Thin Metal Wires Research Articles

High-temperature capacitive energy storage in polymer nanocomposites through nanoconfinement

Polymeric-based dielectric materials hold great potential as energy storage media in electrostatic capacitors. However, the inferior thermal resistance of polymers leads to severely degraded dielectric energy storage capabilities at elevated temperatures, limiting their applications in harsh environments. Here we present a flexible laminated polymer nanocomposite where the polymer component is confined at the nanoscale, achieving improved thermal-mechanical-electrical stability within the resulting nanocomposite. The nanolaminate, consisting of nanoconfined polyetherimide (PEI) polymer sandwiched between solid Al2O3 layers, exhibits a high energy density of 18.9 J/cm3 with a high energy efficiency of ~ 91% at elevated temperature of 200°C. Our work demonstrates that nanoconfinement of PEI polymer results in reduced diffusion coefficient and constrained thermal dynamics, leading to a remarkable increase of 37°C in glass-transition temperature compared to bulk PEI polymer. The combined effects of nanoconfinement and interfacial trapping within the nanolaminates synergistically contribute to improved electrical breakdown strength and enhanced energy storage performance across temperature range up to 250°C. By utilizing the flexible ultrathin nanolaminate on curved surfaces such as thin metal wires, we introduce an innovative concept that enables the creation of a highly efficient and compact metal-wired capacitor, achieving substantial capacitance despite the minimal device volume.

Numerical simulation of endovascular treatment options for cerebral aneurysms

AbstractPredicting the long‐term success of endovascular interventions in the clinical management of cerebral aneurysms requires detailed insight into the patient‐specific physiological conditions. In this work, we not only propose numerical representations of endovascular medical devices such as coils, flow diverters or Woven EndoBridge but also outline numerical models for the prediction of blood flow patterns in the aneurysm cavity right after a surgical intervention. Detailed knowledge about the postsurgical state then lays the basis to assess the chances of a stable occlusion of the aneurysm required for a long‐term treatment success. To this end, we propose mathematical and mechanical models of endovascular medical devices made out of thin metal wires. These can then be used for fully resolved flow simulations of the postsurgical blood flow, which in this work will be performed by means of a Lattice Boltzmann method applied to the incompressible Navier–Stokes equations and patient‐specific geometries. To probe the suitability of homogenized models, we also investigate poro‐elastic models to represent such medical devices. In particular, we examine the validity of this modeling approach for flow diverter placement across the opening of the aneurysm cavity. For both approaches, physiologically meaningful boundary conditions are provided from reduced‐order models of the vascular system. The present study demonstrates our capabilities to predict the postsurgical state and lays a solid foundation to tackle the prediction of thrombus formation and, thus, the aneurysm occlusion in a next step.

Three-Dimensional Guidance Laws for Spacecraft Propelled by a SWIFT Propulsion System

This paper discusses the optimal control law, in a three-dimensional (3D) heliocentric orbit transfer, of a spacecraft whose primary propulsion system is a Solar Wind Ion Focusing Thruster (SWIFT). A SWIFT is an interesting concept of a propellantless thruster, proposed ten years ago by Gemmer and Mazzoleni, which deflects, collects, and accelerates the charged particles of solar wind to generate thrust in the interplanetary space. To this end, the SWIFT uses a large conical structure made of thin metallic wires, which is positively charged with the aid of an electron gun. In this sense, a SWIFT can be considered as a sort of evolution of the Janhunen’s E-Sail, which also uses a (nominally flat) mesh of electrically charged tethers to deflect the solar wind stream. In the recent literature, the optimal performance of a SWIFT-based vehicle has been studied by assuming a coplanar orbit transfer and a two-dimensional scenario. The mathematical model proposed in this paper extends that result by discussing the optimal guidance laws in the general context of a 3D heliocentric transfer. In this regard, a number of different forms of the spacecraft state vectors are considered. The validity of the obtained optimal control law is tested in a simplified Earth–Venus and Earth–Mars transfer by comparing the simulation results with the literature data in terms of minimum flight time.

Effects of Pd Alloying and Coating on the Galvanic Corrosion between Cu Wire and Bond Pads for a Semiconductor Packaging

Semiconductor chips are packaged in a process that involves creating a path to allow for signals to be exchanged with the outside world and ultimately achieving a form to protect against various external environmental conditions such as heat and moisture. The wire bonding type of packaging is a method in which thin metal wires are bonded to pads to create an electrical connection between the chip and the lead frame. An Epoxy Molding Compound (EMC) can be applied to protect semiconductor chips from external environmental conditions such as heat, shock, and moisture. However, EMC contains halogen elements and sulfides and has hydrophilic properties, which can lead to a corrosive environment. The present study aims to evaluate the influence of chloride, which is a contaminant formed during the PCB manufacturing process. To this end, the galvanic corrosion of bonding wire materials Cu wire, Cu wire alloyed with 1% Pd, and Cu wire coated with Pd was investigated. The first ball bond was bonded to the Al pad and the second stitch bond was bonded to the Au pad of the manufacturing process, after which the galvanic corrosion behavior in the semiconductor packaging module specimen was analyzed. A model of galvanic corrosion behavior was also proposed.

On the role of higher-order condition of strain gradient plasticity in the cyclic torsion of thin metallic wires: Experiments and modeling

Cyclic torsion tests are performed on micron-scale copper wires with and without surface passivation to study the role of the higher-order condition in the plastic behavior of thin wires under non-proportional loading. A typical strengthening size effect is observed in the symmetric cycles. More obvious strength enhancement exists in the torsional response of passivated copper wires. An unusual Bauschinger effect is found during the loading-unloading cycles, which is more pronounced in passivated wires. The finite element implementation based on Gudmundson's strain gradient plasticity theory is developed for wire torsion to characterize the observed size-dependent phenomena. The higher-order boundary conditions are introduced to simulate the passivated surface. The predicted radial distributions of plastic strain, stress components, and geometrically necessary dislocation density for the passivated and unpassivated wires are given and compared. This work provides a reasonable basis for understanding the role of higher-order conditions of strain gradient plasticity.

Experimental investigation to assess the surface integrity in WEDM of Al-based hybrid composite material

Aluminum-based hybrid composites are used in various engineering applications due to their unique properties, such as high strength, good wear resistance, excellent corrosion resistance, and low density. Aluminum metal matrix (AMMC) composites reinforced with ceramic particles can be more difficult to machine than traditional aluminum alloys because of their increased hardness and abrasiveness. Wire electric discharge machining is a non-traditional machining process that uses a thin metal wire, typically made of molybdenum, brass or tungsten to cut through a workpiece using electrical discharge sparks. This process is useful for precision machining of complex shapes and profiles in hard or difficult to machine materials. WEDM is a commonly used process for cutting Al-SiC-ZrO2 HAMMCs due to their hardness and difficulty in machining using conventional techniques. The present study examines the relationship between machining parameters like pulse on time (TON), pulse off time (TOFF), peak current (IP) and wire feed (WF) and material removal rate (MRR) and surface roughness ( Ra) for Al-SiC-ZrO2 in WEDM. The Box-Beckham Design was used to plan the experiments, and response surface method was employed to develop the models. The pulse duration, TOFF, IP, and quadratic terms of [Formula: see text] and [Formula: see text] are the most influential factors of the MRR. The TON, IP and interaction term (TON × IP), and [Formula: see text] were the most significant factors for Ra. Multi-response optimization of process parameters was obtained using the desirability function approach. Furthermore, the machined samples were analyzed for surface integrity using SEM techniques. The prediction from this model validated the confirmation results.

Electromagnetically spinning viscometer designed for measurement of low viscosity in low shear rate region

The electromagnetically spinning method for measurement of fluid viscosity was improved to obtain accurate values of low viscosity in the low shear rate region. Harmful effects derived from the mechanical friction to the smooth rotation of the rotor are thoroughly eliminated by employing a viscosity probe suspended by a thin metal wire. In our previous study, the motion of the meniscus of the sample surface also acted as a troublesome resistant torque for probe rotation, which was addressed by employing a sandwiched structure of the disk probe between the bottom and top plates. The measurements were carried out in two procedures. In the freely oscillating operation, we could measure the viscosity of the atmosphere with a viscosity of approximately 1/100 of that of water. The second type of quasi-steady measurement enabled a measurement of pure water in the range of shear deformation rates smaller than 1 s−1.

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.

Scratching lithography, manipulation, and soldering of 2D materials using microneedle probes

We demonstrate a facile technique to scratch, manipulate, and solder exfoliated flakes of layered 2D materials using a microneedle probe attached to the precision xyz manipulators under an optical microscope. We show that the probe can be used to scratch the flakes into a designated shape with a precision at micrometer scales; move, rotate, roll-up, and exfoliate the flakes to help building various types of heterostructures; and form electric contacts by directly drawing/placing thin metal wires over the flake. All these can be done without lithography and etching steps that often take long processing time and involve harmful chemicals. Moreover, the setup can be easily integrated into any van der Waals assembly systems, such as those in a glove box for handling air/chemical-sensitive materials. The microneedle technique demonstrated in this study, therefore, enables quick fabrications of devices from diverse 2D materials for testing their properties at an early stage of research before conducting more advanced studies and helps to build different types of van der Waals heterostructures.

Influence of HCl Concentration on Corrosion Behavior between Au or Cu Bonding Wires and the Bond Pad for Semiconductor Packaging

Wire bonding, one of the methods for electrically connecting a semiconductor chip with a substrate, involves attaching thin metal wires to pads. It is the oldest electrical connection method that exhibits high compatibility with other processes. The metal wires used for electrical connection in wire bonding are mainly made of Au, Cu, and Ag. After the wire bonding, molding is performed using the epoxy molding compound (EMC). However, EMC inevitably contains ions such as halogen elements. In addition, it absorbs moisture due to its hydrophilicity, creating a corrosive environment with electrolytes. In this study, we evaluated the influence of hydrochloric acid concentration on corrosion behavior between Au or Cu bonding wires and sputtered Al bond pads. The electrochemical factors such as corrosion potential difference (ΔE), galvanic corrosion current density (ig), and anodic and cathodic Tafel slopes were found to influence galvanic corrosion behavior. Galvanic corrosion tendency in first bond and second bond areas of PCB unit specimen was confirmed.

Prediction of slip activity of crystal grains around semi-circular and semi-elliptical notches in thin-sheet specimens of pure titanium using formulated macroscopic stress distribution and crystal orientation

Thin metal sheets and wires are important materials for various devices used in electrical, mechanical, and medical fields. With the downsizing of these devices, demand for thinner sheets and wires has increased. Amongst the many metals available, pure titanium has been attracting much attention for use in medical and dental devices because of its good biocompatibility in addition to its light weight and high corrosion resistance. However, thin metal sheets and wires are usually polycrystalline materials and, with the downsizing of materials, there is a loss of homogeneity during deformations. Inhomogeneous deformation becomes significant in thin sheets and wires, owing to the different crystal orientations and geometries of crystal grains. Furthermore, the shapes of such devices are not uniform, unlike, say, a simple rod. Therefore, macroscopic stress and strain concentrations should be taken into consideration when designing these devices as they affect the localization of deformation and the resultant fracture. In this study, semi-circular and semi-elliptical notched specimens made of thin-sheet polycrystalline pure titanium are subjected to tensile testing. Inhomogeneous deformation caused by crystallographic slip is observed near the notch root. Analysis of the crystal orientation and observation of the slip line show that the slip initiation in crystal grains is affected by the macroscopic stress distribution and can be predicted from the slip activity calculated from both the critical resolved shear stress on the slip systems and the resolved shear stress acting on prospective slip planes obtained from the macroscopic multiaxial stress distribution.

Intense widely controlled terahertz radiation from laser-driven wires

Irradiation of a thin metallic wire with an intense femtosecond laser pulse creates a strong discharge wave that travels as a narrow pulse along the wire surface. This traveling discharge efficiently emits secondary radiation with spectral characteristics that are mostly defined by the wire geometry. Several examples of designs are considered here in the context of generation of intense terahertz radiation with controllable characteristics for various scientific and technological applications. The proposed setup may be easily realized, and it has the merits of robustness, versatility, and high conversion efficiency (reaching several percent) of laser energy to terahertz radiation.

Size and passivation effects in the torsion of thin metallic wires

Size and passivation effects in the torsion of thin metallic wires

(General Student Poster Award Winner - 1st Place) Nitrogen-Doped and Phosphorus-Doped Carbon Fiber Ultramicroelectrodes As Electrochemical Sensors for Detection of Hydrogen Peroxide

Ultramicroelectrodes (UMEs) are generally defined as electrodes with sizes ≤25 µm. UMEs can be prepared by several methods including by sealing a conductive filament like thin metal wire or a single carbon fiber in a glass capillary. The small size of UMEs makes them useful as probes for measuring electroactive species in confined spaces (for example, inside living cells, etc.), and also enables very effective mass transport, resulting in rapid achievement of steady-state response and facilitating measurement of fast electrochemical reactions. Application of UMEs often requires modification of the electrode surface to improve the selectivity and the sensitivity towards the target analyte. Surface modification methods are time-consuming and may require expensive equipment. Previous research in our group demonstrated that a simple soft nitriding method could be employed to introduce surface nitrogen on carbon fiber (CF). The technique improved electrochemical response of CF-UMEs towards hydrogen peroxide (a reactive oxygen species that has been related to various malignancies and disorders) and, in separate experiments, also enabled deposition of electroactive metal nanoparticles on the UME surface. Since the presence of phosphorus heteroatoms on carbon electrodes has been shown to impart similar benefits, here we investigate a simple phosphorus doping strategy to make P-doped CF-UMEs. We compare their properties towards the electrocatalytic reduction of H2O2 to both N-doped CF-UMEs and unmodified CF-UMEs.

Magnetic metasurfaces with metallic inclusions

Purpose of this paper is the development and creation of the magnetic metasurfaces with metallic inclusions operating both in the microwave and terahertz frequency ranges. Methods. The Maxwell’s equations and the expressions for the effective medium parameters are used to build the analytical models of the magnetic metasurfaces based on either a ferromagnetic (FM) or antiferromagnetic (AFM) dielectric matrix, containing a two-dimensional periodic structure of thin metal (non-magnetic) wires surrounded by insulators. Numerical simulation of such structures operating in the microwave range is carried out using the MaxLLG software package. The magnetron sputtering, liquid etching, optical lithography, and lift-off photolithography are used to create bicomponent magnetic metasurfaces, consisting of two magnetic materials with very different values of magnetization. The study of linear and nonlinear characteristics of the bicomponent magnetic metasurfaces is carried out using the methods of microwave and Brillouin spectroscopy. Results. Based on the developed analytical model of the magnetic metasurface with metallic (nonmagnetic) inclusions it is shown that the FM metasurface possesses properties of a left-handed medium in a microwave range and the AFM metasurface possesses similar properties in a terahertz range. In the last case, the material parameters of the AFM metasurface are twice negative in two frequency bands. For the magnetic metasurfaces with metallic magnetic inclusions, the formation of absorption bands in the spectrum of a traveling magnetostatic surface spin wave due to the resonant properties of the inclusions has been established. In the nonlinear regime, the effect of nonreciprocal parametric three-wave resonance was obtained. Conclusion. The results presented in the paper demonstrate a number of physical phenomena that are observed only in the magnetic metasurfaces with metallic (nonmagnetic and magnetic) inclusions.

Excitation of electric toroidal dipole resonance and design of chiral materials

Toroidal multipole is a particular type of current excitation and is currently the focus of nanophotonics and metamaterials research. However, the excitation of toroidal dipoles is a challenging task because of their low scattering power. In this paper, using vertically incident polarized light, the Electric toroidal dipolar (ETD) resonance response can be successfully excited by a reasonable arrangement of thin metal wires and long metal arms without the need for a complex metal ring structure. The results indicate that the toroidal dipole moment G cannot be ignored at 0.61 THz and 0.65 THz. By rearranging the metamaterial structure that excited the ETD response, the multi-band circular dichroism, and negative refraction are successfully realized. The proposed structure can be applied in many fields, such as the research of toroidal multipoles, left-handed materials, and circularly polarized converters.

Laser measurements of static and dynamic dipole polarizability for 11 metal atoms using fast exploding wires in vacuum and integrated-phase technique

The rapid electrical explosion of thin metal wires in a vacuum can completely vaporize the wire and form a fast-expanding gas cylinder of metal atoms. Thin metal wires 12.7 μm in diameter made of W, Mo, Pt, Pd, Ni, Cu, Au, and Al completely evaporated during the first ∼10 ns under the action of a fast-rising current of ∼1 kA/ns. Laser interferometry and the integrated phase technique were used to reconstruct the dynamic atomic polarizability for fully vaporized thin metal wires at 532 and 1064 nm wavelength, calculate the static atomic polarizability, the first dipole-allowed electronic transition energy, and transition wavelengths, and compare our reconstructions with available tabulated values.

Design, Analysis and Experimental Investigations of a Double-Arm Based Micro-Gripper for Thin and Flexible Metal Wires Manipulation.

A robotic system for the automatic wire pulling of coreless motor winding is designed, including the design of an opening-closing control system and a micro-gripper’s tip structure with a double-armed elastic-beam structure for the support part and an enveloping clamping structure for the tip part. The micro-gripper captures the electrode wire from the root, encircles the wire after the envelope region is closed, and the thin and flexible electrode wire is pulled to the top of the electrode pad by the movement of the micro-gripper and released. The mechanical index of the micro-gripper is simulated to obtain the optimal structural parameters. The experimental results show that the electrode wire’s maximum bearing force is about 0.3 N. Under this reaction force, the deformation of the tip-envelope region of the micro-gripper is about 27.5 μm, which is sufficient for electrode wire pulling micro-manipulation. By comparison with the steel micro-gripper, the silicon micro-gripper has more advantages in shape integrity, machinability and mechanical properties.

Simulation and Measurement of Pressure Rise in GIS 145 kV due to Internal Arcing

Internal arc testing of metal-enclosed, SF6 gas insulated switchgear (GIS) is defined by IEC 62271-203 and is not a part of mandatory type tests.
 However, due to the increasing demands on the safety of personnel, more often the implementation of this test is required in the tender documentation. According to IEC, the duration of the electric arc is related to the performance of the protective system determined by the first and second stage of protection. For the rated short-circuit current equal or higher than 40 kA, during the first stage of protection (0.1 s), no external effects on enclosure other than the operation of pressure relief device is permitted. During the second stage of protection (≤0.3 s) no fragmentation is permitted, but burn-through is acceptable. The test should be carried out on the GIS compartment with the smallest volume at nominal gas pressure. Since a newly developed GIS 145 kV is designed as a three-phase encapsulated, arc initiation is achieved by short connecting of all three phase conductors in the vicinity of a partition by means of a thin metal wire. This ensures that two electric arcs burn simultaneously commutating between the phases, so the possibility of enclosure burn-through in this type of GIS is minimized. In order to prevent the release of SF6 gas in the atmosphere during the testing, a test enclosure should be placed in a protective gastight enclosure filled with air or more often SF6 gas at pressure of 0.1 MPa. This test object configuration significantly complicates the pressure rise calculation and increases the testing cost. In order to prevent enclosure fragmentation, the pressure difference between the test enclosure and the protective enclosure during the test should always be less than the bursting pressure of test enclosure. Also, the protective enclosure should be designed to withstand the maximum pressure rise that may occur after pressure relief device opens. In order to assess the likelihood of passing the upcoming type test for newly developed GIS, a computer program for calculation of pressure and temperature in the test enclosure and protective enclosure was developed. The mathematical model is based on the paper of the working group CIGRE A3.24, published in 2014. The basic model shown in the paper is enhanced by the real properties of the SF6 gas/plasma, evaporation of the electrode material and the insulator ablation. The contribution of exothermic/endothermic reactions between the gas and the electrode material on the pressure and temperature rise was also considered. At the same time, the measurements of pressure rise in GIS enclosure and protective enclosure were carried out in Končar High Power Laboratory. The experiments performed on a copper and aluminum electrodes in SF6 gas confirmed significantly higher contribution of aluminum electrodes to the pressure and temperature rise compared to the copper electrodes. The computer program is verified by measurement results.

Clear imaging of ion cloud rotation using a combination of a thin metal wire, a micro-channel plate attached to a phosphor screen, and a high-speed camera

To obtain the radial profile of the ion velocity ui(r) of a pure ion cloud, for the first time, we successfully captured images of the shadow of a thin rotating metal wire by scanning the pure ion cloud using a combination of a micro-channel plate attached to a phosphor screen and a high-speed camera. It appears that the rotation angle of the measured metal wire agrees with the estimated value based on the theory of two-dimensional equilibria of non-neutral plasmas, rather than the magnetron motion of a single ion confined in a Penning trap. This method may be utilized as a tool to experimentally investigate ui(r, t) in electrically non-neutral two-fluid plasmas, which is an unexplored topic in advanced plasma physics.