Effect of nitrogen ion implantation on impact wear

The effect of nitrogen ion implantation on the impact wear of several metals and alloys with different hardnesses was studied. An impact testing machine was built for this study. In this machine, bullet-shaped projectiles are bounced against a metal surface which is either stationary or rotating. Wear was determined by weight loss measurements. Scanning electron microscopy pictures were taken to study the surface damage. It was found that nitrogen ion implantation improved the impact wear of most of the materials studied. With sliding motion added during the impact, nitrogen ion implantation has little effect.     

Adaptive 2D finite element simulation of metal forming processes

The development and integration of available current methods and the development of new methods for an adaptive finite element analysis of metal forming processes are presented. The analysis includes large-strain, elastic–plastic, and thermal effects. Many numerical methods such as mesh generation, simulation of the contact between the workpiece and tool and die, and optimization of the finite element mesh are integrated and incorporated. In addition, an algorithm is developed which can detect certain severely distorted elements where the area of integration is approaching zero. The advantage of correcting these regions of locally distorted elements is demonstrated. These numerical methods are implemented in a finite element program developed for simulating metal forming processes, with the emphasis on automating the analysis. Examples include an axisymmetric stress simulation of a coldheading process, a plane strain simulation of an extrusion process and a plane strain simulation of orthogonal metal cutting, all with noticeable thermal effects. The orthogonal cutting forces and feed forces calculated are compared with two sets of experimental data, with good agreement.     

Microwave plasma enhanced chemical vapor deposition diamond synthesis from high carbon content source

To synthesize diamond films by microwave plasma enhanced chemical vapor deposition (MPECVD), the methane concentration (CH₄/H₂)plays a crucial role. It is well-known that there always exists a critical methane concentration (≤0.6%) only below which a good quality diamond film can be obtained. In this study, however, the phenomena of diamond synthesis resulting from high carbon concentration conditions were observed. The molten metals, e.g., Ag, Cu, were used as the deposition substrates on which crystalline diamonds can be achieved from a methane content of CH₄/H₂≥6% or even from solid carbon sources. These results suggest that there may exist a low methane content boundary layer (<0.6%) in the proximity of molten metal surface on which suitable species, CH, CH⁺, H_α and H_β are composed for the diamond nucleation and growth similar to the condition as in the conventional low methane contents. The molten metal inclines to dissolve other forms of carbonaceous materials other than diamond, and thus keeps a much higher steady supply of carbon atoms that enhances the quality as well as the growth rate of the forming diamonds. Received: 23 June 2001 / Accepted: 23 July 2001     

A new precipitate phase in Al-4wt. % Cu thin-film interconnects

We report here the identification of a new precipitate phase in thin-film Al-4wt.%Cu metallization used for interconnects on integrated circuits. The phase is based on a trigonal distortion of a face centered cubic lattice. Computer simulation of electron diffraction intensities suggests that the basis structure is isomorphous with Al₂Ca but with a large and ordered population of vacancies on Cu sites. The reason for the formation of the new phase and its implications for electromigration reliability are discussed.     

Microstructure and thermal behavior of Sn-Zn-Ag solders

The microstructure and thermal behavior of the Sn-Zn-Ag solder were investigated for 8.73–9% Zn and 0–3.0% Ag. The scanning electron microscopy (SEM) analysis shows the Ag-Zn compound when the solder contains 0.1% Ag. X-ray diffraction (XRD) analysis results indicate that Ag₅Zn₈ and AgZn₃ become prominent when the Ag content is 0.3% and above. Meanwhile, the Zn-rich phase is refined, and the Zn orientations gradually diminish upon increase in Ag content. The morphology of the Ag-Zn compound varies from nodular to dendrite structure when the Ag content increases. The growth of the Ag-Zn compounds is accompanied by the diminishing of the eutectic structure of the Sn-9Zn solder. Differential scanning calorimetry (DSC) investigation reveals that the solidus temperature of these solders exists at around 198°C. A single, sharp exothermic peak was found for the solders with Ag content less than 0.5%. Liquidus temperatures were identified with the DSC analysis to vary from 206°C to 215°C when the Ag content ranges from 1.0% to 3.0%     

Quantification of free ketene acetals and determination of cure kinetics of poly(ortho ester)s by a facile deuterium labeling method

A facile method was developed to quantify unreacted ketene acetals during polymerization of poly(ortho ester)s. The method was based on isotopic (deuterium) labeling of the unreacted ketene acetal groups arising from the diketene acetal monomer, 3,9-diethylidene-2,4,8,10-tetraoxaspiro[5,5]undecane (DETOSU). In deuterium oxide, free ketene acetals are hydrolyzed to an α-deuterated ester; ortho ester bonds are hydrolyzed to the nondeuterated analog. The relative abundance of the deuterated ester side chain can be quantified by gas chromatography-mass spectrometry (GC-MS). In the current method, aliquots of a diketene acetal/polyol(s) reaction mixture were dissolved (crosslinked polymers swollen) in methylene chloride and excess D₂O. The diketene acetal/polyol(s) reaction mixture was hydrolyzed under mildly acidic conditions to yield pentaerythritol dipropionate (PDP; hydrolysis product of DETOSU). PDP was extracted into an organic phase, silylated, and analyzed by GC-MS. Fragments corresponding to the C₂H₅C?O+ ion (57 a.m.u.) and C₂H₄DC?O+ ion (58 a. m. u.) were monitored and the quantity of free ketene acetal groups were calculated from the peak areas of the chromatograms. The precision of the method was ±0.1%. The accuracy, as compared to a parallel ¹H-NMR study, was within 5%. This method permits determination of the cure end-point of a poly(ortho ester) polymerization reaction to within ±0.25%. The curing kinetics agreed well with DSC branching/crosslinking measurements. © 1994 John Wiley & Sons, Inc.     

Synthesis of polyurethane resins and its improvement on dimensional stability and finishing performances of medium‐ and small‐diameter softwoods

This study analyzed the effects of polyurethane (PU) resin treatments on surface homogeneity, dimensional stability, and finishing performances of medium‐ and small‐diameter softwoods produced in Taiwan. Two‐pack PU resins were prepared by combing short castor oil‐modified alkyd resin serving as a polyol with polymeric 4,4′‐diphenymethane diisocyanate (PMDI) serving as a hardener, by the molar ratio of NCO/OH+COOH of 1.2. Four types of short oil‐modified alkyd resins with different polyhydric alcohols (glycerin and pentaerythritol) and polybasic acids (phthalic anhydride and isophthalic acid) were synthesized. Three kinds of medium‐ and small‐diameter softwoods, including China fir, Taiwanina, and Japanese fir with a diameter of 10–15 cm were obtained from Hui‐Sun Forest Station, Taiwan. The wood coating of nitrocellulose (NC) lacquer including sanding sealer and top clear was used. Results show that the surface hardness, homogeneity, moisture excluding efficiency, and antiswelling efficiency of woods were enhanced by PU resin treatments. Among all the PU resins, the isophthalic acid and pentaerythritol‐containing PU resin (IPA‐P‐MDI) achieved the best improved efficiency on dimensional stability of woods. Results of two types of finishing procedure, i.e. NC lacquer sanding sealer plus top clear and top clear only, applied onto the PU‐treated woods revealed that the hardness, adhesion, and durability of NC lacquer films on the PU‐treated wood were superior to those of untreated one, especially for top clear finishing alone. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Enhanced output power of near-ultraviolet InGaN-GaN LEDs grown on patterned sapphire substrates

Near-ultraviolet nitride-based light-emitting diodes (LEDs) with peak emission wavelengths around 410 nm were fabricated onto c-face patterned sapphire substrates (PSS). It was found that the electroluminescence intensity of the PSS LED shown 63% larger than that of the conventional LED. For a typical lamp-form PSS LED operating at a forward current of 20 mA, the output power and external quantum efficiency were estimated to be 10.4 mW and 14.1%, respectively. The improvement in the light intensity could be attributed to the decrease of threading dislocations and the increase of light extraction efficiency in the horizontal direction using a PSS.