Development of a lead-free composite solder from Sn–Ag–Cu and Ag-coated carbon nanotubes

The microelectronic applications of lead-free solders pose ever-increasing demands. We seek to improve the solder by forming composites with Ag-coated single-walled carbon nanotubes (Ag-coated SWCNTs). These were incorporated into 96.5Sn–3.0Ag–0.5Cu solder alloy with an ultrasonic mixing technique. Composite solder pastes with 0.01–0.10 wt% nanotube reinforcement were prepared. The wettability, melting temperature, microstructure and mechanical properties of the composite solders were determined, and their dependency on nanotube loading assessed. Loading with 0.01 wt% Ag-coated SWCNTs improved the composite solder’s wetting properties, and the contact angle was reduced by 45.5 %, while over loading of the coated nanotubes up to 0.10 wt% degraded the wettability. DSC results showed only slight effects on the melting behavior of the composite solders. Cross-section microstructure analysis of the spreading specimens revealed uniform distribution of the intermetallic compounds throughout the solder matrix, and EDS analysis identified the phases as β-Sn, Ag₃Sn and Cu₆Sn₅. The mechanical properties of composite specimens, compared with those of unloaded 96.5Sn–3.0Ag–0.5Cu solder, had a maximal improvement in the shear strength of 11 % when the nanotube loading was 0.01 wt% of Ag-coated SWCNTs.     

A method for design of Mth-band filters

The objective of this paper is to present a theory, constraints, and a design method for nonlinear-phase halfband and Mth-band filters. Based on a time-domain property, the constraints and properties in the frequency domain are derived. They are the generalization of the well-known conditions for linear-phase Mth-band filters. Having found all necessary conditions, we present the design method based on an eigenfilter that minimizes the mean-squared errors. The design method is also extended to the design of nonlinear-phase Mth-band filters with properties of R-regularity, or equiripple stopband attenuation, or impulse responses that have complex coefficients. Design examples of various Mth-band filters with different properties are presented, discussed, and compared with the linear-phase case     

Grain refinement behavior of an aluminum alloy by inoculation and dynamic nucleation

Grain refinement offers several benefits in aluminum casting applications. Two methods are normally used to achieve a grain-refined microstructure: inoculation and dynamic nucleation. Inoculation is widely applied in industry, but is not an efficient process. Dynamic nucleation, achieved by application of localized forced convection with rapid cooling, is an alternative process. However, a deeper understanding of dynamic nucleation is required if this process is to be used commercially. This study aims to understand the grain refinement behavior of an aluminum alloy under the influences of inoculation and dynamic nucleation. A rapid quenching method was used to investigate the combined effects of inoculation and dynamic nucleation on the solid fraction, particle density and particle size of the secondary nuclei. In addition, the effects of the particle density of the secondary nuclei on the final cast microstructure were studied. The rapid quenching results show that dynamic nucleation by application of forced convection with localized cooling to the melt yields an increased solid fraction and particle density of secondary nuclei. The solid fraction and particle density are further increased by inoculation. This study also shows that increasing the convection level in an inoculated melt held at a temperature slightly above the liquidus temperature increases the effectiveness of dynamic nucleation, which consequently yields a finer microstructure of the final cast samples. The findings suggest that grain refinement can be effectively achieved by applying forced convection with localized cooling to create a low fraction solid of secondary nuclei in the melt prior to pouring and casting.     

Influence of process parameters on SAC305 lead-free solder powder produced by centrifugal atomization

In the present work, a centrifugal atomizer was constructed in order to study the effects of operating parameters: rotating speed, melt feed rate, shape and size of atomizer, and oxygen content in the atomizer chamber, on the characters of SAC305 powder. It was evidenced from the experimental results that the median size of the atomized powders became smaller with increasing rotating speed, decreasing melt feed rate, and the use of larger atomizer. At same operating conditions, a cup shaped atomizer was able to give approx. 11% finer powder compared to that from a flat-disk shaped one. Median particle size appeared to be smaller with decreasing oxygen content in the chamber. SEM micrographs revealed that SAC305 particles atomized under atmospheric condition were found to form various shapes: ligament, teardrop, flake, and irregular. The shape of powder particles tends to be rounder with decreasing oxygen content in the chamber. Fine particles of SAC305 powder (− 45 μm) containing oxygen less than 100 ppm could be synthesized by purging nitrogen gas into the atomizing chamber. Production yield of the SAC305 powder increased with increasing atomizer's rotating speed, lower melt feed rate, and larger atomizer.     

Characterization of flow behavior of semi-solid slurries containing low solid fractions in high-pressure die casting

Understanding the flow behavior of semi-solid slurries containing low solid fractions is key to the success in applying this process in the die casting industry. With these low initial solid fractions, the flow behavior of semi-solid slurries is quite complicated, making it difficult to model accurately. This present work developed and studied characterization methods for the flow behavior of semi-solid slurries at low solid fractions in high-pressure die casting. A new parameter, the ratio of gate speed to initial solid fraction (V_g/f_s), was proposed to be correlated to the normalized flow interface length, blister area and tensile properties. Results from the flow pattern analysis suggest that the flow behavior can be controlled to achieve laminar flow by varying the initial solid fraction. Blister test results show the trend that slurry die casting conditions with high V_g/f_s values exhibit high blister areas. Die casting conditions with excessively high gate speeds and insufficient solid fractions result in turbulent flow patterns and high levels of blister defect. The results of tensile test and fracture surface analysis are consistent with other analysis results. The samples formed by liquid die casting and slurry die casting with high V_g/f_s values have gas porosity due to turbulent flow pattern during die filling. On the other hand, the samples formed by slurry die casting with too low V_g/f_s values contain shrinkage porosity. This is because of insufficient time for shrinkage feeding due to a combination of a high solid fraction and a low gate speed. This study has demonstrated that die casting with slurries containing low initial solid fractions gives die casters another process parameter to adjust, which can help reduce and control the gas and shrinkage porosities.     

Characterization of Flow Behavior of Semi-Solid Slurries with Low Solid Fractions

Semi-solid slurry casting is a metal-forming process that involves transforming liquid metal into slurry having a low solid fraction and then forming the slurry into solid parts. To successfully apply this slurry-forming process, it is necessary to fully understand the flow behavior of semi-solid slurries. This present work applied the rapid quenching method and the modified gravity fluidity casting to investigate the flow behavior, which involves characterizations of the initial solid fraction, fluidity, and microstructure of semi-solid slurries. Three commercial aluminum alloys were used in this study: 383 (Al-Si11Cu), 356 (Al-Si7MgFe), and 7075 (Al-Zn6MgCu) alloys. The results show that the initial solid fractions can be controlled by varying the rheocasting time. The rapid quenching mold can be used to determine the initial solid fractions. In this method, it is important to apply the correcting procedure to account for growth during quenching and to include all the solid phases. Results from the fluidity study of semi-solid slurries show that the fluidity decreases as the initial solid fraction increases. The decrease is relatively rapid near the low end of the initial solid fraction curves, but is quite slow near the high end of the curves. All the three alloys follow this trend. The results also demonstrate that the slurries that contain high solid fractions of up to 30 pct can still flow well. The microstructure characterization results show that the solid particles in the slurries flow uniformly in the channel. A uniform and fine microstructure with limited phase segregation is observed in the slurry cast samples.     

Fibroblast Growth Factor 23 and Osteoporosis: Evidence from Bench to Bedside

Osteoporosis is a chronic debilitating disease caused by imbalanced bone remodeling processes that impair the structural integrity of bone. Over the last ten years, the association between fibroblast growth factor 23 (FGF23) and osteoporosis has been studied in both pre-clinical and clinical investigations. FGF23 is a bone-derived endocrine factor that regulates mineral homeostasis via the fibroblast growth factor receptors (FGFRs)/αKlotho complex. These receptors are expressed in kidney and the parathyroid gland. Preclinical studies have supported the link between the local actions of FGF23 on the bone remodeling processes. In addition, clinical evidence regarding the effects of FGF23 on bone mass and fragility fractures suggest potential diagnostic and prognostic applications of FGF23 in clinical contexts, particularly in elderly and patients with chronic kidney disease. However, inconsistent findings exist and there are areas of uncertainty requiring exploration. This review comprehensively summarizes and discusses preclinical and clinical reports on the roles of FGF23 on osteoporosis, with an emphasis on the local action, as opposed to the systemic action, of FGF23 on the bone. Current gaps in knowledge and future research directions are also suggested to encourage further rigorous research in this important field.     

Variation of microstructure and mechanical property of slurry die cast Al-Si-Mg-Fe alloy

Semi-solid metal processing technologies have been intensively studied in recent years. Gas Induced Semi-Solid (GISS) is a slurry preparation technique for producing non-dendritic or globular structures for cast alloys. In the present study, GISS technique was used in conjunction with conventional die cast process for casting Al–Si–Mg–Fe alloy. The shape of die cast specimen was designed as a simple flat plate. The variation of microstructures and tensile properties of specimens from different locations of cast plates was studied. The results show that the specimens from bottom location, near the gate section and the middle location of cast plates are stronger and more ductility than those from the top location. The microstructural examination reveals that the specimens from top location of cast plates contain more defects, such as shrinkage pores than those from the other locations. These defects are resulted in lower strength and ductility of the cast product.