Formation and Properties of Ln-Si-O-N Glasses (Ln = Lanthanides or Y)

Homogeneous Y-Si-O-N glasses containing 15 or 20 eq% nitrogen (N) were prepared from compositions with Y/Si ratios in the vicinity of that of the lowest eutectic point on the Y₂O₃–SiO₂ phase diagram. The liquidus on the phase diagram shifted toward lower temperatures by incorporation of N. The density, the elastic moduli, and the glass transition temperature of the Y-Si-O-N glasses increased with incorporation of N. This is due to the closer packing of atoms in the glasses by the substitution of N, which is in three-fold coordination with Si, for O which is in two-fold coordination, and the stronger covalent nature of the Si–N bond compared with the Si–O bond. The coefficient of thermal expansion of the Y-Si-O-N glasses increased with increasing Y content, because the discontinuity of the glass network developed with increasing nonbridging anions by the introduction of Y. In contrast, the glass transition temperature and the elastic moduli increased with Y content due to the high coordination of Y for O, and the relatively high cationic field strength of Y. Furthermore, the effect of cationic field strength on properties of Ln-Si-O-N glasses (Ln = lanthanides or Y) is discussed.     

Processing Strategy for Producing Highly Anisotropic Silicon Nitride

Silicon nitride with a preferred orientation of large elongated grains was obtained by tape casting of raw powder slurry seeded with rodlike β-Si₃N₄ particles, followed by a gas pressure sintering under 1 MPa nitrogen pressure. The large elongated grains developed from seeds lay in planes parallel to the casting direction in a two-dimensional distribution. Increased fracture toughness (11.1 MPa·m^1/2) and bending strength (1100 MPa) were achieved in the direction perpendicular to the grains alignment compared to specimens with a random distribution of elongated grains. Morover, the specimens exhibited a high Weibull modulus of 46 due to the uniform distribution of large grains.     

Spherical Aluminum Nitride Fillers for Heat-Conducting Plastic Packages

It is necessary for encapsulants to have not only a suitable coefficient of thermal expansion (CTE) compatible to IC devices and a low dielectric constant to reduce the device propagation delay, but also a high thermal conductivity to dissipate large amounts of heat from power-hungry, high-speed IC and high-density packages. Fillers such as silica have been mixed with polymers to improve their properties. Aluminum nitride (AlN) is considered as an alternative one, because it has a higher theoretical thermal conductivity of ∼320 W/mK¹, a compatible CTE with silicon chips and a low dielectric constant. Commercial AlN fillers are angular in shape, because they are prepared via grinding coarse AlN powders synthesized by direct nitridation of aluminum metal and classification. The angular AlN are not expected to have high fluidity when mixed with polymers and hence low packing density. Recently, we successfully obtained single-crystalline spherical AlN fillers. Furthermore, polymer composites filled with the spherical AlN showed excellent thermal conductivity (>8 W/mK) as encapsulants for dissipating the heat generated in electronic devices.     

Synthesis of High Density and Transparent Forsterite Ceramics Using Nano-Sized Precursors and Their Dielectric Properties

Forsterite (Mg₂SiO₄) ceramics were prepared using Mg(OH)₂ and SiO₂ as precursors, and the effect of powder characteristics of Mg(OH)₂ on calcination and sintering was investigated. The use of highly dispersed Mg(OH)₂ powder (HD powder) resulted in a lower calcination temperature. Forsterite powder of high homogeneity and small particle size prepared from the HD powder enabled synthesis of high-density forsterite ceramics by ordinary sintering without applying external pressure. Moreover, transparent forsterite ceramics were successfully synthesized through addition of excess Mg to the precursors to compensate for Mg evaporated during the sintering process. Subsequent dielectric measurements revealed that the transparent forsterite ceramics had a very low dielectric loss (tan δ<10⁻⁴).     

High-energy NdFeB magnets and their applications

In sintered NdFeB magnets, additive elements for increasing coercivity decrease residual magnetization. Also, fine magnetic powder oxidization prevents identification of the stoichiometry composition (Nd ₂Fei₁₄B).To improve the magnetic properties of a sintered NdFeB magnet, the authors have developed a method involving two alloys. Magnetic Nd ₂Fei₁₄Balloy and a rare- earth- rich alloy (including richer dysprosium content) are melted individually and mixed together after coarse pulverization. After the sintering process, dysprosium in the sintered body is enriched in each grain region near the grain boundary. The two- alloy method minimizes the liquid phase necessary to keep the coercive force at a useful level, and thus results in compositions closer to stoichiometry. The energy product of magnets having an inhomogeneous dysprosium distribution is typically 360 kj - m ^{- 3} (45 MG.Oe) at production level. The corrosion characteristics of cobalt- substituted NdFeB magnets also were investigated. These magnets are now used in voice coil motors for hard disk drives and contribute to shortening access time and hard- drive downsizing.     

Thermal management of edge‐lit wide color gamut backlight for LCD using red laser diodes and cyan LEDs

The color gamut is one of the critical parameters that dictate the image quality of displays. The liquid crystal displays using white color light‐emitting diodes (LEDs) as the backlight, though having been widely employed recently, are not very satisfactory in terms of their color gamut because of the broad spectrum inherent to white LEDs. This prompted the authors to develop improved liquid crystal displays using an edge‐lit wide color gamut backlight that used red laser diodes and cyan LEDs. Generating laser beams with high color purity, the laser diodes are light sources with a significant effect on expanding the color gamut. However, laser diodes, red ones in particular, have unfavorable thermal characteristics. To cope with this shortcoming, the authors clearly defined the restrictive criteria for laying out two kinds of light source on the edge‐lit backlight and made a prototype 55‐type laser backlight for performance evaluation.     

A manufacturing XML schema definition and its application to a data management system on the shop floor

Digitization for sharing knowledge on the shop floor in the machinery industry has been given much attention recently. To help engineers use digitization practically and efficiently, this paper proposes a method based on manufacturing case data that has a direct relation to manufacturing operations. The data are represented in XML schema, as it can be easily applied to Web-based systems on the shop floor. The definitions were made for eight manufacturing methods including machining and welding. The derived definitions consist of four divisions of metadata, work-piece, process and evaluation. Three divisions except for the “process” division are common to the manufacturing methods. The average number of elements for a manufacturing method is about 200. The represented schema is also used to convey knowledge such as operation standards and manufacturing troubleshooting on the shop floor. Using the definitions, a data management system is developed. It is a Web-based Q&A system, in which the engineers specify the manufacturing case data mainly by selecting from the candidates. Then, the system fills in the blank portions and/or shows messages to help complete the case data. The proposed method is evaluated through practical scenarios of arc welding and machining.     

Ultra light-weight and high-resolution X-ray mirrors using DRIE and X-ray LIGA techniques for space X-ray telescopes

We are developing novel ultra light-weight and high-resolution X-ray micro pore optics for space X-ray telescopes. In our method, curvilinear micro pore structures are firstly fabricated by silicon deep reactive ion etching (DRIE) or X-ray LIGA processes. Secondly, side walls of the micro structures are smoothed by magnetic field assisted finishing and/or hydrogen annealing techniques for high reflectivity mirrors. Thirdly, to focus parallel X-ray lights from astronomical objects, these structures are elastically or plastically bent into a spherical shape. Fourthly, the bent structures are stacked to form a multi-stage X-ray telescope. In this paper, we report on fabrication and X-ray reflection tests of silicon and nickel X-ray mirrors using the DRIE and LIGA processes, respectively. For the first time, X-ray reflections were confirmed on both of the mirrors. Estimated rms roughnesses were 5 nm and 3 nm for the silicon and nickel mirrors, respectively.     

Current dependence of performance of TES microcalorimeters and characteristics of excess noise

We are developing transition edge sensor (TES) microcalorimeter arrays for future Japanese astronomy missions. Although 6.6 eV energy resolution for 5.9 keV and 74 μs decay time are achieved, our energy resolution was limited by the excess noise of unknown origin. The dominant noise showed 1/R dependence and it only appeared when the current through the TES, I, is larger than 10 μA. This is explained if we assume a constant voltage noise source with a level of 2(4kT_CR_n)^1/2. We also investigated the influence of I on the TES performance and found the TES sensitivity is reduced when the ratio of current to the critical current I/I_C is large. It can explain the reduction of observed when operated without a magnetic shield. We also found a strong correlation between I_C and or the baseline width. Thus, we conclude that I_C is an essential parameter for the TES performance.