Fabrication and preliminary assessment of aramid reinforced polymer composite material

A knowledge of the material constituents and fabrication process is generally required for easing the composite material properties study and characterization. This paper presents the methodology of aramid reinforced polymer composite material preliminary assessment and fabrication. The demonstration is carried out through the development of mechanical properties characterization specimen. The composite material specimen is fabricated by utilizing the open mould with hand lay-up method, where three types of laminates include of unidirectional, orthotropic, quasi-isotropic cross plies are demonstrated. A template is applied for preparing specific fibre orientation 45°angle. Plies are lay accordingly with guided by a square guide for minimizing the off-orientation angle defect. Preliminary assessment is included of verification of unidirectional aramid fabric quality, cured specimen physical defect, internal defect through micrography analysis and material volume fraction prediction. Average specimen fibre volume fraction of 0.64 is predicted by determined the fibre filament geometry detail through micrography analysis. There are several fabrication defects had been identified. The defect identification findings shall be referred for further improvement of material preparation and fabrication method.

A Review on the Fabrication and Reliability of Three-Dimensional Integration Technologies for Microelectronic Packaging: Through-Si-Via and Solder Bumping Process

With the continuous miniaturization of electronic devices and the upcoming new technologies such as Artificial Intelligence (AI), Internet of Things (IoT), fifth-generation cellular networks (5G), etc., the electronics industry is achieving high-speed, high-performance, and high-density electronic packaging. Three-dimensional (3D) Si-chip stacking using through-Si-via (TSV) and solder bumping processes are the key interconnection technologies that satisfy the former requirements and receive the most attention from the electronic industries. This review mainly includes two directions to get a precise understanding, such as the TSV filling and solder bumping, and explores their reliability aspects. TSV filling addresses the DRIE (deep reactive ion etching) process, including the coating of functional layers on the TSV wall such as an insulating layer, adhesion layer, and seed layer, and TSV filling with molten solder. Solder bumping processes such as electroplating, solder ball bumping, paste printing, and solder injection on a Cu pillar are discussed. In the reliability part for TSV and solder bumping, the fabrication defects, internal stresses, intermetallic compounds, and shear strength are reviewed. These studies aimed to achieve a robust 3D integration technology effectively for future high-density electronics packaging.

Reflections on Early Stages of Environmentally Assisted Cracking from Corrosion Pits

A perspective is presented on the evolution of damage due to environmentally assisted cracking (EAC), from crack precursor development through to long crack growth. The variable nature of crack precursors is highlighted with an observation that uncontrolled chemistry excursions or fabrication defects could eliminate any significant delay associated with that step in the damage evolution process. Specimen preparation by machining and grinding can be critical in determining the apparent susceptibility of the metal to EAC and corrosion, and an example for 316L stainless steel is given to show how physical defects generated by the grinding wheel can become the dominant site for pitting attack relative to MnS inclusions. Corrosion pits are the most commonly observed precursor to cracks in aqueous chloride environments. The loci of sites of crack initiation around a pit are discussed and the inherent challenges in quantifying the growth of cracks smaller than the pit depth described with implications for modelling of the pit-to-crack transition. The remarkably enhanced stress corrosion crack growth rate data for short and small cracks in a 12Cr steam turbine blade in a simulated condensate environment are discussed in the context of crack electrochemistry modelling and the implications for engineering integrity.

Suppressing meta-holographic artifacts by laser coherence tuning

A metasurface hologram combines fine spatial resolution and large viewing angles with a planar form factor and compact size. However, it suffers coherent artifacts originating from electromagnetic cross-talk between closely packed meta-atoms and fabrication defects of nanoscale features. Here, we introduce an efficient method to suppress all artifacts by fine-tuning the spatial coherence of illumination. Our method is implemented with a degenerate cavity laser, which allows a precise and continuous tuning of the spatial coherence over a wide range, with little variation in the emission spectrum and total power. We find the optimal degree of spatial coherence to suppress the coherent artifacts of a meta-hologram while maintaining the image sharpness. This work paves the way to compact and dynamical holographic displays free of coherent defects.

Fabrication defects and limitations of AlSi10Mg lattice structures manufactured by selective laser melting

Additive manufacturing has enabled the production of lattice structures with tailored mechanical properties. However, process limitations still exist, affecting the quality of the struts, practically limiting sizes and types of printable unit cells. Typically, long, thin, unsupported horizontal struts exhibit large deviations from ideal geometries, due to high surface roughness and internal porosity. AlSi10Mg specimens were designed and fabricated by laser powder bed fusion to investigate the role of strut orientation, size, and overhang length using different sets of process parameters. Visual inspection, three-dimensional scanning, and metallographic inspection of the cross-sections were performed. A quality control methodology based on dimensional and geometric tolerances has been defined in order to quantitatively characterize the quality of the struts. Optimized process parameters were selected and used to fabricate octet-truss specimens which were then characterized by compression testing.

Fabrication of a TiC-Ti Matrix Composite Coating Using Ultrasonic Vibration-Assisted Laser Directed Energy Deposition: The Effects of Ultrasonic Vibration and TiC Content

Titanium and its alloys exhibit superior properties of high corrosion resistance, an excellent strength to weight ratio and outstanding stiffness among other things. However, their relatively low hardness and wear resistance limit their service life in high-performance applications of structure parts, gears and bearings, for example. The fabrication of a ceramic reinforced titanium matrix composite (TMC) coating could be one of the solutions to enhance the microhardness and wear resistance. Titanium carbide (TiC) is a preferable candidate due to the advantages of self-lubrication, low cost and a similar density and thermal expansion coefficient with titanium. The fabrication of TiC-TMC coatings onto titanium using a laser directed energy deposition (LDED) process has been conducted. The problems of TiC aggregation, low bonding quality and the generation of fabrication defects still exist. Considering ultrasonic vibration could generate acoustic steaming and transient cavitation actions in melted materials, which could homogenize the distribution of reinforcement materials and promote the dissolution of TiC into liquid titanium. In this study, for the first time, we investigate the ultrasonic vibration-assisted LDED of TiC-TMC coatings. The effects of ultrasonic vibration and reinforcement content on the phase compositions, reinforcement aggregation, bonding quality, fabrication defects and mechanical properties (including microhardness and wear resistance) of LDED deposited TiC-TMC coatings have been investigated. With the assistance of ultrasonic vibration, the aggregation of TiC was reduced, the porosity was decreased, the defects in the bonding interface were reduced and the mechanical properties including microhardness and wear resistance were increased. However, the excessive TiC content could significantly increase the TiC aggregation and manufacturing defects, resulting in the reduction of the mechanical properties.

Robust Geometries for Second-Harmonic-Generation in Microrings Exhibiting a 4-Bar Symmetry

Microring resonators made of materials with a zinc-blend or diamond lattice allow exploiting their 4-bar symmetry to achieve quasi-phase matching condition for second-order optical nonlinearities. However, fabrication tolerances impose severe limits on the quasi-phase matching condition, which in turn degrades the generation efficiency. Here, we present a method to mitigate these limitations. As an example, we studied the geometry and the pump wavelength conditions to induce the second-harmonic generation in silicon-based microrings with a second-order susceptibility χzxy(2)≠0. We found the best compromises between performances and experimental requirements, and we unveil a strategy to minimize the impacts of fabrication defects. The method can be easily transferred to other material systems.

Metastable Dark Current in BRITE Nano-Satellite Image Sensors

Dark current in charge-coupled devices (CCDs) is one of the most important sources of impulsive noise present in scientific images. While the dark current originating in the fabrication defects (mainly impurities) is stable and dependent only on temperature, the one present in the proton-irradiated sensors shows a range of metastable states which makes calibration of images almost impossible. In this paper, we show an extended analysis of such metastabilities present in Kodak KAI 11000M CCD sensors employed in the BRITE (BRIghtest Target Explorer) astrophysical mission over 7 years of in-orbit work. Our collection of dark current characteristics has an unprecedented time span, large temperature range and high number of investigated pixels. A special methodology based on the Gaussian mixture model was proposed for identification and characterization of the metastable states in the dark current. We identified several interesting properties of the metastability and found an experimental rule for the dark current in tristable defects. The results shed a new light on the dark current problems, its modeling and the mitigation in an image sensor working in space.