systematically optimizes laser process parameters using finite‐element modeling and the Taguchi method to achieve the desired bead geometry and thermal stress distribution with minimal heat input. Comparative analysis between laser active brazing (LAB) and conventional furnace brazing was conducted through metallography, shear testing, and autoclave testing. Results indicate that LAB parameters significantly affect bead thickness and shear strength, with laser‐brazed joints demonstrating superior quality and stability post‐autoclave testing compared with furnace‐brazed joints. The thermodynamic and kinetic aspects of the brazing process were also analyzed. In conclusion, the LAB method for brazing 316Ti to alumina proves to be a successful and efficient alternative, with joint properties meeting or exceeding those of traditional furnace brazing.

Role of inclusion clusters on fatigue crack initiation in powder metallurgy nickel-based FGH96 superalloy

Inclusion clusters with a size of several tens of micrometers were found to be inclined to early crack initiation, resulting in an abnormally reduced fatigue life. Fatigue tests were conducted to elucidate crack initiation behaviors of inclusion clusters in nickel-based powder metallurgy (P/M) FGH96 superalloy. The inclusion clusters with varying sizes and shapes located at grain boundaries are composed of Al2O3, MgO and ZrO2 particles. The inclusion cluster with large size within 25-35 μm, small average particle distance within 0-4 μm and large orientation relative to loading direction within 35-66° will be more likely to cause crack initiation. In particular, the inclusion clusters with large size and high aggregation degree experience extruding during processing and subsequent heat-treatments due to the difference in thermal expansion coefficient with the matrix behave multiple cracking before fatigue loading, thereby facilitating crack initiation in the surrounding matrix grains. Moreover, as the main cracking part of inclusion clusters, the Al2O3 particles exhibit self-cracking and interface debonding, owing to higher hardness and poorer deformation coordination degree with matrix compared to other component inclusion particles.

Study on the Oxidation Behavior of TiB2-CeO2-Modified (Nb,Mo,Cr,W)Si2 Coating on the Surface of Niobium Alloy

A novel TiB2-CeO2-modified (Nb,Mo,Cr,W)Si2 coating was prepared on a Nb-5W-2Mo-1Zr alloy substrate using two-step slurry sintering and halide-activated pack cementation to address the limitations of a single NbSi2 coating in meeting the service requirements of niobium alloys at elevated temperatures. At 1700 °C, the static oxidation life of the coating exceeded 20 h, thus indicating excellent high-temperature oxidation resistance. This was due to the formation of a TiO2-SiO2-Cr2O3 composite oxide film on the coating surface, which, due to low oxygen permeability, effectively prevented the inward infiltration of oxygen. Additionally, the dense structure of the composite coating further enhanced this protective effect. The composite coating was able to withstand over 1600 thermal shock cycles from room temperature to 1700 °C, and its excellent thermal shock performance could be attributed to the formation of MoSi2, CrSi2, and WSi2 from elements such as Mo, Cr, and W, which were added during modification. In addition to adjusting the difference in thermal expansion coefficients between the layers of composite coatings to reduce the thermal stress generated by thermal shock cycles, the formation of silicide compounds also improved the overall fracture toughness of the coating and thereby improved its thermal shock resistance.

Michelson interferometer based on a fiber with a germanium-doped core and inner cladding for high-temperature sensing

We proposed and demonstrated a temperature sensor based on a fiber Michelson interferometer. The Michelson Interferometer contains a special fiber with a germanium-doped core and pure silica inner cladding, so the interference spectrum is formed as a result of interference of the mode of the core and one of the modes of the inner cladding. The existence of inner cladding reduces the number of interacting cladding modes. When annealing the sensor for 300 min at a temperature of 600 °C, no thermal hysteresis of the interference spectrum was observed. The temperature sensitivities of the proposed sensor are 48 pm/°C in the range of 20–250 °C and 78 pm/°C in the range of 250–600 °C. But when the sensor was exposed to a constant temperature of 700 °C and above for a few hours, a shift in the wavelength of the dip of the interference spectrum is observed. This wavelength shift, which occurs even at a fixed temperature, depends on the temperature of annealing. It can be explained by a number of processes occurring in glass at high temperatures: the changing fictive temperature of the glass, diffusion of germanium oxide from the core, and formation of mechanical stresses resulting from the difference in thermal expansion coefficients of the core and cladding, and relaxation of these mechanical stresses at an elevated temperature.

Stress relaxation and improved fracture toughness of metal bonding using flexible monolith sheets and an epoxy adhesive

AbstractWhile epoxy resins exhibit excellent mechanical and insulating properties as well as excellent stability against heat and chemicals, epoxy adhesives also have drawbacks such as brittleness and stress concentration. Rubber-based materials are often added to epoxy adhesives to increase toughness, but they are sensitive to heat and moisture, limiting their effectiveness in harsh environments. In this study, we propose a new sheet-type adhesive consisting of a conventional liquid epoxy adhesive and an epoxy monolith sheet with internal continuous pores, using the advantageous properties of the flexibility and toughness of the epoxy monolith to avoid stress concentration. We evaluated the adhesion strength for metal bonding using the sheet-type epoxy adhesives via a lap-shear tensile adhesion test at various temperatures. The total destruction energy was also estimated via a tapered double cantilever beam test. Furthermore, a heat cycle adhesion test was conducted using two types of metallic materials with different coefficients of thermal expansion to elucidate the effect of the monolith sheet on the improvement of interfacial failure induced by stress concentration.

Characterization of mechanical and temperature effects on delamination and basic strength behaviors of PVC coated PUR foam substrate used in bus dashboard

This study focuses on the delamination and characterization of different loadings and temperature conditions of polyvinyl chloride (PVC)-coated polyurethane (PUR) foam component layers commonly used in bus dashboards. The method was developed through mechanical and thermal tests.The study involves the examination of primer and no primer PVC-coated PUR components using SEM (Scanning Electron Microscope), tensile-compression, three-point bending, primer characterization, peel, PUR material thermal expansion, and thermal tests. Physical and material tests were conducted to determine the mechanical properties of PVC and PUR foam and the material properties of the primer. Fourier transform infrared spectroscopy (FTIR) analysis was also conducted to identify the functional groups present in the PVC, PUR, and primer materials, helping to understand the material interactions.Some tests produced the expected results, while others did not. The primer characterization and three-point bending tests were unsuccessful due to sample foam breakage. However, tensile-compression tests, peel tests, thermal expansion tests, and thermal tests yielded the desired outcomes. During thermal testing of primed samples, it was observed that the samples shortened and bent as the primer material melted and began to separate from the PVC and PUR layers. This bending and swelling were attributed to the difference in thermal expansion coefficients between the melting primer material and the PVC and PUR layers. The results demonstrate that PVC-coated PUR components can be effectively separated, and they also highlight opportunities for design modifications to improve the durability of bus dashboards.

Influence of residual stress on the high-temperature tribological performance of nickel-based superalloy

This study introduces a method for generating residual compressive stress by utilizing differences in thermal expansion coefficients of materials. A corresponding experimental device has been developed. Using this method, experiments were conducted to investigate the effects of residual compressive stress on the tribological properties of the nickel-based superalloy Ni16Cr13Co4Mo. The results indicate that residual stress significantly affects the friction behavior and wear resistance of the superalloy. The stabilization time of the friction coefficient as well as the wear rate reaches a minimum under moderate residual compressive stresses. Moderate residual compressive stress can facilitate the formation of a tribo-oxide layer and enhance its bonding strength with the substrate, thereby shortening the time for stabilization of the friction coefficient and reducing the wear rate. Finite element simulation of static ball-on-disc contact model also shows that residual stress alters the internal stress distribution inside the alloy, and changes its yield and plastic behavior. Under moderate residual compressive stress, a reduction in maximum von Mises stress can be achieved, which is consistent with the variation rule of friction coefficient and wear rate in the tests.

Field-assisted sintering of MC-Ti3SiC2 composites with adjustable thermal expansion coefficient

Tool materials for precision glass moulding made of WC or SiC bear the risk of glass breakage due to a difference in the coefficient of thermal expansion (CTE) between the mould and the glass. The aim of this study is to develop a MAX phase composite with increased CTE and thus reduced CTE difference. A mixture of Ti3SiC2 and 10 vol% SiC powder was sintered between 1250 °C and 1350 °C using the field-assisted sintering technique (FAST). In addition to the sintering temperature, the dwell time and the initial particle size were varied using a full factorial experimental design. Complete densification, homogeneous carbide distribution and no grain coarsening were observed for specimens sintered at 1300 °C for 10 min at 50 MPa. The grain size of SiC and Ti3SiC2 is approximately 0.3 μm, although larger grains occasionally occur. Identified process parameters were successfully transferred to TiC reinforced Ti3SiC2 composites. While the carbide content can be specifically controlled by mixing, the MAX phase partially decomposes during sintering. MC additions between 10 and 30 vol% resulted in an adjustable CTE in the range 6.8–9.0 ppm/K.

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A method is described to measure the thermal expansion coefficient of fused quartz glass. The measurement principle is to monitor the change in resonance frequency of a Fabry–Perot cavity as its temperature changes; the Fabry–Perot cavity is made from fused quartz glass. The standard uncertainty in the measurement was less than 0.6 (nm·m-1)·K-1\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$(\ extrm{nm}{\\cdot } \ extrm{m}^{-1}){\\cdot }\ extrm{K}^{-1}$$\\end{document}, or 0.15 %. The limit on performance is arguably uncertainty in the reflection phase-shift temperature dependence, because neither thermooptic nor thermal expansion coefficients of thin-film coatings are reliably known. However, several other uncertainty contributors are at the same level of magnitude, and so any improvement in performance would entail significant effort. Furthermore, measurements of three different samples revealed that material inhomogeneity leads to differences in the effective thermal expansion coefficient of fused quartz; inhomogeneity in thermal expansion among samples is 24 times larger than the measurement uncertainty in a single sample.

Raman Investigation on Silicon Nitride Chips after Soldering onto Copper Substrates.

The unique electrical properties of silicon nitride have increased the applications in microelectronics, especially in the manufacture of integrated circuits. Silicon nitride is mainly used as a passivation barrier against water and sodium ion diffusion and as an electrical insulator between polysilicon layers in capacitors. The interface with different materials, like semiconductors and metals, through soldering may induce residual strains in the final assembly. Therefore, the dentification and quantification of strain becomes strategically important in optimizing processes to enhance the performance, duration, and reliability of devices. This work analyzes the thermomechanical local strain of semiconductor materials used to realize optoelectronic components. The strain induced in the β-Si3N4 chips by the soldering process performed with AuSn pre-formed on copper substrates is investigated by Raman spectroscopy in a temperature range of -50 to 180 °C. The variation in the position of the E1g Raman peak allows the calculation of the local stress present in the active layer, from which the strain induced during the assembly process can be determined. The main reason for the strain is attributed to the differences in thermal expansion coefficients among the various materials involved, particularly between the chip, the interconnection material, and the substrate. Micro-Raman spectroscopy allows for the assessment of how different materials and assembly processes impact the strain, enabling more informed decisions to optimize the overall device structure.

Comprehensive evaluation of CFRP laminates using NDT methods for aircraft applications

The evaluation of carbon fiber reinforced polymers (CFRP) laminates during and after the Mode I test was successfully conducted, integrating non-destructive testing of acoustic emission (AE) and ultrasound scanning. Two different specimens [+45°/-45°/0°]2S and [0°/+45°/-45°]2S were used to detect the effects of stacking sequences of the laminates. Results indicated that applying AE sensors to the specimens slightly affect to the laminate performance. Thus, the laminates are validated and showed that for [+45°/-45°/0°]2S laminates, the system can withstand load and increase the displacement at break more than twice of [0°/+45°/-45°]2S laminates. Moreover, the ultrasound scanning showed that the crack trace is visible. [+45°/-45°/0°]2S laminates have smaller crack around 24 mm compared to [0°/+45°/-45°]2S laminates with 30 mm. Image analysis revealed that after specimen are forced to open, the [+45°/-45°/0°]2S laminates can prevent long crack compared to [0°/+45°/-45°]2S laminates. The double cantilever beam (DCB) test, employing various stacking sequences, demonstrated excellent examination results using non-destructive testing. Theoretical calculations regarding residual thermal expansion due to different coefficients of thermal expansion also revealed a slight impact of varying manufacturing temperatures on the laminates. These findings offer valuable insights for detecting, predicting, and preventing specimen failures in aircraft and aerospace structures without resorting to destructive examinations, facilitating appropriate preventive maintenance.

Development of an electro-thermo-mechanical 4D printed multi-shape smart actuator: Experiments and simulation

This investigation presents an experimental and numerical approach to developing 4D printed multi-shape actuators with an integrated electrical self-triggering system. It employs a multifunctional shape memory carbon black Polylactic Acid (PLA) layer embedded within rubbery thermoplastic polyurethane (TPU). Notably, these thermo-responsive actuators are programmed and triggered using Joule’s effect, eliminating the need for an external heat source and enabling precise control of temperature gradients. Two distinct motion mechanisms are employed: the differences in thermal expansion coefficient between the PLA/TPU polymers below the glass transition temperature, and the shape memory effect of the PLA layer above the glass transition temperature. As a result, a diverse range of motion responses can be achieved by adjusting the potential differences. A coupled electro-thermo-mechanical finite element model is used to gain further insight into the motion mechanisms, offering predictive capabilities beyond the ones reported by previous models. The developed technology provides enhanced actuation capabilities to conventional bi-shape SMP actuators, offering a versatile range of bending cycles. Furthermore, Joule’s effect enables the implementation of closed-loop control systems, which is essential for developing autonomous robotic systems.

Increased accuracy of service life prediction for fiber metal laminates by consideration of the manufacturing-induced residual stress state

Fiber metal laminates (FML) combine the high specific properties of fiber-reinforced polymers with the ductility and damage tolerance of metals. However, during the manufacturing process of FMLs, in-plane residual stresses arise in the single layers of the laminate. The stresses mainly originate from the different coefficients of thermal expansion of the two materials and lead to an inhomogeneous stress state in the thickness direction of the laminate. This work investigates the influence of such thermal residual stress (TRS) on the fatigue life in an FML by experimentally varying the TRS in identical layups using modified cure cycles. The experimental investigations show that the amount of TRS directly influences the fatigue performance of such laminates. Reducing the TRS, particularly the tensile residual stresses in the metal layers, slows the fatigue crack growth during cyclic loading. This leads to a significantly delayed crack initiation and slower crack propagation. Knowledge of material behavior is essential for utilizing the full potential of structural health monitoring (SHM) in component lifetime predictions. Predictive models require a set of input parameters to perform this task. Since the TRS in an FML significantly contributes to the component's fatigue life, its consideration in predictive approaches is inevitable. This finding is discussed based on a phenomenological damage accumulation model initially developed for composite materials.

Application of Friction Riveting technique for the assembly of electronic components on printed circuit boards (PCB)

This study focuses on the effects of reducing the diameter of rivets used in Friction Riveting due to the need for downscaling when joining assemblies on a smaller scale. The Friction Riveting process has shown promising feasibility for a variety of material combinations and applications in the transportation industry. Recent research has explored the potential application of this technique in electronics, specifically for the assembly of printed circuit boards (PCBs), using AA-2024-T351 rivets on thin glass-fiber-reinforced epoxy substrates (FR4). The joint formation of joints produced with PCBs was investigated in terms of process temperature evolution, microstructural changes, and mechanical properties. Joints were obtained at process temperatures ranging from 285 ºC to 368 ºC. The use of 4 mm rivets resulted in extensive delamination, weak joint mechanisms, and cracking, impaired by the different coefficients of thermal expansion of the materials involved. Reducing the rivet diameter to 3 mm significantly improved joint quality. A further reduction to 2.5 mm minimized delamination but led to insufficient anchorage and cracking. Joints produced with a 3 mm rivet diameter achieved the highest ultimate tensile force of 276 N. This study sets the foundation for applying the Friction Riveting process to practical PCB assemblies, demonstrating that optimizing the process parameters to the diameter-to-thickness ratio can balance sufficient rivet anchoring, minimize delamination, and reduce cracking.

Effect of different HVOF coatings on the tribological behavior of PVD/HVOF duplex coatings

CrN film shows obvious differences in hardness, elastic modulus, and thermal expansion coefficient between film and substrate, suffering from poor adhesion and wear resistance. Here we combined PVD and HVOF technologies to produce CrN/WC-12Co and CrN/WC-10Co-4Cr coatings, and then compare their mechanical and tribological behavior with that of CrN film. We show that the PVD/HVOF coatings exhibit higher hardness, load carrying capability, and adhesion; the wear resistance also be improved greatly, especially for CrN/WC-10Co-4Cr. We discuss the wear mechanism of such duplex coatings and analyze the influence of different HVOF coatings on the deposition characteristic of CrN film.

Experimental and Simulation Studies on Stable Polarity Reversal in Aged HVDC Mass-Impregnated Cables

Mass-impregnated (MI) cables have been used for many years as cables in high-voltage direct current (HVDC) systems. In line commutated converter (LCC) HVDC systems, polarity reversal for power flow control can induce significant electrical stress on MI cables. Furthermore, the mass oil and kraft paper comprising the impregnated insulation have significantly different coefficients of thermal expansion. Load fluctuations in the cable lead to expansion and contraction of the mass, creating pressure within the insulation and causing redistribution of the impregnant. During this process, shrinkage cavities can form within the butt gaps. Since the dielectric strength of the cavities is lower than that of the surrounding impregnation, cavitation phenomena in impregnated paper insulation are considered a factor in degrading insulation performance. Consequently, this study analyzes the electrical conductivity of thermally aged materials and investigates the transient electric field characteristics within the cable. Additionally, it closely analyzes the formation and dissolution of cavities in MI cables during polarity reversal based on a numerical model of pressure behavior in porous media. The conductivity of the impregnated paper indicates that it has excellent resistance to thermal degradation. Simulation results for various load conditions highlight that the interval of load-off time and the magnitude of internal pressure significantly influence the cavitation phenomenon. Lastly, the study proposes stable system operation methods to prevent cavitation in MI cables.

Fabrication of penetrating pores in epitaxial Ge-on-Si through preferential etching along threading dislocations

Epitaxial Ge-on-Si possesses a high density of threading dislocations (TDs) due to the lattice mismatch and difference in thermal expansion coefficient. By employing the lattice distortion at the TDs, we demonstrate that penetrating pores along TDs can be formed in both p- and n-type heteroepitaxial Ge layers through a preferential etching. It has been found that the preferential etching at TD sites takes place in the porosification process of Ge-on-Si samples and is independent of the doping type and concentration. The penetrating pores follow the path of the TD lines and can penetrate the entire Ge layer of 1.3 μm to further porosificate the Si substrate. The effects of anodic current density and total etching duration have been thoroughly investigated on forming penetrating pores at TD sites. The dissolution mechanism in the porosification process has been revealed by dissolution valence calculation and recorded potential curves. Our findings shed light on Ge perforation in both p- and n-type Ge-on-Si and show great potential in Si-based integrated photonics and microelectronics.

A novel bi-material tubular metamaterial with twist effects under thermal and uniaxial loads

In this work, a novel bi-material missing rib-type tetra-chiral tubular metamaterial (BMTTM) is designed by utilizing the base materials with different coefficients of thermal expansion (CTEs), and considering various material combinations. Counterintuitively, twist effect can be observed with temperature variation or uniaxial load for the BMTTM. The theoretical formations of the twist angle, Poisson's ratio (PR) and CTE are established and verified subsequently by numerical simulations. Theoretical and numerical results indicate that tailoring twist angle of the BMTTM can be achieved by manipulating the base material combination and the microstructural geometry. The BMTTM proffers a novel avenue to design temperature sensors, actuators, and satellite support tubes, serving in fluctuating temperature environments.

Efficient and environmentally friendly separation and recycling of cathode materials and current collectors for lithium-ion batteries by fast Joule heating

Spent Li-ion batteries(LIBs) cathodes possess high recycling value. To improve subsequent recovery efficiency and product purity, separating the cathode materials from the aluminum foil is critical. However, traditional separation methods are characterized by high energy consumption, low recycling efficiency, and environmental pollution. This research presents a novel method that involves injecting Joule heat directly into the aluminum foil in the air, resulting in the melting and slight thermal decomposition of the PVDF binder, which reduces its adhesive properties. Owing to the difference in thermal expansion coefficients between the binder and aluminum foil, an instantaneous thermal stress was generated at the interface of the cathode materials and aluminum foil, resulting in a peeling force. This method enabled a rapid and efficient separation of lithium iron phosphate (LFP) and ternary Li-ion (NCM) battery cathode materials. The optimal separation conditions, separation mechanism, and properties of the recovered products were investigated thoroughly using high-speed camera imaging, temperature rise calculations, and microscopic characterization. This chemical-free method avoids the generation of wastewater and gas emissions. Under optimal experimental parameters, the separation efficiency and purity of cathode material reached 99 % and 99.7 %, respectively. Additionally, this method preserves both the structural integrity of the aluminum foil and the crystalline structure of the cathode materials, offering a new pathway for sustainable recycling of end-of-life LIBs.

Structural Origins of the Anisotropic Thermal Expansion of BINOL Crystals

Measurement of the unit cell of (R)-BINOL over a 200° temperature range (300–100 K) reveals an anisotropic contraction where the c-axis contracts ca. 2.3% compared to a ca. 0.45% contraction of the a and b axes, a ca. six-fold difference in linear thermal expansion coefficient. This contraction corresponds to a decrease in the helical pitch of the 31 screw axis in the [001] direction. The anisotropic nature of the contraction is rationalised by a thorough analysis of intermolecular contacts within the crystal and their impact on the conformation of the molecule and crystal packing.Graphical The crystal structure of (R)-BINOL exhibits a pronounced anisotropic thermal expansion.