Potential for integration of electrophoretic deposition into electronic device manufacture; demonstrations using silver/palladium

A silver palladium (Ag/Pd) alloy powder is used as an example material to illustrate potential applications of electrophoretic deposition (EPD) in electronics manufacturing, in particular the forming of multilayer devices. The dispersion and deposition of the Ag/Pd powder in acetic acid is characterized. It is found that deposition can be explained by the direct action of electrostatic force on individual particles. Depositions of this Ag/Pd powder are then used to demonstrate: forming of a continuous layer on a rigid substrate; forming of continuous layers in laminated and sintered BaTiO₃ multilayers; and incorporation of patterned depositions into a multilayer by either overcasting the patterned deposition with a particulate slip to form a multicomponent tape, or direct lamination of the patterned deposition to a low temperature co-fired ceramic (LTCC) tape. It is shown that electrically conducting layers can be formed at an average thickness of only two times the diameter of the starting powder. Continuous conductor lines thirty times the average diameter of the starting powder were formed.     

Understanding TES microcalorimeter noise and energy resolution

We have performed numerical calculations of the noise in voltage-biased superconducting transition edge-based X-ray microcalorimeters, using a finite-element model. Details of the model are discussed, as well as results for different absorber geometries. The results are in agreement with an analytical model and show that the amount of internal thermal fluctuation noise can be reduced by using a segmented absorber. The simulation also agrees well with experimental data, which, for our detectors, contain no major unidentified noise sources. Furthermore, the discrepancy between the (small-signal) theoretical and the measured energy resolutions for 5.9 keV X-rays, for our sensors typically a factor of 2, is explained by a more accurate modelling of the sensor responsivity, taking into account the large signal behaviour.     

Modeling and Analysis of a Long Thin Conducting Stripline

A long thin conducting stripline embedded in a dielectric and centered between two large conducting plates, i.e., the stripline environment, is considered. The stripline is modeled as infinitely long, infinitely thin, and perfectly conducting by first considering a stripline of finite length, thickness, and conductivity in a dielectric layer. Starting from Maxwell's equations and assuming that the current on the stripline is a propagating wave in length direction, asymptotic expressions for the fields inside and in the neighbourhood of the stripline are deduced. These expressions are used to model the stripline in the stripline environment, which leads to a boundary-value problem for the electric potential. This problem is solved by two different approaches, leading to integral equations for the current and for an auxiliary function describing the electric potential. A relation between the current and the auxiliary function is deduced, which is used to obtain asymptotic expressions for current and impedance. Results are compared with a numerical solution of the integral equation for the current and with results in literature.     

Dynamic vulcanisation of EPDM/PE-based thermoplastic vulcanisates studied along the extruder axis

Simple blending and dynamic vulcanisation of EPDM/PE blends using the resol/SnCl₂ system was studied in an extruder using a series of sampling devices. The melting of the PE pellets occurs just in front of and in the first kneading zone. Upon complete melting of the PE phase, the EPDM/PE blends reach very quickly their final morphology. Crosslinking of the EPDM phase to high levels occurs already when the PE phase is not yet fully molten. The higher the EPDM content, the higher the viscous dissipation, the higher the melt temperature and, consequently, the higher the crosslinking rate. For the EPDM/PE (50/50; w/w) TPV a transition from continuous via co-continuous to fully dispersed EPDM is observed, which is driven by crosslinking. Although the degree of crosslinking of the EPDM rubber is very high, this does not prevent phase inversion of the blend. The EPDM/PE interface is rather blurred, because PE crystalline lamellae are growing into the EPDM domains, probably because of the high compatibility between PE and EPDM (60 wt% of ethene). This study shows that dynamic vulcanisation in extruders proceeds quite differently from that in batch kneaders, where melting, mixing and crosslinking are separated in time. In extruders mass and heat transport, melting of the thermoplastic, morphology development (including dispersion and phase inversion), distribution and dissolution of (crosslinking) chemicals and crosslinking of the rubber do not occur as independent phenomena, but mutually and/or continuously interact.     

Life cycle of hydroprocessing catalysts and total catalyst management

Hydroprocessing catalysts based on Ni, Co, Mo and W are used in various refinery processing applications where several deactivation mechanisms become of importance (coke formation, active phase sintering, metals deposition, poisoning) in the catalyst's life cycle. The life cycle of commercial hydroprocessing catalysts is very complex and includes the catalyst production, sulfidation, use, oxidative regeneration followed by re-sulfidation and reuse or, if reuse is not possible, recycling or disposal. To understand the changes in catalyst properties taking place during a life cycle, the catalyst quality in the different stages can be best monitored by using advanced analytical techniques. The catalyst's life cycle is further complicated by numerous technical, environmental and organizational issues involved. In principle, different companies can be involved in each of the life cycle steps. Leading catalyst manufacturers, together with specialized firms, offer refineries a total catalyst management concept, starting with the purchase of the fresh catalyst and ending with its final recycling or disposal. Total catalyst management includes a broad range of services, ensuring optimal timing during the change-out process, reliable, smooth and safe operations, minimal downtime and maximum catalyst and unit performance.     

Separating n-alkane mixtures by exploiting differences in the adsorption capacity within cages of CHA, AFX and ERI zeolites

The saturation capacity of n-alkanes in CHA, AFX and ERI zeolites, that consist of cages separated by windows, decreases with increasing carbon number. The major aim of the present communication is to demonstrate the possibility of separating n-alkane mixtures relying on differences in saturation capacities. To investigate this possibility, Configurational-Bias Monte Carlo simulations for adsorption of C3–nC6, nC4–nC6, and nC5–nC6 mixtures in CHA, AFX and ERI were carried out for equimolar bulk fluid phase. These mixture simulations show that for operation at fluid phase fugacities below about 1 MPa, the adsorbed phase in equilibrium with the bulk vapor phase is predominantly the alkane with the longer chain length, i.e. nC6. However, for operation at pressures in excess of 1 MPa, the adsorbed phase in equilibrium with the bulk liquid phase is richer in the component with the smaller chain length. In some cases, the nC6 is practically excluded from the zeolite.     

Validity of the Parabolic Effective Mass Approximation in Silicon and Germanium n-MOSFETs With Different Crystal Orientations

This paper investigates the validity of the parabolic effective mass approximation (EMA), which is almost universally used to describe the size and bias-induced quantization in n-MOSFETs. In particular, we compare the EMA results with a full-band quantization approach based on the linear combination of bulk bands (LCBB) and study the most relevant quantities for the modeling of the mobility and of the on-current of the devices, namely, the minima of the 2-D subbands, the transport masses, and the electron density of states. Our study deals with both silicon and germanium n-MOSFETs with different crystal orientations and shows that, in most cases, the validity of the EMA is quite satisfactory. The LCBB approach is then used to calculate the values of the effective masses that help improve the EMA accuracy. There are crystal orientations, however, where the 2-D energy dispersion obtained by the LCBB method exhibits features that are difficult to reproduce with the EMA model.     

Prediction of necking of high strength steel tubes during hydroforming—multi-axial loading

This article studies tubular hydroforming of high strength low alloy (HSLA) and dual phase (DP600) straight tubes under the action of end feeding loads. Experiments demonstrate that higher end feed loads enhance the formability of the tubes and increase the internal fluid pressure for onset of necking and bursting. Because of the action of the internal pressure and the axial compressive load, the onset of localization (necking) is due to a complex three-dimensional state of stress. Using free expansion experiments, approximate upper and lower bound strain-based forming limit curves are determined for the tube materials. These limit curves, in turn, are used to derive upper and lower bound extended stress-based forming limit curves [Simha et al., Prediction of necking in tubular hydroforming using an extended stress-based FLC. Transactions of the ASME Journal of Engineering Materials and Technology 2007;129(1): 36-47]. In conjunction with finite element computations that use solid elements to model the tube, these stress-based limit curves are used to predict upper and lower bound necking pressures under the action of end feed loading. These predictions of necking pressures, when an appropriate coefficient of tube-die friction is used, are found to bracket the experimentally measured necking pressures. Computations using plane stress shell elements to model the tubes are shown to give erroneous results, since the plane stress approximation is not valid when tubes are hydroformed in a die.     

Driving Mechanisms of Delamination Related Reliability Problems in Exposed Pad Packages

Exposed pad packages were introduced in the late 1980s and early 1990s because of their excellent thermal and electrical performance. Despite these advantages, the exposed pad packages experience a lot of thermo-hygro-mechanical related reliability problems during qualification and testing. Examples are die lift, which occurs predominantly after moisture sensitivity level conditions, and die-attach to leadframe delamination leading to downbond stitch breaks during temperature cycling. In this chapter, nonlinear finite element (FE) models using fracture mechanics based J-integral calculations are used to assess the reliability problems of the exposed pad package family. Using the parametric FE models any geometrical and material effects can be explored to their impact on the occurrence diepad delamination, and dielift. For instance the impact of diepad size is found to be of much less importance as the impact of die thickness is. Using the fracture mechanics approach, the starting location for the delamination from thermo-hygro-mechanical point of view is deducted. The results indicate that when diepad delamination is present, cracks are likely to grow beneath the die and dielift will occur. The interaction between dielift and other failure modes, such as lifted ball bonds, are not found to be very significant. The FE models are combined with simulation-based optimization methods to deduct design guidelines for optimal reliability of the exposed pad family.     

Modeling alternative zoning strategies in forest management

To satisfy public demands for environmental values, forest companies are facing the prospect of a reduction in wood supply and increases in costs. Some Canadian provincial governments have proposed intensifying silviculture in special zones dedicated to timber production as the means for pushing out the forest possibility frontiers. In this paper, we compare the traditional two‐zone land allocation framework which includes ecological reserves and integrated forest management zones with the triad — a three‐zone scheme which adds a zone dedicated to intensive timber production. We compare the solutions of the mixed‐integer linear programs formulated under both land‐allocation frameworks. We explore through sensitivity analysis the conditions under which the triad regime can offset the impact on timber production from increased environmental demands. We show that under the realistic conditions characteristic to Coastal British Columbia, higher environmental demands may be satisfied under the triad regime without increasing the financial burdens on the industry or reducing its wood supply. This occurs, however, only if regulatory constraints in timber production zone are flexible.