Effect of microarc oxidation coating on fatigue performance of Ti-Al-Zr alloy

Ceramic coatings of different thickness were fabricated on Ti6Al2Zr1Mo1V alloy by microarc oxidation (MAO), and the effect of the coating on fatigue life was evaluated by 810 Material Test System. The microstructure, phase and chemical composition of the coatings were determined by SEM, XRD and EDS techniques. The coating mainly consists of rutile and a small amount of anatase TiO₂. With oxidation time ranging from 10 to 30 min, the coating thickness increases from 13 to 25 μm, while the interface between coating and substrate becomes more zigzag, characterized by increasing overgrowth regions of coating into substrate. Under the same cyclic stress of 750 MPa, the fatigue life decreases from 2.08 × 10⁶ cycles for uncoated specimen to about 3 × 10⁴ cycles for microarc oxidized specimen. Under the cyclic stress, the thicker the coating, the more cracks initiate in the overgrowth regions of coating into substrate near the interface, which are considered as the notch sites of stress concentration to induce the crack initiation, also is the key factor to cause the facture.     

Nanocrystalline nickel films with lotus leaf texture for superhydrophobic and low friction surfaces

Nanostructured Ni films with high hardness, high hydrophobicity and low coefficient of friction (COF) were fabricated. The surface texture of lotus leaf was replicated using a cellulose acetate film, on which a nanocrystalline (NC) Ni coating with a grain size of 30 ± 4 nm was electrodeposited to obtain a self-sustaining film with a hardness of 4.42 GPa. The surface texture of the NC Ni obtained in this way featured a high density (4 × 10³ mm⁻²) of conical protuberances with an average height of 10.0 ± 2.0 μm and a tip radius of 2.5 ± 0.5 μm. This structure increased the water repellency and reduced the COF, compared to smooth NC Ni surfaces. The application of a short-duration (120 s) electrodeposition process that deposited “Ni crowns” with a larger radius of 6.0 ± 0.5 μm on the protuberances, followed by a perfluoropolyether (PFPE) solution treatment succeeded in producing a surface texture consisting of nanotextured protuberances that resulted in a very high water contact angle of 156°, comparable to that of the superhydrophobic lotus leaf. Additionally, the microscale protuberances eliminated the initial high COF peaks observed when smooth NC Ni films were tested, and the PFPE treatment resulted in a 60% reduction in the steady-state COFs.     

High frequency ultrasonic detection of C-crack defects in silicon nitride bearing balls

A non-destructive testing method for silicon nitride bearing balls based on ultrasonic resonance spectroscopy is proposed here. Through the theoretical study of their elastic vibrations, it is possible to characterize the balls using a vibration mode that is similar to surface wave propagation. The study of the influence of C-crack defects on the resonances of Rayleigh modes is presented here. These C-cracks are typically formed by impacts between balls during finishing or handling. They are frequently found on the surface of silicon nitride bearing balls and these C-cracks decrease the rolling contact fatigue life considerably. This kind of defect is difficult to detect because the C-shaped surface crack is very small and narrow (500 μm × 5 μm), and its depth does not exceed 50 μm. The proposed methodology can both excite spheroidal vibrations in the ceramic balls and detect such vibrations over a large frequency range. In particular, high frequency vibrations are considered because these are similar to the surface waves propagating in the cortical zone of the ceramic balls and consequently they can be used to detect C-crack defects.     

The effect of nanostructured surface layer on the fatigue behaviors of a carbon steel

A nanostructured surface layer was formed on a carbon steel by means of surface mechanical attrition treatment (SMAT). The microstructure of the surface layer of the SMATed sample was characterized by using scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Microhardness and residual stress distribution along the depth from the SMATed surface layer were measured at the same time. Fatigue behaviors of the carbon steel subjected to the SMAT process were investigated. A nanostructured layer with average grains size of ∼12.7 nm was formed, of which microhardness is more than twice as high as that in matrix and residual compressive stress can reach about −400 MPa with maximum depth of ∼600 μm. The fatigue strength of as-received sample is 267 MPa and that of SMATed sample is 302 MPa based on fatigue life 5 × 10⁶ cycles. The SMAT process has improved the fatigue strength by as much as 13.1% for the carbon steel. It is shown that the SMAT is an effective method to render the material with the features, such as a nanostructured and work-hardened surface layer as well as compressive residual stresses, which can pronouncedly improve the fatigue strength of the carbon steel.     

Investigation of cross-polarized heterodyne technique for measuring refractive index and thickness of glass panels

A new mathematical model of cross-polarized heterodyning is proposed for measuring glass panels. An optical system is presented for obtaining relative thickness variation and difference distribution of refractive indices simultaneously, and the dual-balanced coherent demodulation technique is used. The experiment results show that the transmittance of light beam can be less than 0.5% when the vibration amplitude of the glass panels is equal to 5 mm. It takes about 200 s to scan the whole glass sample with size of 1430 × 1360 mm². The resolution of the thickness variation is 0.3 μm, and the lateral sampling resolution is 1 mm.     

Enhanced transmission through nano-aperture on a tapered metallic substrate

The optical transmission and distribution through a subwavelength slit on a tapered metallic substrate was investigated. By using a 45° tapered structure rather than a traditional metallic plate, a 6-fold transmission enhancement could be achieved. This is due to the asymmetrical excitation of surface waves and the matching of propagation constants between the surface waves and slit waveguide. In addition, by patterning surface corrugations in the exit plane, the beam could be focused. By tuning the period of the surface corrugations, we were able to adjust the focal length. For an input wavelength of 0.5 μm, the focal point could be kept within 0.6 μm with a focal length extending from 0.5 μm to 2.5 μm and a grating period ranging from 0.5 μm to 0.6 μm.     

Structural and electrical properties of AlN films deposited using reactive RF magnetron sputtering for solar concentrator application

AlN is an interesting material with some excellent properties like high hardness (>11 GPa), high temperature stability (>2400 °C), good electrical resistivity (>10¹⁰ Ω cm), and good thermal conductivity (>100 W/m K). These properties make it useful in the field of photo voltaic systems. Cooling of solar cells in solar concentrator application is of major concern because high temperature reduces their efficiency. In the present work we deposited AlN coating, with and without an Al interlayer, on various substrates like Si, quartz, and copper using RF magnetron sputtering. Deposition conditions such as Al interlayer (deposition time = 5-20 min), Ar:N₂ ratio (N₂% = 0-75%) and substrate bias (0 and −50 V) were changed in order to study their effect on coating properties. Coating surface roughness increased from 0.05 to 0.15 μm with increase in Al interlayer thickness. The coating thickness decreased from 4.4 to 3.1 μm with increase in N₂ gas % and films grew in (0 0 2) orientation. Films deposited on copper using Al interlayer showed good electrical resistance of ∼10¹³ Ω. Films deposited on copper without Al interlayer showed presence of voids or micro cracks and poor electrical properties. AlN films deposited at −50 V bias show cracking and delamination.     

Influence of surface topography and pore architecture of alkali-treated titanium on in vitro apatite deposition

Alkali-treated titanium surfaces have earlier shown to induce bone-like apatite deposition. In the present study, the effect of surface topography of two-dimensional and pore architecture of three-dimensional alkali-treated titanium substrates on the in vitro bioactivity was investigated. Titanium plates with a surface roughness of R_a = 0.13 μm, 0.56 μm, 0.83 μm, and 3.63 μm were prepared by Al₂O₃ grit-blasting. Simple tetragonal and face-centered Ti6Al4V scaffolds with spatial gaps of 450-1100 μm and 200-700 μm, respectively, were fabricated by a three-dimensional fiber deposition (3DFD) technique. After alkali treatment, the titanium plates with a surface roughness of R_a = 0.56 μm were completely covered with hydroxyapatite globules after 7 days in simulated body fluid (SBF), while the coverage of the samples with other surface roughness values remained incomplete. Similarly, face-centered Ti₆Al₄ scaffolds with spatial gaps of 200-700 μm exhibited a full surface coverage after 21 days in SBF, while simple tetragonal scaffolds with spatial gaps of 450-1100 μm were only covered for 45-65%. This indicates the importance of surface topography and pore architecture for in vitro bioactivity.     

Surface characterization of Pd/Ag23 wt% membranes after different thermal treatments

Hydrogen permeation measurements of 1.5-10 μm thick Pd/Ag23 wt% membranes before and after thermal treatments at 300 °C in air (both sides) or in the temperature range 300-450 °C in N₂ (feed side) and Ar (permeate side) were performed. Accompanying changes in surface topography and chemical composition were subsequently investigated by atomic force microscopy (AFM), X-ray photoelectron spectroscopy (XPS) and Auger electron spectroscopy (AES) depth profiling. For a 2 μm thick membrane, the surface roughness increased for all annealing temperatures applied, while a temperature of 450 °C was required for an increase in roughness of both membrane surfaces to occur for the 5 μm membrane. The thickest membrane, of 10 μm, showed changed surface roughness on one side of the membrane only and a slight decrease in hydrogen permeance after all heat treatments in N₂/Ar. X-ray photoelectron spectroscopy investigations performed after treatment and subsequent permeation measurements revealed segregation of silver to the membrane surfaces for all annealing temperatures applied. In comparison, heat treatment at 300 °C in air resulted in significantly increased hydrogen permeance accompanied by increasing surface roughness. Upon exposure to oxygen, Pd segregates to the surface to form a 2-3 nm thick oxide layer (PdO), with more complex segregation behavior after subsequent reduction and permeance measurements in pure hydrogen. The available permeance data for the Pd/Ag23 wt% membranes after heat treatment in air at 300 °C is found to depend linearly on the inverse membrane thickness, implying bulk limited hydrogen permeation for thicknesses down to 1.5-2.0 μm.     

Vacuum-deposited wave-guiding layers on STW resonators based on LiTaO3 substrate as love wave sensors for chemical and biochemical sensing in liquids

A promising approach to apply the Love wave concept to commercially available low-loss surface acoustic wave (SAW) devices of the type Murata SAF 380 is presented. Thin wave-guiding layers of variable thickness are coated on the piezoelectric substrate of the devices. Two different layer materials were used: sputtered SiO₂ and a new polymer in this field, parylene C (poly-[2-chloro-p-xylylene]). Insertion loss, resonance frequency, frequency changes during protein precipitation and noise of the devices are discussed as a function of the thickness of the wave-guiding layer. It is demonstrated that the application of an optimized wave-guiding layer increases the sensitivity. When using SiO₂ as wave-guiding layer, an optimum layer thickness of 4 μm leads to a detection limit of 1.7 pg/mm². Therefore, the detection limit is improved by factor 7.7 as compared to uncoated SAW devices. Parylene-coated devices reach a detection limit of 2.9 pg/mm² at an optimum layer thickness of 0.5 μm. This corresponds to an improvement by factor 4.3. As the SAW devices used in this study are commercially available at low costs, applying appropriate wave-guiding layers permits an application as chemical or biochemical sensors with excellent sensitivities. Moreover, parylene-coated devices combine the sensitivity increase by excitation of Love waves with an excellent protective effect against corrosive attacks by the surrounding medium. Therefore, these sensors are most suitable for biosensing in conducting buffer solutions.     

Novel ultrasmall Si-nanowire-based arrayed-waveguide grating interleaver with spirals

A novel layout is presented to achieve an ultrasmall arrayed-waveguide grating (AWG) interleaver based on Si-nanowire waveguides. Spiral waveguides are inserted in the middle of arrayed-waveguide to obtain a large lightpath (required for the ultra-high diffraction order) in a small occupied area. A designed ultrasmall AWG interleaver with a free spectral range of 0.8 nm has a total size of only about 73 μm × 372 μm (0.027 mm²).     

Surface damage morphology investigations of silicon under millisecond laser irradiation

The surface damage morphologies of single crystal silicon induced by 1064 nm millisecond Nd:YAG laser are investigated. After irradiation, the damage morphologies of silicon are inspected by optical microscope (OM) and atomic force microscope (AFM). The plasma emission spectra of the damaged region are detected by the spectrometer. It is shown that surface oxidation and nitridation have occurred during the interaction of millisecond laser with silicon. In addition, the damage morphologies induced by 2 ms and 10 ns pulse width laser are compared. The damage morphology obtained by 2 ms laser is an evident crater. Three types of damage morphologies are formed at different laser energy densities. The circular concentric ripples are found surrounding the rim of the crater. The spacing of the ripples is 15 ± 5 μm. Two types of cracks are observed: linear crack and circular crack. The linear crack is observed in the center of the damaged region which propagates to the periphery of the damaged region. The circular crack is located at the rim of the crater. The damage morphology induced by 10 ns laser is surface layer damage. The periodic linear waves are generated due to the interference between the incident beam and the scattered beam. The spacing of the ripples is 1.54 μm which is close to the incident laser wavelength 1.064 μm. The linear crack is located at the center of the damaged region. Furthermore, for the same laser energy density, the dimension of the damaged region and the crater depth induced by 2 ms laser are greater than that of 10 ns laser. It indicates that the damage mechanism under millisecond pulse laser irradiation is strongly different from the case of nanosecond pulse laser.     

Electron beam induced green luminescence and degradation study of CaS:Ce nanocrystalline phosphors for FED applications

Green luminescence and degradation of Ce³⁺ doped CaS nanocrystalline phosphors were studied with a 2 keV, 10 μA electron beam in an O₂ environment. The nanophosphors were synthesized by the co-precipitation method. The samples were characterized using X-ray diffraction, Transmission electron microscopy, Scanning electron microscopy/electron dispersive X-ray spectroscopy and Photoluminescence (PL) spectroscopy. Cubic CaS with an average particle size of 42 ± 2 nm was obtained. PL emission was observed at 507 nm and a shoulder at 560 nm with an excitation wavelength of 460 nm. Auger electron spectroscopy and Cathodoluminescence (CL) were used to monitor the changes in the surface composition of the CaS:Ce³⁺ nanocrystalline phosphors during electron bombardment in an O₂ environment. The effect of different oxygen pressures ranging from 1 × 10⁻⁸ to 1 × 10⁻⁶ Torr on the CL intensity was also investigated. A CaSO₄ layer was observed on the surface after the electron beam degradation. The CL intensity was found to decrease up to 30% of its original intensity at 1 × 10⁻⁶ Torr oxygen pressure after an electron dose of 50 C/cm². The formation of oxygen defects during electron bombardment may also be responsible for the decrease in CL intensity.     

Nanolayered multilayer coatings of CrN/CrAlN prepared by reactive DC magnetron sputtering

Single-phase CrN and CrAlN coatings were deposited on silicon and mild steel substrates using a reactive DC magnetron sputtering system. The structural characterization of the coatings was done using X-ray diffraction (XRD). The XRD data showed that both the CrN and CrAlN coatings exhibited B1 NaCl structure with a prominent reflection along (2 0 0) plane. The bonding structure of the coatings was characterized by X-ray photoelectron spectroscopy and the surface morphology of the coatings was studied using atomic force microscopy. Subsequently, nanolayered CrN/CrAlN multilayer coatings with a total thickness of approximately 1 μm were deposited on silicon substrates at different modulation wavelengths (Λ). The XRD data showed that all the multilayer coatings were textured along {2 0 0}. The CrN/CrAlN multilayer coatings exhibited a maximum nanoindentation hardness of 3125 kg/mm² at a modulation wavelength of 72 Å, whereas single layer CrN and CrAlN deposited under similar conditions exhibited hardness values of 2375 and 2800 kg/mm², respectively. Structural changes as a result of heating of the multilayer coatings in air (400-800 °C) were characterized using XRD and micro-Raman spectroscopy. The XRD data showed that the multilayer coatings were stable up to a temperature of 650 °C and peaks pertaining to Cr₂O₃ started appearing at 700 °C. These results were confirmed by micro-Raman spectroscopy. Nanoindentation measurements performed on the heat-treated coatings revealed that the multilayer coatings retained hardness as high as 2250 kg/mm² after annealing up to a temperature of 600 °C.     

Property improvement of pulsed laser deposited boron carbide films by pulse shortening

Growth characteristics and surface morphology of boron carbide films fabricated by ablating a B₄C target in high vacuum with a traditional KrF excimer laser and a high brightness hybrid dye/excimer laser system emitting at the same wavelength while delivering 700 fs pulses are compared. The ultrashort pulse processing is highly effective. Energy densities between 0.25 and 2 J cm⁻² result in apparent growth rates ranging from 0.017 to 0.085 nm/pulse. Ablation with nanosecond pulses of one order of magnitude higher energy densities yields smaller growth rates, the figures increase from 0.002 to 0.016 nm/pulse within the 2-14.3 J cm⁻² fluence window. 2D thickness maps derived from variable angle spectroscopic ellipsometry reveal that, when ablating with sub-ps pulses, the spot size rather than the energy density determines both the deposition rate and the angular distribution of film material. Pulse shortening leads to significant improvement in surface morphology, as well. While droplets with number densities ranging from 1 × 10⁴ to 7 × 10⁴ mm⁻² deteriorate the surface of the films deposited by the KrF excimer laser, sub-ps pulses produce practically droplet-free films. The absence of droplets has also a beneficial effect on the stoichiometry and homogeneity of the films fabricated by ultrashort pulses.     

Femtosecond laser-induced mesoporous structures on silicon surface

By femtosecond laser line-by-line scanning irradiating, large-scale microstructures were formed on the surface of silicon with dimensions of 1 × 1 mm². Scanning electron microscope investigations exhibited that homogeneous surface microstructures, such as directional-arranged bacilliform mesoporous structures, have been successfully prepared. The dependence of the surface morphology on laser pulse energy was analyzed, and the results indicated that the bacilliform mesoporous structures only can be textured within a certain energy range. The optical reflective spectrum measurement revealed that the presence of bacilliform mesoporous structures can significantly enhance the absorptivity of silicon at visible light range. This work would help to control the formation of surface micro/nanostructures on silicon and other materials, which has potential applications in solar energy, photoelectronics, biology and material science.     

Design and analysis of novel octagonal photonic crystal fiber with F-doped elliptical hole core

A design of octagonal photonic crystal fiber (OPCF) with F-doped elliptical hole core is proposed. The proposed design is simulated through an full vector finite element method (FVFEM) and anisotropic perfectly matched layers (APML). Numerical results show that the designed OPCF has the ultra-flattened dispersion of 0 ± 0.4 ps/(nm km) from 1.34 μm to 1.72 μm (380 nm band) which covers S, C and L communication bands, a low confinement loss of less than 10⁻⁷ dB/m in the same wavelength range, and the corresponding birefringence and nonlinear coefficient are about 2.12 × 10⁻² and 50.67 W⁻¹ km⁻¹ at 1.55 μm, respectively. The proposed OPCF may have great potential applications in super-continuum (SC) generation, dispersion compensation, polarization maintaining and so on.     

Physical bounds of metallic nanofingers obtained by mechano-chemical atomic force microscope nanolithography

To obtain metallic nanofingers applicable in surface acoustic wave (SAW) sensors, a mechano-chemical atomic force microscope (AFM) nanolithography on a metallic thin film (50 nm in thickness)/piezoelectric substrate covered by a spin-coated polymeric mask layer (50-60 nm in thickness) was implemented. The effective shape of cross-section of the before and after etching grooves have been determined by using the AFM tip deconvolution surface analysis, structure factor, and power spectral density analyses. The wet-etching process improved the shape and aspect ratio (height/width) of the grooves and also smoothed the surface within them. We have shown that the relaxed surface tension of the polymeric mask layer resulted in a down limitation in width and length of the lithographed nanofingers. The surface tension of the mask layer can be changed by altering the initial concentration of the polymer in the deposition process. As the surface tension reduced, the down limitation decreased. In fact, an extrapolation of the analyzed statistical data has indicated that by decreasing the surface tension from 39 to 10 nN/nm, the minimum obtainable width and length of the metallic nanofingers was changed from about 55 nm and 2 μm to 15 nm and 0.44 μm, respectively. Using the extrapolation’s results, we have shown that the future SAW sensors buildable by this nanolithography method possess a practical bound in their synchronous frequency (∼58 GHz), mass sensitivity (∼6125 MHz-mm²/ng), and the limit of mass resolution (∼4.88 × 10⁻¹⁰ ng/mm²).     

Modeling of plasma-controlled surface evaporation and condensation of Al target under pulsed laser irradiation in the nanosecond regime

Phase transition on the surface of an aluminium target and vapour plasma induced by laser irradiation in the nanosecond regime at the wavelengths of 1.06 and 0.248 μm with an intensity of 10⁸-10⁹ W/cm² in vacuum are analysed. Particular attention is paid to the wavelength dependence of the observed phenomena and the non-one-dimensional effect caused by the Gaussian laser intensity distribution. A transient two-dimensional model is used which includes conductive heat transfer in the condensed phase, radiative gas dynamics and laser radiation transfer in the plasma as well as surface evaporation and back condensation at the phase interface. It is shown that distinctions in phase transition dynamics for the 1.06 and 0.248 μm radiation result from essentially different characteristics of the laser-induced plasmas. For the 1.06 μm radiation, evaporation stops after the formation of hot optically thick plasma, can occasionally resume at a later stage of the pulse, proceeds non-uniformly in the spot area, and the major contribution to the mass removal occurs in the outer part of the irradiated region. Plasma induced by the 0.248 μm laser is much more transparent therefore evaporation does not stop but continues in the subsonic regime with the Mach number of about 0.1.     

Surface morphology and optical properties of ZnO epilayers grown on Si(1 1 1) by metal organic chemical vapor deposition

Heteroepitaxial ZnO epilayers were grown on Si(1 1 1) substrates using a vertical geometry atmospheric pressure metal organic chemical vapor deposition (AP-MOCVD) system. The growth temperature was varied from 550 °C to 650 °C in steps of 25 °C. The ZnO growth rate and surface morphology were strong functions of the growth temperature and ranged from ∼0.16 μm/h to 1.36 μm/h. The surface morphology of the ZnO films changed from granular to sharp tips as the growth temperature increased. The effect of buffer thickness was also examined, and was found to have a strong effect on the optical properties of the ZnO. An optimized growth condition for ZnO epilayers was found at 625 °C, producing a FWHM in the room temperature photoluminescence (PL) spectrum of 4.5 nm and a preferred growth orientation along the (0 0 2) direction.Transmission electron microscopy images and selected area diffraction patterns showed excellent crystalline quality of both the buffer and ZnO overlayer. When non-optimized growth temperatures were employed, post-growth annealing was found to greatly enhance the ratio of band-edge to deep level emission.