Nanotechnology in the Chemical Industry – Opportunities and Challenges

The traditional chemical industry has become a largely mature industry with many commodity products based on established technologies. Therefore, new product and market opportunities will more likely come from speciality chemicals, and from new functionalities obtained from new processing technologies as well as new microstructure control methodologies. It is a well-known fact that in addition to its molecular structure, the microstructure of a material is key to determining its properties. Controlling structures at the micro- and nano-levels is therefore essential to new discoveries. For this article, we define nanotechnology as the controlled manipulation of nanomaterials with at least one dimension less than 100nm. Nanotechnology is emerging as one of the principal areas of investigation that is integrating chemistry and materials science, and in some cases integrating these with biology to create new and yet undiscovered properties that can be exploited to gain new market opportunities. In this article market opportunities for nanotechnology will be presented from an industrial perspective covering electronic, biomedical, performance materials, and consumer products. Manufacturing technology challenges will be identified, including operations ranging from particle formation, coating, dispersion, to characterization, modeling, and simulation. Finally, a nanotechnology innovation roadmap is proposed wherein the interplay between the development of nanoscale building blocks, product design, process design, and value chain integration is identified. A suggestion is made for an R&D model combining market pull and technology push as a way to quickly exploit the advantages in nanotechnology and translate these into customer benefits.     

Arc erosion reduction on electrical contacts using transversecurrent injection

Electrical contact lifetime is often directly determined by arc erosion. A method for reducing are erosion was developed consisting of injecting from an external current source an additional electrical current flowing parallel to the contact surface. This method was examined in three are environments using the additional transverse electrical current with a density less than 1 A/mm²: 1) automobile ignition contacts; 2) pulsed air arc; and 3) low pressure (P=100 mTorr) arc in nitrogen, SEM and X-ray examination showed that application of a transverse current in a contact during arcing changed the phase composition and microstructure of the contact surface. Under optimal conditions, the microstructure which is formed is significantly more erosion resistant than without the transverse current injection     

A model for a uniform steady-state vacuum arc with a hot anode

A model is formulated and evaluated for a Uniform electrical discharge sustained in vapor evaporated from an arc-heated anode. The plasma potential is positive with respect to both the cathode and anode. For a Cu anode, the anodic vapor dominates the plasma for current densities exceeding 8 kA/m². The anode heating potential is approximately 6.5 V, and the dominant cooling mechanism is evaporation for current densities exceeding 20 kA/m². Over the range 10 to 10000 kA/m², the electron density increases from 8×10¹⁷ to 5×10²³ m^-3, while the ionization fraction rises from 0.3% to 4%. At the lower end of this current range the electrical resistivity of 4 mΩ-m is determined primarily by electron-neutral collisions, while with increasing current the resistivity decreases to 0.7 mΩ-m, with electron-ion collisions contributing an equal share. This hot-anode vacuum arc may have potential for industrial application as a macroparticle-free high-deposition-rate coating source     

Momentum interchange between cathode-spot plasma jets andbackground gases and vapors and its implications on vacuum-arcanode-spot development

Expressions are developed for the momentum flux density in collimated and expanding cathode-spot plasma jets by multiplying the ion flux density by the momentum carried by individual ions. Cathode spots placed in gas background produce a hemispherical metal-vapor plasma region whose radius can be predicted by equating the plasma-jet momentum flux density with the background gas pressure. In hot anode vacuum arcs and in anode-spot vacuum arcs a vapor plume from the anode expands into the cathodic plasma. Significant expansion occurs when the anodic vapor pressure becomes comparable to the cathodic momentum flux density     

Ion current collected at various distances and argon backgroundpressures in a copper vacuum arc

The ion current collected by a probe biased at the cathode potential and located behind an annular anode of a vacuum arc is measured as a function of distance to the cathode and background argon pressure. The arc is formed between a circular Cu cathode and an annular anode. Arc current is 170 A, and the arc duration is 0.9 s. The arc is ignited by momentary contact of a movable W trigger rod (held at anode potential) with the cathode. Arc voltage, arc current, and ion current are measured using an analog data acquisition card and a personal computer. Arc voltage and arc current values are stable during the arc and their normalized standard deviation is less than 0.07. Ion current is noisy and fluctuates during the arc with a normalized standard deviation that varies from 0.5 at p<0.1 torr up to more than 1.5 at p>1 torr     

Twenty-five years of progress in vacuum arc research andutilization

Progress in understanding and applying vacuum arcs is reviewed. Laser diagnostics have demonstrated the existence of micron-sized regions in the cathode spot plasma having electron densities exceeding 10²⁶ m^-3. The expanding plasma produces a highly ionized jet whose ions typically have charge states of 1-3 and energies of 50-150 eV. Gas dynamic and explosive emission models have been formulated to explain cathode spot operation. In cases where the arc is constricted at the anode, forming an anode spot, or the anode is thermally isolated, forming a hot anode vacuum arc, material emitted from the anode may dominate the interelectrode plasma. Evaporation from liquid droplets may also provide a substantial component of the plasma, and the presence of these droplets can have deleterious consequences in applications. The vacuum arc has been extensively utilized as a plasma source, particularly for the deposition of protective coatings and thin films, and as a switching medium in electrical distribution circuit breakers     

Sagdeev Potential and Sheath Criterion for a Multi‐Component Plasma

A charged sheath between a multi‐component plasma and an absorbing and conducting wall was considered analytically in the framework of a hydrodynamic model. The model accounted for the inertia and pressures of all the plasma components and both wall polarities. An existence criterion for the steady sheath with a monotonous distribution of the electric potential was derived based on analysis of the Sagdeev potential. The model was applied to some special cases of two‐and three‐component plasmas such as a plasma with macroparticles, and electro‐positive and ‐negative plasmas. (© 2006 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Ion current distribution within a toroidal duct of a filteredvacuum arc deposition system

Vacuum arcs were established on a 90-mm-diameter Ti cathode in a deposition apparatus consisting of a spacer, 122 mm-diameter annular anode, quarter-torus magnetic macroparticle filter, and a deposition chamber. A toroidal magnetic field generally parallel to the torus walls of up to 20 mT was applied. The ion current in various cross-sections of the toroidal duct was measured using: 1) a disc probe of 130-mm diameter, oriented normal to the torus axis used to measure the transmitted ion current, and 2) a hollow cylindrical probe of 135-mm diameter and 25-mm height, whose axis coincided with the torus axis, used to measure ion current losses to the duct wall. The distribution of ion current loss was studied using an 8-segment hollow cylindrical multiprobe, where the individual probes were equally distributed on the circumference of a 130-mm-diameter circle. It was shown that: 1) the ratio of ion currents collected on the cylindrical and disc probes at first decreases with increasing the toroidal field, and then becomes approximately constant; 2) the presence of the large-diameter disc probe does not influence the value of the ion current on the cylindrical probe; and 3) the maximum ion current density near the torus walls is located in the +g direction and displaces in the -(B×g) direction with increasing the toroidal field, where g and B are the vectors of the centrifugal acceleration and the magnetic field, respectively