Elevated temperature impact on performance of Low Temperature Co-fired Ceramic dielectrics

The need for electronics to operate at temperatures of 200°C and above continues to grow. These applications include avionics, aerospace, automotive, downhole drilling, mining, and many others. To satisfy this demand, a significant amount of research and development has been conducted. Despite the efforts, the number of new electronic components designed specifically for high-temperature operation is still relatively limited. In Low Temperature Co-fired Ceramic (LTCC) packages, LTCC materials are generally used as the host media for a number of pre-fabricated semiconductor components. As a result, reliability of the entire LTCC package largely depends on the performance of the least robust component. Ferro A6M-E and Ferro L8 are the two well-established and recognized LTCC dielectrics widely used for mid and high frequency LTCC applications, including several high reliability aerospace and defense applications that require demanding Mil-Spec qualifications. This study is our first attempt to characterize and understand basic high-temperature dielectric properties of these two commercial LTCC materials. The secondary objective is to initiate a dialogue in attempt to establish reliability requirements for LTCC packages dedicated for high-temperature operation.     

Effects of Ti,Y, and Hf additions on the thermal properties of ZrB2

Reactive hot pressing was utilized to synthesize and densify four ZrB₂ ceramics with impurity contents low enough to avoid obscuring the effects of dopants on thermal properties. Nominally pure ZrB₂ had a thermal conductivity of 141 ± 3 W/m K at 25 °C. Additions of 3 at% of Ti, Y, or Hf decreased the thermal conductivity by 20 %, 30 %, and 40 %, respectively. The thermal conductivity of (Zr,Hf)B₂ was similar to ZrB₂ synthesized from commercial powders containing the natural abundance of Hf as an impurity. This is the first study to demonstrate that Ti and Y additions decrease the thermal conductivity of ZrB₂ ceramics and report intrinsic values for thermal conductivity and electrical resistivity of ZrB₂ containing transition metal additions. Previous studies were unable to detect these effects because the natural abundance of Hf present masked the effects of these additions.     

Development of LTCC micro-hotplate with PTC temperature sensor for gas-sensing applications

Low temperature co-fired ceramic (LTCC) micro-hotplates show wide applications in gas sensors and micro-fluidic devices. It is easily structured in three-dimensional structures. This paper presents the low power consumption micro-hotplates which were developed with PTC (positive temperature coefficient) temperature sensor and inter-digitated electrodes. The paper presents two different structures for micro-hotplate with platinum as a heating element. The PTC temperature sensor using two different materials viz. PdAg and platinum paste are developed with micro-hotplates. The simulation has been achieved through COMSOL for LTCC and alumina micro-hotplates. The temperature variation with power consumption has been measured for the developed LTCC micro-hotplates. The change in resistance of PTC temperature sensors was measured with micro-hotplate temperature. The aim of this study was to place a temperature sensor with the gas sensor module to measure and control the temperature of micro-hotplate. A SnO₂ sensing layer is coated on LTCC micro-hotplate using screen printing and characterized for the sensing of carbon monoxide gas (CO). This study will be beneficial for designing hotplates based on LTCC technology with low power consumption and better stability of temperature for gas-sensing applications.     

A cathode support structure for use in a magnetron oscillator experiment

A low temperature co-fired ceramic (LTCC) material system has been used to develop a protype field emission cathode structure for use in an experimental magnetron oscillator. The structure is designed for used with 30 gated field emission array (GFEA) die electrically connected through silver metal traces and electrical vias. To approximate a cylinder, the cathode structure (48 mm long and 13.7 mm in diameter) is comprised of 10 faceted plates which cover the GFEA dies. Slits in the facet plates allow electron injection. The GFEA die (3 mm × 8 mm) are placed in axial columns of 3 and spaced azimuthally around a cylindrical support structure in a staggered configuration resulting in 10 azimuthal locations. LTCC manufacturing techniques were developed in order to fabricate the newly designed cathode with seven layers wrapped to form the cylinder with electrical traces and vias. Two different cathode wrapping techniques and two different via filling techniques were studied and compared. Two different facet plate manufacturing techniques were studied. Finally, four different support stand configurations for firing the cylindrical structure were also compared with a square post stand having the best circularity and linearity measurements of the fired structure.     

Tribological behavior of graphene reinforced chemically bonded ceramic coatings

To investigate tribological behavior of graphene reinforced chemically bonded ceramic coatings at different temperatures, tribological tests at room temperature, 200 °C and 500 °C were carried out. Results show that the fracture toughness and the hardness of the coating are improved with the introduction of graphene. Besides, the friction coefficient of the coating decreases with the addition of graphene at the room temperature and 200 °C. The coating without graphene achieves the similar friction coefficient at all temperatures. However, the coating with graphene achieves the lowest friction coefficient at 200 °C, and achieves the highest at 500 °C. In addition, the wear rate of the coating decreases with the increase of graphene. Besides, the wear rate at 200 °C is almost similar with that at room temperature. In contrast, the wear rate at 500 °C is much larger than those at room temperature and 200 °C. The mechanisms for graphene to decrease the friction coefficient and improve the wear resistance of chemically bonded ceramic coatings at evaluated temperatures are clarified.     

Solid state reactions between SiC and Ir

Reactivity between SiC and Ir as a function of SiC-crystallinity was investigated by diffusion bonding technique under a vacuum and over the temperature range of 1200–1450 °C. As reaction products, various Ir-silicides and free unreacted-C were detected. Reactivity is strongly affected by the temperature and SiC-crystallinity involving a series of interactions, from “no reaction” to “massive exothermic reactions”. In particular, interfacial phenomena are more pronounced by the presence of defects and grain boundaries.Solid state reactions result in formation of fine C-precipitates rearranged in a quasi-periodic microstructure. On the contrary, clustering of highly ordered C-precipitates (C-graphitized) occurs after “massive reactions” take place.A relationship between the degree of graphitization (from 1 to multi-layers of graphene), temperature and SiC crystallinity was found by Raman spectroscopy. 2D-layering phenomenon is enhanced in polycrystalline SiC at high temperature.     

湿式摩擦副滑摩过程温度场分析及实验验证

湿式摩擦副滑摩过程温度场与应力场相互耦合作用,温度场分布受到多种因素影响,其中压力、旋转速度、润滑流量作为湿式摩擦副工作参数对其温度场的影响尤为显著。在理论分析基础上,采用有限元数值模拟分析与实验研究相结合的方法,对摩擦界面温度场时空分布特性进行研究,同时研究界面温度场在摩擦副工作压力、相对转速和润滑流量作用下的变化规律。研究表明:在对偶钢片和摩擦片近外径侧更易出现高温和应力集中区,且对偶钢片相对于摩擦片更易出现温度和应力分布不均匀情况;温度场中高温集中区与应力场中应力集中区相对应,最大温度随着压力增加、相对转速增大、润滑流量减少而显著上升,该结果得到试验结果的验证。     

Methodology for optimization of pouring variables using bottom pour for low masses of SS304 (<300 kg) in investment casting process (case study)

Bottom pour ladles with stopper rod systems are commonly used in the metal casting industry. However, stopper rod bottom-pouring systems have not yet been developed for the lower thermal masses of alloys typically used in the investment casting industry. Large thermal masses used with bottom pour systems are typically limited for ladles larger than 700 kg and to certain alloys with higher fluidity and longer solidification time like cast iron, aluminum alloys etc. In this study, bottom pour ladle designs and low thermal mass refractory systems have been developed and evaluated in production investment foundry trials with 300 kg pouring ladle. The ladles system and pouring practices used will be described along with the results from the pouring trials for SS304 that represents typical alloys used in Investment casting industries. Optimization of the variables used in an experimentation using Genetic algorithm is also explained.     

Electrical Breakdown Properties and Space Charge Formation in High Temperature Region in Ultraviolet Ray Irradiated PVC

Polyvinyl chloride (PVC) is the most popular insulating material for electric wiring instruments. However, an exothermic reaction above 150 °C may cause deterioration of the insulating properties of PVC. Therefore, it is important to clarify the heat degradation in PVC, not only to investigate the ignition of electrical wiring products but also to use electrical products safely. It is known that ultraviolet (UV) irradiation causes chemical deterioration of PVC and an increase in its conductivity. Generally, it has been thought that the electrical breakdown properties, electrical conduction, and insulating performance are affected by space charge accumulation in an insulating material. A high temperature pulsed electroacoustic (PEA) system usable up to 250 °C has been developed, and the PEA system can measure the space charge distribution and conduction current in the high temperature range simultaneously. In this investigation, the space charge distribution and conduction current were measured up to electrical breakdown in a non‐UV irradiated sample (normal PVC) and in 353 nm and 253 nm UV‐irradiated PVC samples in the range from room temperature to 200 °C in a DC electric field. In the short wavelength UV irradiated PVC sample (253 nm, 300 h), a deterioration of breakdown strength at 90 °C to 150 °C and negative packet‐like charges were observed at 60 °C and 100 °C, a positive charge accumulated in front of both the anode and cathode above 90 °C, and a higher electric field near the cathode side because the positive charge of the cathode side was greater.