Double-ceramic-layer thermal barrier coatings based on La2(Zr0.7Ce0.3)2O7/La2Ce2O7 deposited by electron beam-physical vapor deposition

Double-ceramic-layer (DCL) thermal barrier coatings (TBCs) of La₂(Zr_0.7Ce_0.3)₂O₇ (LZ7C3) and La₂Ce₂O₇ (LC) were deposited by electron beam-physical vapor deposition (EB-PVD). The composition, interdiffusion, surface and cross-sectional morphologies, cyclic oxidation behavior of DCL coating were studied. Energy dispersive spectroscopy and X-ray diffraction analyses indicate that both LZ7C3 and LC coatings are effectively fabricated by a single LZ7C3 ingot with properly controlling the deposition energy. The chemical compatibility of LC coating and thermally grown oxide (TGO) layer is unstable. LaAlO₃ is formed due to the chemical reaction between LC and Al₂O₃ which is the main composition of TGO layer. Additionally, the thermal cycling behavior of DCL coating is influenced by the interdiffusion of Zr and Ce between LZ7C3 and LC coatings. The failure of DCL coating is a result of the sintering of LZ7C3 coating surface, the chemical incompatibility of LC coating and TGO layer and the abnormal oxidation of bond coat. Since no single material that has been studied so far satisfies all the requirements for high temperature applications, DCL coating is an important development direction of TBCs.     

Nanocomposite cerium oxide polymer matching layers with adjustable acoustic impedance between 4 MRayl and 7 MRayl

A new class of materials for ultrasonic matching layers is presented. The materials consist of nanoscale cerium oxide particles in an epoxy functionalized organic inorganic hybrid polymer matrix. The cerium oxide agglomerates to particles with 20 nm diameters. The content of particles in the polymer matrix could be increased to 75 wt.% which corresponds to 37 vol.%. The most technical important piezoelectrical ceramics have an acoustic impedance of about 30 MRayl, to improve coupling into water or biological tissue with an acoustic impedance of about 1.5 MRayl a matching layer should have an acoustic impedance of about 6.8 MRayl. With a filling degree of 75 wt.% the new composite material reaches an acoustic impedance of 7 MRayl. The materials are synthesized by a hydrolytic condensation combined with polymerization. This way of synthesis allows the use of organic solvents to adjust the viscosity of the sol and the application of different coating techniques. Ultrasound transducers (100 MHz) were built to test the new matching layers and an increase of the voltage signal amplitude of about 100% could be detected.     

Microscopic observation of laser glazed yttria-stabilized zirconia coatings

Thermal barrier coatings (TBCs) are frequently used as insulation system for hot components in gas-turbine, combustors and power plant industries. The corrosive gases which come from combustion of low grade fuels can penetrate into the TBCs and reach the metallic components and bond coat and cause hot corrosion and erosion damage. Glazing the top coat by laser beam is advanced approach to seal TBCs surface. The laser beam has the advantage of forming a dense thin layer composed of micrograins. Plasma-sprayed yttria-stabilized zirconia (YSZ) coating was glazed with Nd-YAG laser at different operating conditions. The surface morphologies, before and after laser treatment, were investigated by scanning electron microscopy. Laser beam assisted the densification of the surface by remelting a thin layer of the exposed surface. The laser glazing converted the rough surface of TBCs into smooth micron-size grains with size of 2-9 μm and narrow grain boundaries. The glazed surfaces showed higher Vickers hardness compared to as-sprayed coatings. The results revealed that the hardness increases as the grain size decreases.     

In situ formation of low friction ceramic coatings on carbon steel by plasma electrolytic oxidation in two types of electrolytes

In situ formation of ceramic coatings on Q235 carbon steel was achieved by plasma electrolytic oxidation (PEO) in carbonate electrolyte and silicate electrolyte, respectively. The surface and cross-section morphology, phase and elemental composition of PEO coatings were examined by means of scanning electron microscopy (SEM), X-ray diffraction (XRD) and energy-dispersive X-ray spectroscopy (EDS). The bond strength of the coating was determined using a direct pull-off test. The hardness as well as tribological properties of the ceramic coating was primarily studied. The results indicated that the coating obtained in carbonate electrolyte was Fe₃O₄, while the coating achieved from silicate electrolyte was proved to be amorphous. Both kinds of coatings showed coarse and porous surface. The Fe₃O₄ coatings obtained in carbonate electrolyte showed a high bonding strength to the substrate up to 20 ± 2 MPa and the value was 15 ± 2 MPa for the amorphous coatings obtained in carbonate electrolyte. The micro hardness of the amorphous coating and the Fe₃O₄ coating was 1001 Hv and 1413 Hv, respectively, which was more than two and three times as that of the Q235 alloy substrate (415 Hv). The friction coefficient exhibited by amorphous coating and Fe₃O₄ coating was 0.13 and 0.11, respectively, both lower than the uncoated Q235 substrate which ranged from 0.17 to 0.35.     

Preparation and characterization of p-type transparent conducting tin-gallium oxide films

p-Type transparent conducting tin-gallium oxide (TGO) films were successfully fabricated on quartz substrates by DC magnetron sputtering of GaSn alloy films followed by thermal oxidation. XRD characterization indicated that the TGO films maintain rutile structure of the tin oxide (SnO₂). UV-vis transmittance spectra indicated that the films have a transmittance higher than 85% in the visible region, with an optical band-gap around 3.8 eV. Hall effect measurement showed that electrical properties of the TGO films were dependent on oxidation temperature. Oxidation at too high or low temperature was unfavorable for p-type conduction. It is found that the optimum oxidation temperature for highest hole concentration (8.84 × 10¹⁸ cm⁻³) was in the range of 600-650 °C.     

Acoustic impedance microscopy for biological tissue characterization

A new method for two-dimensional acoustic impedance imaging for biological tissue characterization with micro-scale resolution was proposed. A biological tissue was placed on a plastic substrate with a thickness of 0.5 mm. A focused acoustic pulse with a wide frequency band was irradiated from the “rear side” of the substrate. In order to generate the acoustic wave, an electric pulse with two nanoseconds in width was applied to a PVDF-TrFE type transducer. The component of echo intensity at an appropriate frequency was extracted from the signal received at the same transducer, by performing a time–frequency domain analysis. The spectrum intensity was interpreted into local acoustic impedance of the target tissue. The acoustic impedance of the substrate was carefully assessed prior to the measurement, since it strongly affects the echo intensity. In addition, a calibration was performed using a reference material of which acoustic impedance was known. The reference material was attached on the same substrate at different position in the field of view. An acoustic impedance microscopy with 200 × 200 pixels, its typical field of view being 2 × 2 mm, was obtained by scanning the transducer. The development of parallel fiber in cerebella cultures was clearly observed as the contrast in acoustic impedance, without staining the specimen. The technique is believed to be a powerful tool for biological tissue characterization, as no staining nor slicing is required.     

Bonding and impedance matching of acoustic transducers using silver epoxy

Silver epoxy was selected to bond transducer plates on glass substrates. The properties and thickness of the bonding medium affect the electrical input impedance of the transducer. Thus, the thickness of the silver epoxy bonding layer was used as a design parameter to optimize the structure for the transducer input impedance to match the 50 Ω output impedance of most radio frequency (RF) generators. Simulation and experimental results show that nearly perfect matching is achieved without using any matching circuit. At the matching condition, the transducer operates at a frequency band a little bit below the half-wavelength resonant frequency of the piezoelectric plate. In experiments, lead titanate (PT) piezoelectric plates were employed. Both full-size, 11.5 mm × 2 mm × 0.4 mm, and half-size, 5.75 mm × 2 mm × 0.4 mm, can be well matched using optimal silver epoxy thickness. The transducer assemblies demonstrate high efficiency. The conversion loss from electrical power to acoustic power in soda-lime glass is 4.3 dB. This loss is low considering the fact that the transducers operate at off-resonance by 12%. With proper choice of silver epoxy thickness, the transducer can be matched at the fundamental, the 3rd and 5th harmonic frequencies. This leads to the possible realization of triple-band transducers. Reliability was assessed with thermal cycling test according to Telcordia GR-468-Core recommendation. Of the 30 transducer assemblies tested, none broke until 2900 cycles and 27 have sustained beyond 4050 cycles.     

Finite element simulation of stress distribution and development in 8YSZ and double-ceramic-layer La2Zr2O7/8YSZ thermal barrier coatings during thermal shock

In this paper, the thermal stress of the double-ceramic-layer (DCL) La₂Zr₂O₇/8YSZ thermal barrier coatings (TBCs) fabricated by atmospheric plasma spraying (APS) during thermal shock has been calculated. The residual stress of the coating after being sprayed has been regarded as the initial condition of the first thermal cycle. The characteristic of the stress development during the thermal cycle has been discussed, and the influence of the defects on the failure mode during the thermal cycle has also been discussed systematically. Finite element simulation results show that there exist higher radial thermal shock stresses on the ceramic layer surface of these two coatings. There also exist higher thermal stress gradient at the interface between the ceramic layer and the metallic layer. Higher thermal stress in 8YSZ/NiCoCrAlY coating lead to the decrease of thermal shock property as compared to that of LZ/8YSZ/NiCoCrAlY coating. The addition of LZ ceramic layer can increase the insulation temperature, impede the oxygen transferring to the bond coating and can also reduce the thermal stress. Considering from the aspects of thermal insulation ability and the thermal shock resistance ability, DCL type LZ/8YSZ TBCs is a more promising coating material compared with the single-ceramic-layer (SCL) type 8YSZ TBCs for the application.     

Self-lubricative coating grown by micro-plasma oxidation on aluminum alloys in the solution of aluminate-graphite

Aluminum trioxide ceramic coatings with high hardness were grown on surfaces of 2024 Aluminum alloys by micro-plasma oxidation in an aluminate electrolytic solution, which highly improve wear-resisting properties of 2024 Aluminum alloys. However, ceramic coating surfaces are porous and very coarse, which is disadvantageous to practical applications. In this paper, in order to increase the density of the pores and decrease the friction coefficient of the ceramic coatings, different concentrations (2-8 g/l) of graphite were added into the aluminate electrolytic solution. The thickness and hardness of the produced ceramic coatings were measured by HVS-100 micro-hardness tester and thickness tester. The friction coefficient of the coatings was studied by a frictionometer. The phase composition and surface morphology of the MPO films were evaluated through X-ray diffraction (XRD) and scanning electron microscope (SEM). The results show that the thickness of the ceramic coating is about 22 ± 1 μm, surfaces of the ceramic coatings are very uniform and that the coatings consist of mainly aluminum trioxides and a certain amount of graphite, which indicates graphite have entered the ceramic films during the micro-plasma oxidation process. Wear properties results show that the friction coefficient of the ceramic coatings decreased when graphite entered the ceramic films. When the concentration of graphite is 4 g/l, the wear properties of the coatings is the most excellent and the friction coefficient decreases to the lowest, that is 0.09.     

Electroless copper plating on 3-mercaptopropyltriethoxysilane modified PET fabric challenged by ultrasonic washing

Electroless deposition of Cu on poly(ethylene terephthalate) (PET) fabric modified with 3-mercaptopropyltriethoxysilane was investigated. Morphology, composition, structure, thermal decomposing behavior of copper coating PET fabric after ultrasonic washing in water for 1 h were characterized by scanning electron microscopy (SEM), energy dispersive X-ray (EDX) analysis, X-ray photoelectron spectroscopy (XPS), Raman spectrometer, X-ray diffraction (XRD), and thermogravimetric analysis (TG), respectively. Copper plating on modified fabric has good adherence stability and high electric conductivity before and after ultrasonic washing, while copper coating fabric without modification is easily destroyed during the washing process, which leads to the textile changing from conductor to dielectric. As the copper weight on the treated fabric is 28 g/m², the shielding effectiveness (SE) is more than 54 dB at frequency ranging from 0.01 MHz to 18 GHz.     

Modelling and simulation of high-frequency (100 MHz) ultrasonic linear arrays based on single crystal LiNbO3

Background

High-frequency ultrasonic transducer arrays are essential for high resolution imaging in clinical analysis and Non-Destructive Evaluation (NDE). However, the fabrication of conventional backing-layer structure, which requires a pitch (distance between the centers of two adjacent elements) of half wavelength in medium, is really a great challenge.

Objective and method

Here we present an alternative buffer-layer structure with a silicon lens for volumetric imaging. The requirement for the size of the pitch is less critical for this structure, making it possible to fabricate high-frequency (100 MHz) ultrasonic linear array transducers. Using silicon substrate also makes it possible to integrate the arrays with IC (Integrated Circuit). To compare with the conventional backing-layer structure, a finite element tool, COMSOL, is employed to investigate the performances of acoustic beam focusing, the influence of pitch size for the buffer-layer configuration, and to calculate the electrical properties of the arrays, including crosstalk effect and electrical impedance.

Results

For a 100 MHz 10-element array of buffer-layer structure, the ultrasound beam in azimuth plane in water could be electronically focused to obtain a spatial resolution (a half-amplitude width) of 86 μm at the focal depth. When decreasing from half wavelength in silicon (42 μm) to half wavelength in water (7.5 μm), the pitch sizes weakly affect the focal resolution. The lateral spatial resolution is increased by 4.65% when the pitch size decreases from 42 μm to 7.5 μm. The crosstalk between adjacent elements at the central frequency is, respectively, −95 dB, −39.4 dB, and −60.5 dB for the 10-element buffer, 49-element buffer and 49-element backing arrays. Additionally, the electrical impedance magnitudes for each structure are, respectively, 4 kΩ, 26.4 kΩ, and 24.2 kΩ, which is consistent with calculation results using Krimholtz, Leedom, and Matthaei (KLM) model.

Conclusion

These results show that the buffer-layer configuration is a promising alternative for the fabrication of high-frequency ultrasonic linear arrays dedicated to volumetric imaging.     

Ultrasonic assembly of anisotropic short fibre reinforced composites

We report the successful manufacture of short fibre reinforced polymer composites via the process of ultrasonic assembly. An ultrasonic device is developed allowing the manufacture of thin layers of anisotropic composite material. Strands of unidirectional reinforcement are, in response to the acoustic radiation force, shown to form inside various matrix media. The technique proves suitable for both photo-initiator and temperature controlled polymerisation mechanisms. A series of glass fibre reinforced composite samples constructed in this way are subjected to tensile loading and the stress–strain response is characterised. Structural anisotropy is clearly demonstrated, together with a 43% difference in failure stress between principal directions. The average stiffnesses of samples strained along the direction of fibre reinforcement and transversely across it were 17.66 ± 0.63 MPa and 16.36 ± 0.48 MPa, respectively.     

Modelling of a novel high-impedance matching layer for high frequency (>30 MHz) ultrasonic transducers

This work describes a new approach to impedance matching for ultrasonic transducers. A single matching layer with high acoustic impedance of 16 MRayls is demonstrated to show a bandwidth of around 70%, compared with conventional single matching layer designs of around 50%. Although as a consequence of this improvement in bandwidth, there is a loss in sensitivity, this is found to be similar to an equivalent double matching layer design. Designs are calculated by using the KLM model and are then verified by FEA simulation, with very good agreement Considering the fabrication difficulties encountered in creating a high-frequency double matched design due to the requirement for materials with specific acoustic impedances, the need to accurately control the thickness of layers, and the relatively narrow bandwidths available for conventional single matched designs, the new approach shows advantages in that alternative (and perhaps more practical) materials become available, and offers a bandwidth close to that of a double layer design with the simplicity of a single layer design. The disadvantage is a trade-off in sensitivity. A typical example of a piezoceramic transducer matched to water can give a 70% fractional bandwidth (comparable to an ideal double matched design of 72%) with a 3 dB penalty in insertion loss.     

Influence of gas law on ultrasonic behaviour of porous media under pressure

This paper deals with the influence of gas law on ultrasonic behaviour of porous media when the saturating fluid is high pressured. Previous works have demonstrated that ultrasonic transmission through a porous sample with variations of the static pressure (up to 18 bars) of the saturating fluid allows the characterization of high damping materials. In these studies, the perfect gas law was used to link static pressure and density, which is disputable for high pressures. This paper compares the effects of real and perfect gas laws on modeled transmission coefficient for porous foams at these pressures. Direct simulations and a mechanical parameters estimation from minimization show that results are very similar in both cases. The real gas law is thus not necessary to describe the acoustic behaviour of porous media at low ultrasonic frequencies (100 kHz) up to 20 bars.     

Measurements of coating density using ultrasonic reflection coefficient phase spectrum

A nondestructive method to determine the density of coating has been proposed in this paper based on the ultrasonic reflection coefficient phase spectrum (URCPS). A model was set up first to represent the ultrasonic waves reflected from a coating system at normal incident, and the relation between the extremum of URCPS and the coating density was established to provide the principle of determining the density. The ultrasonic method was validated on a series of ZrO2-7 wt.%Y2O3 (YSZ) coatings with various density. The specimens were prepared by electric beam physical vapor deposit (EB-PVD). After deposition, the specimens were irradiated using high-intensity pulsed ion beam (HIPIB) at different ion current density of 100 and 200 A/cm2 to change coating density. The coating densities of as-deposited and post irradiation by HIPIB were derived to be 4940-5030, 5200-5320 and 5390-5470 kg/m3, respectively. The relative error between the coating density measured by the ultrasonic method and Archimedean principle ranging from 2.53% to 6.11%, indicates that the proposed ultrasonic quantification method provides a reliable nondestructive way to determine coating density.     

Microstructure and anti-oxidation property of CrSi2-SiC coating for carbon/carbon composites

To protect carbon/carbon (C/C) composites from oxidation, a new type of oxidation protective coating has been produced by a two-step pack cementation technique. XRD and SEM analysis show, the coating obtained by the first step pack cementation was a porous β-SiC structure, and a new phase of CrSi₂ was generated in the porous SiC coating after heat-treatment according to the second step pack cementation process. Oxidation test shows that, the weight loss of the SiC coated C/C is up to 11.26% after 5 h oxidation in air at 1773 K, and the weight loss of the CrSi₂-SiC coated C/C composites is only 4.15% after oxidation in air at 1773 K for 34 h. The oxidation of C/C composites was primarily due to the reaction of C/C matrix and oxygen diffusing through the penetrable cracks in the coating.     

Fixation of bioactive calcium alkali phosphate on Ti6Al4V implant material with femtosecond laser pulses

Bone implants made of metal, often titanium or the titanium alloy Ti6Al4V, need to be surface treated to become bioactive. This enables the formation of a firm and durable connection of the prosthesis with the living bone. We present a new method to uniformly cover Ti6Al4V with a thin layer of ceramics that imitates bone material. These calcium alkali phosphates, called GB14 and Ca10, are applied to the metal by dip coating of metal plates into an aqueous slurry containing the fine ceramic powder. The dried samples are illuminated with the 790 nm radiation of a pulsed femtosecond laser. If the laser fluence is set to a value just below the ablation threshold of the ceramic (ca. 0.4 J/cm²) the 30 fs laser pulses penetrate the partly transparent ceramic layer of 20-40 μm thickness. The remaining laser fluence at the ceramic-metal interface is still high enough to generate a thin metal melt layer leading to the ceramic fixation on the metal. The laser processing step is only possible because Ti6Al4V has a lower ablation threshold (between 0.1 and 0.15 J/cm²) than the ceramic material. After laser treatment in a fluence range between 0.1 and 0.4 J/cm², only the particles in contact with the metal withstand a post-laser treatment (ultrasonic cleaning). The non-irradiated rest of the layer is washed off. In this work, we present results of a successful ceramic fixation extending over larger areas. This is fundamental for future applications of arbitrarily shaped implants.     

Experimental measurements of acoustical properties of snow and inverse characterization of its geometrical parameters

Snow is a sound absorbing porous sintered material composed of solid matrix of ice skeleton with air (+water vapour) saturated pores. Investigation of snow acoustic properties is useful to understand the interaction between snow structure and sound waves, which can be further used to devise non-destructive way for exploring physical (non-acoustic) properties of snow. The present paper discusses the experimental measurements of various acoustical properties of snow such as acoustic absorption coefficient, surface impedance and transmission losses across different snow samples, followed by inverse characterization of different geometrical parameters of snow. The snow samples were extracted from a natural snowpack and transported to a nearby controlled environmental facility at Patsio, located in the Great Himalayan range of India. An impedance tube system (ITS), working in the frequency range 63–6300 Hz, was used for acoustic measurements of these snow samples. The acoustic behaviour of snow was observed strongly dependent upon the incident acoustic frequency; for frequencies smaller than 1 kHz, the average acoustic absorption coefficient was found below than 0.4, however, for the frequencies more than 1 kHz it was found to be 0.85. The average acoustic transmission loss was observed from 1.45 dB cm⁻¹ to 3.77 dB cm⁻¹ for the entire frequency range. The real and imaginary components of normalized surface impedance of snow samples varied from 0.02 to 7.77 and −6.05 to 5.69, respectively. Further, the measured acoustic properties of snow were used for inverse characterization of non-acoustic geometrical parameters such as porosity, flow resistivity, tortuosity, viscous and thermal characteristic lengths using the equivalent fluid model proposed by Johnson, Champoux and Allard (JCA). Acoustically derived porosity and flow resistivity were also compared with experimentally measured values and good agreement was observed between them.     

Ultrasonic properties of water/sorbitol solutions

Ultrasonic longitudinal velocity and attenuation were measured for aqueous solutions of sorbitol at approximately 5 MHz. For pure sorbitol, the ultrasonic velocity reached 3200 m s⁻¹, consequently leading to a high acoustical impedance (around 5 × 10⁶ Rayleigh) and good matching between the ultrasonic transducers and material samples.     

Low frequency in situ metrology of absorption and dispersion of sound absorbing porous materials based on high power ultrasonic non-linearly demodulated waves

The present work is related to acoustic in situ free-field measurements of sound absorption in porous materials, such as cellular plastic foams, glass-wool or recycled felt materials. The emphasis is given towards fine metrology of absorption in view of potential industrial applications. A powerful ultrasonic array working at 40 kHz is used. It enables to measure absorption acoustical data down to 100 Hz due to the exploitation of the non-linear ultrasonic demodulation phenomenon in air. Fine measurements of acoustic absorption are compared to numerical predictions based on the “equivalent-fluid” model (when the squeleton frame is motionless), and to some measurements performed on a Brüel and Kjaer impedance tube. Dispersion curves are also measured and compared to the numerical predictions for some automotive felt materials which are compressed at various ratios. Data obtained with a dedicated portable instrument are also discussed for the same type of materials and configurations.