Reaktive Nanometer‐Multischichten als maßgeschneiderte Wärmequellen beim Fügen

Reactive nanometer multilayers as tailored heat sources for joining The use of traditional joining techniques like soldering or brazing for heat sensitive microstructures often results in damaging or stress induced deformation of the components. Therefore a technology would be desirable, where heat is produced locally and only for a short time. A very promising approach is the application of socalled reactive nanometer multilayers. Reactive nanometer multilayers consist of several hundreds or a few thousands of alternating layers wi^th thicknesses in the nanometer range that can exothermic react wi^th each other. After a local activation of the chemical reaction by an electrical spark or a laser pulse, a self‐sustaining reaction starts, which propagates parallel to the multilayer surface resulting in a stable intermetallic single layer. The peak temperature of the reaction can be above 1000 8C, but the maximum temperature is only reached for several ten milliseconds. Therefore, the heat remains localized in the vicinity of the solder layers surrounding the reactive multilayer. During the entire process the components to be joined exhibit temperatures close to room temperature. We will show new results concerning the fabrication of reactive nanometer multilayers by magnetron and ion beam sputter deposition and the fabrication of free standing nanometer multilayers.     

Reaktive Multischichtsysteme

Reactive Multilayer Systems as tailored heat sources for plastic bondings The use of reactive multilayer systems (RMS) as a heat source for the manufacturing of thermoplastic material bondings makes it possible to completely or partially overcome the limitations of conventional joining techniques, such as gluing or welding. The release of energy, which takes place directly inside the joining zone within milliseconds can be well adapted to the properties of the plastics. Thus undesired changes in the material structure of the joining partners can be avoided. Bonding strengths which are higher than or comparable to those of commercially used joining methods can be achieved. Furthermore, a particular advantage of RMS joining is that no surface pretreatment is required. RMS bondings of thermoplastics achieve high long-term stability for plastics, which themselves are only slightly susceptible to aging.     

Joining Technology in Metal-Ceramic Systems

Metallic alloys and ceramic materials are employed in aggressive and hostile environments, ranging from aerospace to energy production, from offshore to biological applications. Today, production requires materials able to survive for a long time at high temperatures, in highly aggressive atmospheres, both from the chemical and the mechanical points of view. No single material can offer these characteristics, so that “composite” structures (composites, multilayer materials, metal-ceramic joints) are designed and tested under extreme conditions.

In this paper are presented the basic principles underlying joining technologies, a short discussion of the thermodynamic background of wetting processes, recent developments related to non-reactive and reactive wetting, the influence of trace chemical elements (in the solid, liquid and gaseous phases), and some specific aspects of diffusion bonding, brazing and transient liquid phase joining processes.     

Flussmittelfreies Hartlöten unter reaktiver Prozessgasatmosphäre – ein alternatives Verfahren zum Fügen von Aluminiumwerkstoffen

Flux‐free brazing under reactive process gas atmosphere – an alternative process for joining of aluminium materials Due to the high affinity of aluminium towards oxygen, joining of aluminium materials has ever been a challenge. In particular the efficiency of the process and the abandonment of fluxes during controlled atmosphere brazing have been within the focus of current research projects. The specific addition of reactive gases to the inert process gas atmosphere offers a suitable possibility of aluminium brazing without the use of fluxes. Under the application of hydrogen chloride the activation of the brazing and the workpiece surfaces is to be initiated, thus leading to dissolving the oxide layers. Moreover, the strongly reducing gas silane is used, which specifically removes oxygen and water residuals from the controlled atmosphere. Through a suitable controlled atmosphere brazing process the combination of both, reductive and activating additions, is to be used and tested upon their influence on the gas mixtures and materials used [1–5].     

Transparente Barriereschichten auf flexiblen Polymersubstraten

Transparent permeation barrier layers on flexible polymer substrates This paper reviews different vacuum based technologies for manufacturing transparent permeation barrier layers and layer stacks on flexible polymer substrates. With plasma assisted reactive evaporation, a cost‐efficient, highly productive process for food packaging applications is presented. Reactive dual magnetron sputtering is a technology for the deposition of oxide layers with a very low water vapor and oxygen transmission rate at a reasonable deposition rate. Many groups suggest multilayer stacks for the encapsulation of flexible electronic devices. In this paper, an all‐in‐vacuum inline concept for manufacturing such multilayers is presented. It is based on the combination of reactively sputtered barrier layers with interlayers grown by using a magnetron based PECVD process (Magnetron‐PECVD). Both, process parameters, such as deposition rate and process pressure, and important layer properties, such as morphology and the water vapor and oxygen transmission rate are compared for the different single and multi layer technologies.     

Nanostructured Carbon Films

By periodic variation of the deposition conditions nanometer multilayers of amorphous carbon films of varying density are deposited. Such carbon–carbon multilayers can be used for the preparation of X‐ray mirrors of extreme irradiation stability and the optimization of tribological carbon coatings. Combining these techniques with concepts demonstrated in the preparation of fullerenes and nanotubes leads to graphitic films of very high hardness. Potential applications involve such different fields as field emission cathodes for flat panel displays and low‐friction wear‐protecting films.     

Löten und Härten im Vakuum zur Herstellung leistungsfähiger Gesteinwerkzeuge

Brazing and hardening in vacuum for manufacturing of high‐performance tools for construction applications High‐performance tools for applications in construction industry are used under severe service conditions. Huge amounts of construction materials have to be removed in short times with long service times. By sophisticated heat treatment processes or combination of materials construction tools are optimized for the dedicated application. Vacuum brazing is a proven technology to join different materials. Case studies will be presented where vacuum hardening of tool steel and vacuum brazing of hard metal to steel improve tool performance significantly.     

REVIEW OF SOME PROCESSES FOR CERAMIC-TO-METAL JOINING

Various methods are discussed for the joining of ceramics to metals and vice versa. State-of-the-art techniques including refractory metallizations and active metal brazing are detailed from both a processing and applications standpoint. Various approaches to forming ceramic/metal joints or thin film coatings have been developed over the years to address the need to combine the properties of both types of materials for both electrical and structural applications. These methods address not only physical and chemical compatibility concerns but also the need for bonds between dissimilar materials to survive the rigors of use generated by such inevitable mismatches as can be found in expansion, elastic, reactive and thermal cycling behavior.     

Balanceregelung für reaktives Magnetronsputtern zur optischen Großflächenbeschichtung

Best prerequisites for long term stable optical coating are given by reactive Dual Magnetron Sputtering. Requirements for components and techniques for architectural Low‐E coating and TCO coating are discussed. Reliable process stabilization at high deposition rates is possible using Plasma Emission Monitor (PEM) control circuits. The use of multichannel PEM control allows a balance control to improve both the film thickness uniformity and reproducibility of working points for large area coating on glass or web. Examples of horizontal and vertical glass coater for deposition of optical multilayers for different applications are presented.     

Nanoparticle syntheses using non-porous and porous polyelectrolyte multilayers for biological applications

Polyelectrolyte multilayers comprised of poly(allylamine hydrochloride) and poly(acrylic acid) were assembled by layer-by-layer technique for metal nanoparticle syntheses. Using weak polyelectrolytes in LbL process, it is readily available to tune the deposited film properties by simple changing of the dipping solution pH. The PAH/PAA multilayer systems exhibit different surface morphologies and functionalities depending on the assembly conditions. We have studied two distinctive PAH/PAA multilayer films to utilize them for nanoparticle synthesis. The reactive functional groups of the polyelectrolytes within the films were remained after the film deposition or reactivated by a simple pH stimulus, and therefore they were allowed to undergo further chemical reactions to synthesize Pd and Au nanoparticles. Synthesized metal nanoparticles were easily characterized by their optical properties including surface plasmon absorption. These metal nanoparticle-embedded multilayers may have great potentials for biomolecule sensing or catalytically active coatings.     

Innovative Fügeverfahren zur Herstellung von Al‐Leichtbaustrukturen im Schienenfahrzeugbau

Innovative joining techniques for creating light‐weight aluminium structures in railway vehicle production Starting from the development in railway vehicle manufacture, the authors describe today's materials, types of construction, joining techniques, joint and weld types, filler materials and regulatory documents. In addition, they present new processing equipment and engineering principles. On the basis of these findings, they show the perspectives of new construction principles for light‐weight aluminium structures and identify the requirements, the new joining techniques have to meet. The innovative joining techniques, such as: • electron‐beam welding under atmosphere (NV‐EBW) • Friction Stir Welding (FSW) • Laser beam welding (LBW) • Laser beam/electric arc hybrid welding (LBW/LB) are studied with regard to their • properties and particularities • advantages and disadvantages • available equipment • possible applications for railway vehicle manufacture. In addition, costs are compared and an analysis of the benefit is made. Finally, the authors give an outlook on possible applications of the innovative procedures.     

Multifunctional lipid multilayer stamping

Nanostructured lipid multilayers on surfaces are a promising biofunctional nanomaterial. For example, surface-supported lipid multilayer diffraction gratings with optical properties that depend on the microscale spacing of the grating lines and the nanometer thickness of the lipid multilayers have been fabricated previously by dip-pen nanolithography (DPN), with immediate applications as label-free biosensors. The innate biocompatibility of such gratings makes them promising as biological sensor elements, model cellular systems, and construction materials for nanotechnology. Here a method is described that combines the lateral patterning capabilities and scalability of microcontact printing with the topographical control of nanoimprint lithography and the multimaterial integration aspects of dip-pen nanolithography in order to create nanostructured lipid multilayer arrays. This approach is denoted multilayer stamping. The distinguishing characteristic of this method is that it allows control of the lipid multilayer thickness, which is a crucial nanoscale dimension that determines the optical properties of lipid multilayer nanostructures. The ability to integrate multiple lipid materials on the same surface is also demonstrated by multi-ink spotting onto a polydimethoxysilane stamp, as well as higher-throughput patterning (on the order of 2 cm(2) s(-1) for grating fabrication) and the ability to pattern lipid materials that could not previously be patterned with high resolution by lipid DPN, for example, the gel-phase phospholipid 1,2-dipalmitoyl-sn-glycero-3-phosphocholine (DPPC) or the steroid cholesterol.     

陶瓷连接技术及其应用

金属与陶瓷的连接逐渐成为现代制造业中重要的加工手段,连接技术的发展使陶瓷材料可以与传统的金属材料组合使用,并且二者可以互相弥补彼此的不足。此外,由于使用环境越来越苛刻,对连接接头的耐高温性能以及机械性能均提出了更高的要求,因此更加需要大力发展连接工艺。介绍了几种主要的陶瓷连接技术,包括活性金属钎焊、高温活性钎焊、超声辅助陶瓷连接、反应空气钎焊、玻璃连接、过渡液相连接和部分过渡液相连接,对各种陶瓷连接技术的机理进行了相应阐述,同时对缓解陶瓷/金属连接接头残余应力常用的中间层法进行了重点论述。最后,对近年来陶瓷连接技术和发展趋势以及应用做出了展望。     

Organische Bindemittel zum Wärmearmen Fügen

Organic adhesives for low heat joining techniques. The applications of adhesives have been greatly extended by the using of synthetic organic polymers which cures physically or chemically. They give satisfactory adhesion to different materials, flexibility, and mechanical properties even at high temperatures. A particulary important advance was the introduction of chemically or mechanically blocked polymer systems, which reduces curing time and costs of curing equipment.     

陶瓷空气反应钎焊研究综述

高温电化学装置技术优势明显,市场潜力巨大,其特殊的服役环境对钎焊接头提出了更高要求,空气反应钎焊连接方法应运而生。综述了目前常用于RAB连接的钎料种类和已成功实现RAB连接的陶瓷/金属体系,并对相关接头界面组织和综合性能进行了分析。迄今为止,Ag-Cu O钎料使用最广。利用空气反应钎焊方法能够成功实现氧化物、钙钛矿陶瓷自身及其与部分耐高温不锈钢的可靠连接,结合界面成形良好,接头性能稳定。常用于RAB连接的氧化物陶瓷以YSZ和Al_2O_3为代表,LSCF/BSCF/BCFN/BCFZ等典型钙钛矿陶瓷也可利用RAB进行连接。Crofer22 APU,AISI310S和AISI314等耐高温不锈钢与上述钙钛矿陶瓷进行RAB连接后,接头的力学性能、抗氧化能力和气密性均能满足使用需求。在此基础上,对空气反应钎焊的连接特性与研究现状进行了总结。最后,对其发展前景和未来研究方向进行了展望。     

Herstellung von Präzisionsschichten mittels Ionenstrahlsputtern

Precise thin film synthesis by ion beam sputter deposition Ion beam sputter deposition (IBSD) is a promising technique for the fabrication of high performance thin films because of the well defined and adjustable particle energies, which are rather high in comparison to other PVD techniques. Recent developments concerning long‐term stability and lateral uniformity of the ion beam sources strengthen the position of the IBSD technique in the field of precise thin film synthesis. Furthermore, IBSD offers a more independent choice of relevant deposition parameters like particle energy and flux, process gas pressure and deposition rate. In this paper we present our currently installed large area IBSD facility “IonSys 1600”, which was developed by Fraunhofer IWS Dresden and Roth & Rau company (Hohenstein‐Ernstthal). Substrate sizes of up to 200 mm (circular) or up to 500 mm length (rectangular) can be coated and multilayer stacks with up to six different materials are possible. Tailored 1‐ or 2‐dimensional film thickness distributions with deviations of < 0.1 % can be fabricated by a relative linear motion of the substrate holder above an aperture. In order to demonstrate the advantages of the IBSD technique especially for sophisticated materials and films with high requirements concerning purity, chemical composition or growth structure, several examples of deposited multilayers for various applications are presented.     

Modeling the image quality of enhanced reflectance x-ray multilayers as a surface power spectral density filter function

Residual surface roughness over the entire range of relevant spatial frequencies must be specified and controlled in many high-performance optical systems. This is particularly true for enhanced reflectance multilayers if both high reflectance and high spatial resolution are desired. If we assume that the interfaces making up a multilayer coating are uncorrelated at high spatial frequencies (microroughness) and perfectly correlated at low spatial and midspatial frequencies, then the multilayer can be thought of as a surface power spectral density (PSD) filter function. Multilayer coatings thus behave as a low-pass spatial frequency filter acting on the substrate PSD, with the exact location and shape of this cutoff being material and process dependent. This concept allows us to apply conventional linear systems techniques to the evaluation of image quality and to the derivation of optical fabrication tolerances for applications utilizing enhanced reflectance x-ray multilayers.     

Quantification of Protein‐Induced Membrane Remodeling Kinetics In Vitro with Lipid Multilayer Gratings

The dynamic self‐organization of lipids in biological systems is a highly regulated process that enables the compartmentalization of living systems at micro‐ and nanoscopic scales. Consequently, quantitative methods for assaying the kinetics of supramolecular remodeling such as vesicle formation from planar lipid bilayers or multilayers are needed to understand cellular self‐organization. Here, a new nanotechnology‐based method for quantitative measurements of lipid–protein interactions is presented and its suitability for quantifying the membrane binding, inflation, and budding activity of the membrane‐remodeling protein Sar1 is demonstrated. Lipid multilayer gratings are printed onto surfaces using nanointaglio and exposed to Sar1, resulting in the inflation of lipid multilayers into unilamellar structures, which can be observed in a label‐free manner by monitoring the diffracted light. Local variations in lipid multilayer volume on the surface is used to vary substrate availability in a microarray format. A quantitative model is developed that allows quantification of binding affinity (K _D) and kinetics (k_on and k_off). Importantly, this assay is uniquely capable of quantifying membrane remodeling. Upon Sar1‐induced inflation of single bilayers from surface supported multilayers, the semicylindrical grating lines are observed to remodel into semispherical buds when a critical radius of curvature is reached.     

Wetting and laser brazing of Zn-coated steel products by Cu–Si filler metal

Laser brazing is an effective process for joining of steel products widely applied in automobile industry on exposed parts, especially on two following targeted applications: roofs and hatchbacks. The obtaining of good quality joints requires an adequate understanding of interaction phenomena of the brazing filler with the steel surface. This study concerns the investigation of wetting and interfacial reactivity in Cu–Si brazing alloy/Zn-coated steel systems in order to identify how the coating influences the wettability and, consequently, the brazability of steel products. The wetting experiments are performed on hot-dip-galvanized and electro-galvanized coatings, as well as on bare steel. The morphology and chemistry of interfacial reaction products are characterized by SEM-FEG and X-microanalysis.     

Residual Stress Distributions in Glass/Metal‐Joints produced by Ultrasonic Torsion Welding

The development and industrial application of efficient methods to join glass with metals which combine the individual advantages of both material groups are a great technological challenge. One research field of the Institute of Materials Science and Engineering is the production of glass/metal joints by means of ultrasound. Industrial applications are for example the sealing of glass vessels, fixtures in the vacuum technique or lens mounts. For this reason an industrial ultrasonic torsion welding system normally used for metal weldings was modified to be suitable for the demands of high sensitive glass/metal‐joints. With the developed welding system helium‐tight joints of glass and metals can be realized. In comparison to the conventional welding techniques [1] for glass like diffusion welding or adhesive bonding, ultrasonic torsion welding is characterized by very short welding times (< 1s) as well as low welding temperatures (< 450°C). Further advantages of this joining technique are the high automation potential and the environmental compatibility. Furthermore this technique can be applied under normal or specific atmospherical conditions. In spite of the low joining temperatures thermal residual stresses occur during the cooling of the joints due to the different coefficients of thermal expansion of the used materials [2]. In the present paper the measurement and calculation of the temperature distribution and the development of thermal residual stresses are described.