Characteristics of ZnO thin film deposited on various metal bottom electrodes

ZnO films for electronic applications were deposited by radio-frequency (rf) sputtering onto various metal bottom electrodes (Pt/Ti, W, Ni) to investigate such structural properties as crystallinity and surface morphology. The crystallinity, surface morphology and composition of the as-deposited films were studied using X-ray diffraction (XRD), scanning electron microscopy (SEM) and Rutherford back-scattering spectrometry (RBS), respectively. The preferred orientation and surface morphologies were strongly influenced by the type of bottom electrodes. The ZnO films with (200) texturing deposited on Pt/Ti/SiO₂/Si showed a smoother and smaller grain size than those deposited on W and Ni. The ZnO films on Pt and W electrodes exhibited compressive residual stress. This article is based on a presentation made in the 2002 Korea-US symposium on the “Phase Transformations of Nano-Materials”, organized as a special program of the 2002 Annual Meeting of the Korean Institute of Metals and Materials, held at Yonsei University, Seoul, Korea on October 25–26, 2002.     

Superplasticity of fine-grained 7475 Al alloy and a proposed new deformation mechanism

A study has been made to investigate the superplastic deformation mechanisms of 7475 Al alloy in relation to the variation of grain size ranging between 5.5 μm and 13 μm. The strain-rate sensitivity (m) was increased with decreasing grain size in the superplastic deformation regime. Microstructural investigation after tension tests revealed that the dispersoid free zones were produced mostly at the grain boundaries normal to the tensile direction. A new model for describing the deformation behavior of the 7475 Al alloy has been proposed based on the assumption that the grain boundary sliding was accommodated by both diffusional flow and slip. This new model well predicts many aspects of experimental results.     

Separation of oxide inclusions from liquid metal in an applied electrostatic field

It is known that oxide inclusions in liquid metal carry mostly positive charges on their surfaces. In an electrostatic field, therefore, such charged particles suspended in a liquid metal experience forces and accumulate in the region of the negatively charged surface, resulting in the separation of oxide inclusions from the liquid metal. In this study, this principle was experimentally demonstrated for the case of a capacitor cell by the imposition of a d.c. potential on electrodes. The capacitor cell consisted of a dielectric container of Pyrex tube, a high voltage d.c. source, and two electrodes, which were symmetrically attached onto the outer surface of the Pyrex. tube. Experiments were carried out for suspensions of liquid tin/metal oxides, such as SnO₂, WO₃, and PbO under an applied potential of up to 12 kV. All experimental results were in good agreement with the theoretical prediction and showed that the degree of separation was significantly increased with the applied potential.     

Gate location design in injection molding of an automobile junction box with integral hinges

Polymers such as polypropylene or polyethylene offer a unique feature of producing an integral or living hinge for automobiles, which can flex over a million times without causing a failure. However, due to increased fluidity resistance at hinges during molding, several defects such as short shot or premature failure can occur with the improper selection of gate locations. In this paper, a design guideline was induced by investigating resin flow patterns depending on several gate positions obtained by numerical analyses of a simple strip with a hinge. The analyses of the simple strip part showed that the resin at the hinge did not flow until the other side of the strip was filled. Once the resin at the hinge did not flow for a long time enough to be solidified, defects such as short shots or hesitation marks formed. For a practical application of the design guideline determined, four gate systems for an automobile junction box were designed. It was found that the properly determined gate location leads to better resin flow and shorter hesitation time. Finally, injection molding tryouts using a mold that was designed by one of the proposed gate systems were conducted. The experiments showed that hinges without defects could be produced by using the designed gate location to assure the induced design guideline to be reasonable.     

Simulations of the dielectric constant of bonding materials and field emission properties of CNT cathodes

The effect of the dielectric constant (k) of bonding materials in a screen-printed carbon nanotube (CNT) cathode on the field enhancement factor was investigated for high-efficiency CNT cathodes using the ANSYS software. The values obtained by a simulation study were compared to the experimental results obtained for screen-printed CNT cathodes. The field enhancement factor increased as the dielectric constant decreased, reaching a maximum value at a dielectric constant of 1, the value for a vacuum. The findings indicate that the larger sheet resistance of the bonding materials, after the firing process, can be attributed to the larger emission current of the CNT cathode. From these results, it was concluded that the best bonding materials for screen-printed CNT cathodes should have a low dielectric constant and a high sheet resistance. This finding can be used as criteria for selecting bonding materials for use in CNT pastes for highly efficient CNT cathodes.     

The form error prediction in side wall machining considering tool deflection

In this research, an effective method for the form error prediction in side wall machining with a flat end mill is suggested. The form error is predicted directly from the tool deflection without surface generation by cutting edge locus with time simulation. The developed model can predict the surface form error accurately about 300 times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacturing. This study contributes to real time surface shape estimation and cutting process planning for the improvement of form accuracy.     

Magnesium interlayered diamond coating on silicon

Diamond thin films have been deposited using hot filament chemical vapour deposition technique on manually scratched p-Si(1 0 0) substrate, with and without magnesium interlayer. In spite of magnesium melting point being lower (T_m = 649 °C) than the growth temperature of the substrate (T_s  750 °C) used in these experiments, it was found that high quality diamond films could be grown on Mg covered substrate. A liquid substrate is probably generated during the diamond film growth. Raman spectroscopy analysis exhibited only the triply degenerate, zone centre optical phonon peak at 1333 cm⁻¹ indicating that nearly stress free crystallites were present. Broadening of the Raman peak (11.76 cm⁻¹) indicates that some small crystallites also are present. Scanning electron and atomic force microscopy accompanied by X-ray diffraction analysis where used to compare the details of diamond film growth directly on scratched Si(1 0 0) and Mg interlayered scratched Si(1 0 0) substrates.     

Tribological behavior of plasma spray coatings for marine diesel engine piston ring and cylinder liner

High-temperature wear characteristics between plasma spray coated piston rings and cylinder liners were investigated to find the optimum combination of coating materials using the disc-on-plate reciprocating wear test in dry conditions. The disc and plate represented the piston ring and the cylinder liner, respectively. Coating materials studied were Cr₂O₃-NiCr, Cr₂O₃-NiCr-Mo, and Cr₃C₂-NiCr-Mo. Plasma spray conditions for the coating materials were established adjusting stand-off distance to obtain a coating with a porosity content of ∼5%. It was found that a dissimilar coating combination of Cr₂O₃-NiCr-Mo and Cr₃C₂-NiCr-Mo provided the best antiwear performance. The addition of molybdenum was found to be beneficial to improve the wear resistance of the coating. Hardness differences between mating surfaces were also important factors in determining the wear characteristics, so that it should be controlled below 300 in Vickers hardness under dry conditions. Adhesive wear accompanying with metal transfer was a dominant wear mechanism for dry conditions.     

Corrosion resistance of austenitic stainless steel separator for molten carbonate fuel cell

STS310S and SC-STS310S (simultaneously co-deposited chromium and aluminum onto 310S austenitic stainless steel substrate by pack-cementation process) were used as separator materials on the cathode side of a molten carbonate fuel cell. With the STS310S, corrosion proceeded via three steps; a formation step of unstable corrosion product, a protection step against corrosion until breakaway, and an advance step of corrosion after breakaway. The final corrosion product was LiFeO₂ and the loss of mass was 6.5 mg/cm² after a corrosion test of 480 hr at 650°C. The SC-STS310S showed more effective corrosion resistance, however, than did common STS310S. There was especially no corrosion loss on the SC-STS310S after the 480 hr corrosion test. It is anticipated that it will be very useful as an alternative separator on the cathode side off the MCFC in the future.     

A study of tailored blank welding between mild steel sheet and zn-coated steel sheet by CO2 laser beam

Research was conducted on tailored blank welding between mild steel sheet and Zn-coated steel sheet using CO₂ laser beam. The materials used in this study were low carbon steel sheets with a thickness of 1.2 mm and Zn-coated steel sheet with the same thickness and 6.3 μm Zn coating. Experiments were conducted by applying the Taguchi method to obtain optimum conditions for the application of this tailored blank laser welding method in practical manufacturing processes. Optical microscopy, XRD, SEM and TEM analysis were performed to observe the microstructures and to determine the structures of welded zone. In addition, mechanical properties were measured by the microhardness test, tensile test and Erichsen test to evaluate the formability of the welded specimen. There was no trapped Zn in the fusion zone, and the phases of this region consisted of polygonal ferrite, quasi-polygonal ferrite, banitic ferrite and martensite. The elongation value of welded specimen was more than 80% of the value in substrate metal, and the LDH value was more than 90% of the value in substrate metal.