Search Results (8)

Wetting behavior of molten metals on solid substrates is a critical phenomenon influencing numerous industrial applications, including welding, anti-corrosion coatings, and metal additive manufacturing (AM). In particular, molten metal jetting (MMJ), an emerging AM technology, requires that the molten metal remain pinned at the nozzle exit. Thus, each new metal requires a specific nozzle material to ensure consistent droplet ejection and deposition, making it important to rapidly identify the appropriate wetting combinations. However, traditional measurements of wetting angles require expensive equipment and only allow one combination of materials to be investigated at a time which can be time consuming. This work introduces a rapid screening method based on sessile droplet experiments to evaluate wetting profiles across multiple metal–substrate combinations simultaneously. This study investigates the wetting interactions of molten Al alloy (Al4008), Cu, and Sn on various ceramic and metal substrates to identify optimal material combinations for MMJ nozzle designs. Results demonstrate that Al4008 achieves wetting on ceramic substrates such as AlN, TiO₂, and SiC, with varying mechanisms including chemical reactions and weak surface interactions. Additionally, theoretical predictions regarding miscibility gaps and melting point differences were verified for Cu and Sn on refractory metals like Mo and W. Findings from this study contribute to the establishment of a materials compatibility library, enabling the selection of wetting/non-wetting combinations for stable MMJ operation. This resource not only advances MMJ technologies but also provides valuable insights for broader applications such as welding, coating, and printed electronics. Full article

The cold spray deposition technique has been used to produce a new class of solid lubricant coatings using powder feedstocks of the metal disulfides WS₂ or MoS₂, either pure or mixed with Cu and Ni metal powders. Friction and cycle lives were obtained using ball-on-flat reciprocating tribometry of coated 304 SS flats in dry nitrogen and vacuum at higher Hertzian contact stresses (S_max = 1386 MPa (201 ksi)). The measured friction and thickness of the coatings were much lower than for previous studies (COF = 0.03 ± 0.01 and ≤1 µm, respectively), which is due to their high metal disulfide:metal ratios. Cu-containing metal sulfide coatings exhibited somewhat higher cycle lifetimes than the pure metal sulfide coatings, even though the Cu content was only ~1 wt%. Profiling of wear tracks for coatings tested to 3000 cycles (i.e., pre-failure) yielded specific wear rates in the range 3–7 × 10⁻⁶ mm³N⁻¹m⁻¹, similar to other solid lubricant coatings. When compared to other coating techniques, the cold spray method represents a niche that has heretofore been vacant. In particular, it will be useful in many precision ball-bearing applications that require higher throughput and lower costs than sputter-deposited MoS₂-based coatings. Full article

Depending on operating conditions, metals and alloys are exposed to various factors: wear, friction, corrosion, and others. Plasma surface alloying of machine and tool parts is now an effective surface treatment process of commercial and strategic importance. The plasma surface alloying process involves adding the required elements (carbon, chromium, titanium, silicon, nickel, etc.) to the surface layer of the metal during the melting process. A thin layer of the compound is pre-applied to the substrate, then melted and intensively mixed under the influence of a plasma arc, and during the solidification process, a new surface layer with optimal mechanical properties is formed. Copper-based alloys—Cu-X, where X is Fe, Cr, V, Nb, Mo, Ta, and W—belong to an immiscible binary system with high mechanical strength, electrical conductivity, and magnetism (for Fe-Cu) and also high thermal characteristics. At the same time, copper-based alloys have low hardness. In this article, wear tests were carried out on coatings obtained by plasma alloying of CuSn10 and CrxCy under various friction conditions. The following were chosen as a modifying element: chromium carbide to increase hardness and iron to increase surface tension. It is noted that an increase in the chromium carbide content to 20% leads to the formation of a martensitic structure. As a result, the microhardness of the layer increased to 700 HV. The addition of CuSn10 + 20% CrxCy and an additional 5% iron to the composition of the coating improves the formation of the surface layer. Friction tests on fixed abrasive particles were carried out at various loads of 5, 10, and 50 N. According to the test results, the alloy layer of the Fe-Cr-C-Cu-Sn system has the greatest wear resistance under abrasive conditions and dry sliding friction conditions. Full article

Due to the excellent lubricity of V₂O₅ and soft metals, V and Cu have been added to Mo-N based coatings to further improve the tribological properties. In this study, the Mo-V-Cu-N coatings were deposited by high power impulse magnetron sputtering (HIPIMS). The effects of V and Cu on the microstructure and mechanical properties of Mo-N coatings were investigated. With increasing V/Cu content ratio, the deposition rate decreased from 15.4 to 6.5 nm/min, and the microstructure transformed from a featureless structure into a dense columnar structure. At low Cu contents, less than 6.5 at.%, the Mo-V-Cu-N coatings exhibited a single solid solution phase of c-Mo₂(V)N. When the Cu content reached 29.7 at.%, the Mo₄₅V₁Cu₃₀N₂₄ coating showed the lowest surface roughness of 2.0 nm, and the coating changed into a double-phase of c-Mo₂(V)N and c-Cu. The adhesion strength gradually increased from 32.2 to 87.8 N with an increasing V/Cu content ratio. Due to the microstructure densification, a maximum hardness of 27.3 GPa was achieved for the Mo₄₆V₁₅Cu₁N₃₈ coating, which was accompanied by a high compressive residual stress. Full article

With the growth of the automobile, machinery, and aerospace industries, demand for high-performance surface coatings having multifunctional characteristics for use in mechanical parts is increasing. In this study, ternary/quaternary Mo–Cu–Cr–(N) nanocomposite coatings were deposited at different N₂ gas flow rates using direct current magnetron sputtering from a multicomponent single-alloy target. The use of a single-alloy target simplifies the deposition process and improves the coating uniformity. The influence of the nitrogen content was investigated regarding the microstructural, mechanical, and tribological properties, and corrosion resistance of these coatings. The Mo–Cu–Cr–N coating containing 30.5 at.% nitrogen showed a nanocomposite structure comprising transition metal nitride phases (Mo–N/Cr–N) having high mechanical properties and corrosion resistance, while retaining the excellent tribological properties of ternary Mo–Cu–N coatings. Full article

In the present study, we provide useful data related to one of the most promising materials in thin-film solar cell technologies: Cu₂ZnSnS₄ (CZTS) kesterite structures. Sol-gel spin coating and chemical bath deposition methods were used to fabricate and further investigate Mo/CZTS/CdS/ZnO/AZO heterostructures. In order to examine the crystal structure of the samples, Raman scattering measurements using two excitation wavelengths (514.5 nm and 785 nm) were performed. Three Raman bands related to CZTS were found, as well as one that had its origin in CdS. By using laser ablation and performing Raman spectroscopy on these modified samples, it was shown that during the manufacturing process a MoS₂ interlayer was formed between the CZTS and Mo layers. Our method proved that the CZTS layer in a multilayer device structure fabricated by solution-based methods can be decomposed, and thus a detailed analysis of the layer can be performed. Subsequently, current-voltage curves were investigated in terms of the essential electrical properties of glass/Mo/p-CZTS/n-CdS/ZnO/AZO junctions and occurring current transport mechanisms. Finally, AFM data were acquired to study the surface topography of the studied samples. The images showed that these surfaces had a uniform grain structure. Full article

In this study, a new thin-film deposition process, spray coating method (SPM), was investigated to deposit the high-densified CuInSe₂ absorber layers. The spray coating method developed in this study was a non-vacuum process, based on dispersed nano-scale CuInSe₂ precursor and could offer a simple, inexpensive, and alternative formation technology for CuInSe₂ absorber layers. After spraying on Mo/glass substrates, the CuInSe₂ thin films were annealed at 550 °C by changing the annealing time from 5 min to 30 min in a selenization furnace, using N₂ as atmosphere. When the CuInSe₂ thin films were annealed, without extra Se or H₂Se gas used as the compensation source during the annealing process. The aim of this project was to investigate the influence of annealing time on the densification and crystallization of the CuInSe₂ absorber layers to optimize the quality for cost effective solar cell production. The thickness of the CuInSe₂ absorber layers could be controlled as the volume of used dispersed CuInSe₂-isopropyl alcohol solution was controlled. In this work, X-ray diffraction patterns, field emission scanning electron microscopy, and Hall parameter measurements were performed in order to verify the quality of the CuInSe₂ absorber layers obtained by the Spray Coating Method. Full article

We fabricated an electrode chip with a structure coated by an insulation layer that contains dispersed SiO₂ adsorbent particles modified by an amino-group on a source-drain electrode. Voltage changes caused by chelate molecule adsorption onto electrode surfaces and by specific cation interactions were investigated. The detection of specific cations without the presence of chelate molecules on the free electrode was also examined. By comparing both sets of results the complexation ability of the studied chelate molecules onto the electrode was evaluated. Five pairs of source-drain electrodes (×8 arrays) were fabricated on a glass substrate of 20 × 30 mm in size. The individual Au/Cr (1.0/0.1 μm thickness) electrodes had widths of 50 μm and an inter-electrode interval of 100 μm. The fabricated source-drain electrodes were further coated with an insulation layer comprising a porous SiO₂ particle modified amino-group to adsorb the chelate molecules. The electrode chip was equipped with a handy-type sensor signal analyzer that was mounted on an amplifier circuit using a Miniship^TM or a system in a packaged LSI device. For electrode surfaces containing different adsorbed chelate molecules an increase in the sensor voltage depended on a combination of host-guest reactions and generally decreased in the following order: 5,10,15,20-tetrakis(N-methylpyridinium-4-yl)-21H,23H-porphine, tetrakis(p-toluenesulfonate) (TMPyP) as a Cu²⁺ chelator and Cu²⁺ > 2-nitroso-5-[N-n-propyl-N-(3-sulfopropyl)amino]phenol (nitroso-PSAP) as an Fe²⁺ chelator and Fe²⁺ > 4,7-diphenyl-1,10-phenanthrolinedisulfonic acid, disodium salt (BPDSA) as an Fe²⁺ chelator and Fe²⁺ > 3-[3-(2,4-dimethylphenylcarbamoyl)-2-hydroxynaphthalene-1-yl-azo]-4-hydroxybenzenesulfonic acid, sodium salt (XB-1) as a Mg²⁺ chelator and Mg²⁺ > 2,9-dimethyl-4,7-diphenyl-1,10-phenanthrolinedisulfonic acid, disodium salt (BCIDSA) as a Cu²⁺ chelator and Cu²⁺, respectively. In contrast, for the electrode surfaces with adsorbed O,O'-bis(2-aminoethyl)ethyleneglycol-N,N,N',N'-tetraacetic acid (GEDTA) or O,O'-bis(2-aminophenyl)ethyleneglycol-N,N,N',N'-tetraacetic acid, tetrapotassium salt, hydrate (BAPTA) as a Ca²⁺ chelator no increase in the detection voltage was found for all the electrode tests conducted in the presence of Ca²⁺. To determine the differences in electrode detection, molecular orbital (MO) calculations of the chelate molecules and surface molecular modeling of the adsorbents were carried out. In accordance with frontier orbital theory, the lowest unoccupied MO (LUMO) of the chelate molecules can accept two lone pair electrons at the highest occupied MO (HOMO) of the amino group on the model surface structure of the SiO₂ particle. As a result, a good correlation was obtained between the LUMO-HOMO difference and the ion response of all the electrodes tested. Based on the results obtained, the order of adsorbed chelate molecules on adsorption particles reflects the different metal ion detection abilities of the electrode chips. Full article