Fabrication of suspended carbon microstructures by e-beam writer and pyrolysis

A fabrication process has been developed to create suspended carbon microelectromechanical system (C-MEMS) structures. SU-8, a negative photoresist, was used as the starting material and was converted to the desired carbon microstructures using pyrolysis in an inert atmosphere. Suspended carbon-micro and nano electromechanical system (C-MEMS/NEMS) structures with feature sizes down to 500 nm were fabricated by ultra violet/electron beam (EB) lithography and pyrolysis. The problem of charging of the non-conductive SU-8 surface was solved by partially masking a thin metal layer to prevent the repulsion of negative charged electrons before EB writing. Complex suspended C-MEMS structures, such as bridges and networks have been formed. This fabrication method can accurately and reproducibly produce various suspended C-MEMS structures which have applications in microelectronics and biosensing.     

Microscopic study of failure mechanisms in infiltrated carbon fiber felts

Failure mechanisms in infiltrated carbon fiber felts have been studied by optical light microscopy, transmission electron microscopy and scanning electron microscopy combined with mechanical testing experiments. A model is presented which describes crack generation and propagation at layer-layer and fiber-matrix interfaces as well as within matrix carbon layers with different textures. Intensive cracking occurs within high- and less frequently in medium- and low-textured pyrolytic carbon layers. In particular, fracture does not occur directly at the fiber-matrix interface but within the low-textured matrix layer deposited on the fiber. Crack deflection in interface regions between layers with different textures, crack deflection along boundaries of columnar grains in high -textured layers and at interfaces between polyhedral nanoparticles, and finally crack bridging within high -textured lamellae are cooperative failure mechanisms contributing to the toughness enhancement.     

A reduced reaction model for carbon CVD/CVI processes

Carbon-carbon composites are produced by chemical vapor deposition/chemical vapor infiltration (CVD/CVI) processes. Models of carbon-carbon composite production processes will help reduce production costs. Reliable process models must, however, include details of the gas phase kinetics in order to identify optimal conditions. We have combined detailed gas phase kinetics, surface kinetics, and a pore closure model to predict pore geometry changes with respect to time. To determine the dominant gas phase kinetics, we reduced a large set of reactions to a minimal set using a sensitivity, rate, and dimensional analysis approach. These robust and relatively fast techniques can be used under a variety of conditions, including those within the pores of the composite. The process model shows that the deposition profile depends on the kinetic model chosen. Using the more realistic reaction model, conditions for uniform, or inside-out, densification can be suggested.     

Hollow porous carbon microspheres obtained by the pyrolysis of TiO2/poly(furfuryl alcohol) composite precursors

Disordered carbon materials with high porosity were prepared through the pyrolysis of TiO₂/poly(furfuryl alcohol) composites, obtained by the sol-gel method. The composites were prepared starting from titanium tetra-isopropoxide (TTIP) and furfuryl alcohol (FA) as precursors. Two different synthetic procedures for our composites were carried out, based on the addition of furfuryl alcohol (FA) before or after the TiO₂ nanoparticles formation. Also, different TTIP/FA ratio was tested. The hybrid materials obtained by both synthetic routes were pyrolyzed, under argon flow, at 900 °C producing novel TiO₂/carbon composites. All samples were characterized by XRD, FT-IR, DR-FTIR, Raman spectroscopy and TEM. Results indicated the effective FA polymerization on TiO₂ (anatase) nanoparticles, and polymer conversion to disordered carbon after the pyrolysis, simultaneously with TiO₂ anatase-rutile phase transition. The resulting TiO₂/carbon composites were treated with HF solution aiming the oxide dissolution, yielding an extremely porous carbon material as insoluble fraction. The morphology of these porous carbon materials is strongly dependent on the synthetic route adopted for the composite precursor, varying from carbon foam to highly ordered hollow microspheres.     

Ozonation of Pyrolytic Aqueous Phase: Changes in the Content of Phenolic Compounds and Color

Ozonation on the phenols present in pyrolytic aqueous phases attained from biomass thermochemical conversion was evaluated. During ozonation, the dark color of original samples was found to decrease as a function of ozonation time. The oxidation kinetics of phenols was quantified by a method based on the color changes of samples. The oxidation profiles showed different behaviors and in some cases the phenols presented a positive correlation with the relative R color parameter, except eugenol, syringol, and vanillin which were markedly different. Finally, the color changes observed seem to be associated with the changes in the overall content of phenols and with the change in the molecular weight of the heavy fractions that include lignin oligomers.     

Thermal management of a proton exchange membrane fuel cell stack with pyrolytic graphite sheets and fans combined

This work characterizes the thermal management of a proton exchange membrane fuel cell (PEMFC) stack with combined passive and active cooling. A 10-cell PEMFC stack with an active area of 100 cm² for each cell is constructed. Six thermally conductive 0.1-mm-thick Pyrolytic Graphite Sheets (PGSs) are cut into the shape of flow channels and bound to the six central cathode gas channel plates. These PGSs, which are lightweight and have high thermal conductivity, function as heat spreaders and fins and provide passive cooling in the fuel cell stack, along with two small fans for forced convection. Three other cooling configurations with differently sized fans are also tested for comparisons (without PGSs). Although the maximum power generated by the stack with the configuration combining PGSs and fans was 183 W, not the highest among all configurations, it significantly reduced the volume, weight, and cooling power of the thermal management system. Net power, specific power, volumetric power density, and back work ratio of this novel thermal management method are 179 W, 18.54 W kg⁻¹, 38.9 kW m⁻³, and 2.1%, respectively, which are superior to those of the other three cooling configurations with fans.     

大尺寸各向同性热解炭材料的制备与表征

采用一种新的旋转基体稳态流化床沉积装置制备大尺寸的各向同性热解炭材料。利用金相显微镜、扫描电镜、透射电镜和XRD对各向同性热解炭材料的微观结构进行了表征，并对其力学性能进行了测试。结果表明，改进后的旋转基体稳态流化床沉积工艺能够制备出大尺寸的各向同性热解炭材料。材料的结构均匀，气孔较少，主要由球形颗粒状碳结构组成，构成这种球形颗粒状碳结构的是乱层结构的石墨片层堆积体。各向同性热解炭与传统炭材料相比具有较高的杨氏模量、硬度和强度。     

Application of a thermally conductive pyrolytic graphite sheet to thermal management of a PEM fuel cell

This work experimentally investigates the thermal performance of a pyrolytic graphite sheet (PGS) in a single proton exchange membrane fuel cell (PEMFC). This PGS with high thermal conductivity serves as a heat spreader, reduces the volume and weight of cooling systems, and reduces and homogenizes the temperature in the reaction area of the fuel cells. A transparent PEMFC is constructed with PGS of thickness 0.1 mm cut into the shape of a flow channel and bound with the cathode gas channel plate. Eleven thermocouples are embedded at different positions on the cathode gas channel plate to measure the temperature distribution. The water and water flooding inside the cathode gas channels, with and without PGS, were successfully visualized. The locations of liquid water are correlated with the temperature measurement. PGS reduces the maximum cell temperature and improves cell performance at high cathode flow rates. The temperature distribution is also more uniform in the cell with PGS than in the one without PGS. Results of this study demonstrate the promising application of PGS to the thermal management of a fuel cell system.     

Finite element modeling of orthogonal micromachining of anisotropic pyrolytic carbon via damaged plasticity

Engineered features on pyrolytic carbon (PyC) have been demonstrated as an approach to improve the flow hemodynamics of the cardiovascular implants such as bileaflet mechanical heart valve. PyC also finds application in thermonuclear and missile components due to its unique directional thermal properties. However, very little work has been reported on modeling of machining/micromachining of PyC. Note that PyC is a brittle anisotropic material and its machining characteristics differ from plastically deformable isotropic materials. Consequently, this study is aimed at developing a finite element model to understand the mechanics of material removal in the plane of transverse isotropy (horizontally stacked laminae) of PyC. A damaged plasticity model has been used to capture the effect of material degradation under machining. Uniaxial tension/compression tests have been carried out to calibrate the damaged plasticity model. A cohesive element layer has been used between the chip layer and the bulk material to simulate the delamination/peeling effect. The model predicts cutting force and thrust forces at different set of process parameters. The orthogonal cutting model has been validated against the experimental data for different cutting conditions for cutting and thrust forces. In addition, the chip geometry has also been compared. The prediction error in the model lies between 9% and 27%. Parametric studies have also been performed to understand the effect of the machining parameters on the process response. It is found that use of the positive rake angle decreases the cutting forces up to 75%.