Search Results (212)

The parameter degradation and failure mechanisms of 1200 V asymmetric trench-type (AT) silicon carbide (SiC) metal oxide semiconductor field-effect transistors (MOSFETs) under various single and repetitive surge currents, with various gate bias voltages (V_GS) of 0 V, −5 V, and −10 V, are systematically investigated in this work. It is indicated that V_GS has no impact on the single surge reliability, with the same maximum single surge current (SSC_max) under different V_GS. However, during repetitive surge stress (90% and 60% SSC_max), the maximum surge cycles have increased as V_GS increases from −10 V to 0 V. It may be caused by the enhancement of channel-assisted leakage conduction, allowing more surge current to flow through the channel. It is concluded from gate capacitance (Cg-Vg) and low-frequency noise (LFN) characterizations that lower V_GS increases SiC/SiO₂ interface defect density, accelerating parameter degradation during single and repetitive surge stress. Both chip and package failures are observed for single and repetitive surge stress. For single surge stress, the device failure has resulted from the melted source Al as the metal erodes and penetrates through the interlayer dielectric and the ohmic contact layer between the source metal and the SiC-doped region, respectively, leading to a three-terminal short circuit. For repetitive surge stress, the device failure has been caused by the penetration of Al metal into the interlayer dielectric, leading to a gate-source short circuit. This comprehensive research provides valuable guidance for enhancing the surge reliability of SiC MOSFETs. Full article

In hybrid wire arc additive manufacturing with interlayer friction stir processing (UAMFSP), refined microstructures are produced in aluminum alloy builds; however, the thermal parameters governing layer-resolved defect evolution remain poorly understood. In this study, a correlative mechanistic framework is presented in which post-peak cooling rate is identified as a plausible controlling factor for porosity evolution in UAMFSP Al 4043 three-layer walls. A multi-scale characterization is performed by employing infrared thermography, quantitative optical grain morphology analysis (N  =  10,346 grains, Layers 1–3), scanning electron microscopy from 250× to 35,000×, and image-based porosity quantification from calibrated SEM fields. This primary quantitative comparison is established between L1 and L3 only; Layer 2 is excluded from the 250× quantitative analysis owing to its thermally distinct cooling regime and is treated separately. A counterintuitive layer-dependent porosity gradient is reported, wherein the upper layer (L3) exhibited 80% higher porosity (2.90 ± 1.18%) and 107% higher pore density (4283  ±  900 pores/mm²) than the bottom layer (L1), despite recording a 26% lower peak FSP surface temperature (195.1 vs. 263.2 °C) (n = three fields per layer; Cohen’s d ≈ 1.7). Based on these results, the post-peak cooling rate, rather than peak temperature, is identified as a plausible controlling factor for void consolidation quality, as evidenced by the observation that L3 cools at −12.3 °C/s versus −16.2 °C/s for L1, which is consistent with prolonged high-temperature dwell and reduced plastic-flow-assisted pore closure in the upper layer. The anomalously rapid cooling of L2 (−46.9 °C/s), attributed to a bilateral thermal gradient between the substrate and the air-cooled free surface, places it in a thermally distinct regime; accordingly, L2 is utilized exclusively for high-magnification SEM characterization in this study. High-magnification SEM imaging (12,000×–35,000×) revealed a frequent spatial co-location of sub-micron pores with fragmented Al–Si eutectic particles, which is consistent with preferential void persistence near particle–matrix interfaces. Grain morphology also exhibits non-monotonic evolution with build height, with mean circularity following the order L3 (0.645) > L1 (0.621) > L2 (0.569), and the equiaxed grain fraction ranging from 25.5% (L2) to 36.1% (L3) (ANOVA: F = 56.2, p = 5.15 × 10⁻²⁵), while the mean equivalent grain diameter remained below 3.4 μm across all layers. Overall, the outcomes of this study establish post-peak cooling rate, rather than peak temperature, as a plausible controlling factor for void consolidation quality in UAMFSP builds, with the caveat that complete causal isolation requires controlled single-variable experiments. These outcomes are presented as a first mechanistic framework for this class of hybrid process and are intended to motivate targeted controlled experiments, subsurface thermal characterization, and expanded porosity sampling in future investigations of multi-layer additive–deformation manufacturing of Al-based alloys. Full article

This study investigates the effect of SiC nanoparticle addition on the microstructure, interfacial reactions, and mechanical properties of Zn5Al3Ti active solder used for ultrasonic soldering of AlN ceramic to copper substrates. Composite solders containing 3 and 6 wt.% SiC nanoparticles were prepared and applied under flux-free ultrasonic soldering conditions. The solder alloys were evaluated by tensile testing, while the soldered joints were evaluated by shear strength testing. The solder microstructure and interfacial regions were characterized using SEM/EDS analysis. The results showed that the addition of SiC nanoparticles modified the microstructure of the Zn5Al3Ti solder and influenced the mechanical performance of the ceramic/metal joints. Among the investigated systems, the AlN/Zn5Al3Ti + 6 wt.% SiC/Cu joint exhibited the highest shear strength, reaching approximately 101 MPa. SEM/EDS observations revealed the formation of compact multilayered interfacial regions, including possible Cu–Zn intermetallic phases at the Cu/solder interface and Al–Ti–Zn-based reaction products near the solder/AlN interface. The improved joint performance may be attributed to the combined effect of SiC-induced microstructural modification, the presence of Si-containing particles, and the formation of compact metallurgical bonds. The results indicate that Zn5Al3Ti solder modified with 6 wt.% SiC nanoparticles is a promising material for producing strong AlN/Cu joints under the applied ultrasonic soldering conditions. Full article

An Al₂O₃/AlN stack deposited via Atomic Layer Deposition (ALD) methods as a gate insulator for silicon carbide (4H-SiC) has been investigated, focusing on the effects of different Al₂O₃ deposition processes on the nitride layer. In particular, dielectric stacks, consisting of a 10 nm AlN interface (001)-oriented layer directly grown on a 4H–SiC substrate and in 20 nm of additional amorphous Al₂O₃ layers were synthesized in sequential deposition runs by thermal ALD (T-ALD) or plasma-enhanced ALD (PEALD) methods. The evolution of the phenomena occurring at the Al₂O₃/AlN interfaces has been established by in situ ellipsometry measurements. Strong effects of the oxygen plasma because of the O-Al-N bond formation have been clearly observed and corroborated by ex situ structural and electrical characterizations, especially in the case of the plasma-enhanced Al₂O₃ process. In particular, the Al₂O₃/AlN bilayer grown by the Al₂O₃ T-ALD method exhibited good insulating behavior and an 8.7-high dielectric constant was measured. By contrast, the Al₂O₃/AlN bilayer grown by the Al₂O₃ PEALD method demonstrated poor insulating properties. Full article

Applying functional hard protective coatings with friction-reducing and wear-resistant properties to optimize mechanical surfaces and interfaces can significantly enhance the reliability of operating components under extreme conditions and extend their service life. However, the difference of coating preparation technology often leads to great uncertainty in the improvement of the performance and lifetime of functional hard protective coatings. Hence, in this work, TiAlSiCN coatings were deposited at the substrate temperature of 300 °C by varying the C target power from 0 to 900 W using combined high-power impulse magnetron sputtering and pulsed DC magnetron sputtering. The TiAlSiCN coatings deposited at a C target power of 500 W containing the mixed phase of nc-TiAl(C)N, a-Si₃N₄ and a-C exhibit a simultaneous superhardness of 43.5 GPa and favorable toughness, benefiting from the fully dense microstructure and high surface integrity. The superhard TiAlSiCN coatings show excellent friction-reducing and wear-resistant properties with a low friction coefficient of about 0.1 and specific wear rate of 2.78 × 10⁻⁷ mm³·N⁻¹·m⁻¹ under dry reciprocating friction and wear tests. The improved friction and wear performance of TiAlSiCN coatings are mainly attributed to the increased cracking resistance and oxide-based films covering the superhard surface/interface. Full article

In this study, the Ca₃₃Mg₉Al₁₃Si₄₅ layer was fabricated on the SiC_f/SiC surface by APS to simulate the coexistence of high-velocity impact and molten-state deposition. Subsequently, the corrosion and infiltration behaviors of the molten Ca₃₃Mg₉Al₁₃Si₄₅ in air and water-vapor environments (H₂O:O₂ = 90:10 vol%) at 1300 °C for 300 h were investigated. The results indicated that, during corrosion, the molten Ca₃₃Mg₉Al₁₃Si₄₅ infiltrated into the interior of the SiC_f/SiC through interconnected pores. Under high-temperature air corrosion, Ca and Mg remained restricted to the upper-part pore-filling region. Compared with high-temperature air corrosion, Ca and Mg infiltrated deeper along the pores into the interior of the SiC_f/SiC under high-temperature water-vapor corrosion. Once the molten Ca₃₃Mg₉Al₁₃Si₄₅ filled these pores, no obvious elemental diffusion or further infiltration was detected at the interface between the molten Ca₃₃Mg₉Al₁₃Si₄₅ and SiC_f/SiC, suggesting good interfacial chemical stability. The flexural strength of the original SiC_f/SiC was 445 ± 43 MPa, while the SiC_f/SiC with the molten Ca₃₃Mg₉Al₁₃Si₄₅ after high-temperature air corrosion and water-vapor corrosion exhibited flexural strengths of 409 ± 30 MPa and 440 ± 33 MPa. These results demonstrated that the infiltration behavior of the molten Ca₃₃Mg₉Al₁₃Si₄₅ had a relatively minor impact on the mechanical behavior of SiC_f/SiC, enabling the materials to retain mechanical performance close to the original level after high-temperature exposure. Full article

Simultaneously achieving high densification, excellent mechanical properties, and high thermal conductivity remains challenging for aluminum nitride–silicon carbide (AlN-SiC) composites. In this study, fine-grained AlN-SiC composite ceramics were fabricated via in situ reaction hot pressing with the addition of small amounts of silicon (Si) and carbon (C). At an optimal sintering temperature of 1800 °C, the primary phase composition consisted of AlN, SiC and residual graphite, with an average AlN grain size of 0.94 μm. The Si additive melted and wetted the AlN matrix via capillary action, thereby providing sufficient kinetic driving force for densification. Meanwhile, the C additive not only removed oxygen impurities and purified grain boundaries but also reacted in situ with liquid Si to form SiC. The uniformly dispersed SiC particles inhibited the abnormal growth of AlN grains via the grain boundary pinning effect. Consequently, the relative density, flexural strength, and Vickers hardness of the obtained AlN-SiC ceramics reached 99.08%, 365 MPa and 22.58 GPa, respectively. At room temperature, the composite exhibited a thermal conductivity of 66 W/(m·K) and a thermal diffusivity of 32.6 mm²/s. This superior thermal performance is attributed to the purified grain boundaries, uniform SiC distribution, high densification, and tightly bonded SiC/AlN interfaces, which result in weak phonon interfacial scattering. Full article

While aluminum (Al) continues to be a cornerstone for microelectronic interconnect technologies, its chronic tendency toward hillock growth and thermal instability necessitates a transition toward high-performance nanostructured material architectures. This research tackles these reliability bottlenecks by achieving a molecular-level integration of graphene nanoplatelets (GNPs) within Al matrices, a strategy designed to fortify structural resilience. Adopting a green chemistry approach, we synthesized Al-GNP (0.25 vol.%) composite thin films through Pulsed Laser Deposition (PLD) using precursors derived from recycled aluminum. A major obstacle—the formation of the deleterious Al₄C₃ intermetallic phase—was effectively suppressed by ensuring a homogeneous supramolecular dispersion via a specialized dual protocol (ultrasonication and magnetic stirring) during the powder metallurgy stage. Comprehensive physicochemical characterization, utilizing HR-TEM and XRD, verified the structural integrity of the multilayer GNPs (d-spacing = 4.6 Å). Furthermore, surface metrology analysis uncovered a radical shift in growth kinetics: whereas pure Al grew via a “spiky” Volmer-Weber mechanism (Sku = 31.17), the carbon-based inclusion stabilized the film evolution, tempering the kurtosis to Sku = 7.74. Analytical cross-sectional EDS confirmed both stoichiometric fidelity and the achievement of void-free Si/Pt/Al-GNP interfaces. These outcomes prove that a precise nanoscale tailoring of surface morphology via carbonaceous reinforcements significantly bolsters microstructural stamina. Consequently, these PLD-deposited composites emerge as sustainable, cutting-edge candidates for the next generation of microelectronic packaging and interfacial chemistry applications. Full article

This study addresses the corrosion problem of refractory materials during high-temperature molten treatment of pharmaceutical waste salt, and systematically investigates the interface behavior and corrosion mechanism of MgO-based refractory materials in simulated pharmaceutical waste salt (65 wt% NaCl-30 wt% Na₂SO₄-5 wt% CaCO₃). Through sessile drop wetting infiltration experiments, static corrosion tests (950 °C and 1150 °C/48 h), combined with SEM-EDS, XRD characterization, and FactSage thermodynamic calculations, the corrosion resistance of high-purity MgO phase (HM-97) refractory materials and magnesium–aluminum spinel composite phase (MA-85) refractory materials was compared and analyzed. The results show that due to the fine periclase grains and rich grain boundaries, the molten salt infiltration rate of HM-97 material in the 644–800 °C range is significantly higher than that of MA-85. After corrosion at 950 °C, HM-97 and MA-85 formed 47 μm and 53 μm transition layers respectively, and the HM-97 surface generated Ca₃Mg(SiO₄)₂ phase leading to uneven corrosion morphology. At 1150 °C, HM-97 produced long cracks and the transition layer thickness remained almost unchanged due to dissolution, while MA-85 formed an approximately 72 μm transition layer and a dense metamorphic layer. Phase analysis and thermodynamic calculations suggest that the MgAl₂O₄ phase in MA-85 is likely stable at high temperatures, which appears to effectively prevent molten salt infiltration and contribute to forming a protective metamorphic layer, thereby potentially enhancing the material’s corrosion resistance. The MgAl₂O₄ phase is proposed to improve the service performance of MgO-based refractory materials in the molten pharmaceutical waste salt environment. Full article

This article presents preliminary research on the development of a cast iron–ceramic composite for modern braking systems, such as brake discs. The composite matrix is gray cast iron with flake graphite (EN-GJL-150). The reinforcing phase is a porous ceramic composed of SiC and Al₂O₃ particles introduced separately (10% each) and together (70% SiC + 30% Al₂O₃). These particles were applied as a suspension onto polyurethane foam, yielding a ceramic structure with a pore density of up to 10 ppi. The resulting insert was placed in a mold cavity, and cast iron was poured into it. The resulting samples were treated as brake disc material, with a pad made of the commercial friction material P50094 serving as the countersample. Tribological tests showed that the lowest sample wear (average 2.23 mg/5000 m) was achieved for the composite reinforced with SiC + Al₂O₃ particles. This is probably due to the synergy between the antifriction properties of these particles and the lower friction coefficient (µ = 0.180–0.22). Similar mass loss values and the smallest difference between the tested samples were observed for composites with SiC particles (3.01 mg/5000 m) and Al₂O₃ (3.30 mg/5000 m). The second part consisted of microstructural studies. Microstructural analysis of the EN-GJL-150 + SiC + Al₂O₃ composite revealed a previously unobserved nucleation phenomenon at the cast iron–ceramic interface. This confirmed the general assumptions of Riposan’s theory regarding the involvement of oxide microinclusions and complex manganese sulfides of the (Mn, X)S type in the nucleation and crystallization of graphite precipitates. It was also found that, in the case of “in situ” GJL-150 + SiC + Al₂O₃ composites, this theory should account for the beneficial role of ceramic particles in promoting the uniform distribution of type A graphite flakes, which nucleate on their surfaces in the transition zone. Thus, the nucleating role of oxide microinclusions (the first stage of Riposan’s theory) could be taken over by SiC and Al₂O₃ particles, constituting a substrate for the heterogeneous nucleation of (Mn, X)S sulfides. Full article

This study explores the influence of MXene solution as an interfacial liquid on the output performance of a Cu/n-Si-based direct current triboelectric nanogenerator (DC-TENG) system. The ${\mathrm{Ti}}_3{\mathrm{AlC}}_2$ MAX phase was successfully transformed into ${\mathrm{Ti}}_3{\mathrm{C}}_2{\mathrm{T}}_{\mathrm{x}}$ MXene through selective etching and was confirmed by scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS) and X-ray diffraction (XRD) analyses, which revealed an increase in d-spacing from 8.99 to 9.58 Å and a transition from dense layered grains to delaminated, sheet-like structures. Electrochemical impedance spectroscopy (EIS) demonstrated a pronounced reduction in impedance with the introduction of MXene solution, indicating enhanced interfacial conductivity and charge transfer capability. The presence of MXene in deionized (DI) water led to the formation of an electrical double layer (EDL) at the Cu/n-Si interface, contributing to additional interfacial capacitance and more efficient charge relaxation dynamics. As a result, the DC-TENG output was significantly enhanced with the incorporation of MXene into the system, exhibiting a markedly higher current compared to the dry contact condition. Moreover, the MXene solution helped suppress charge decay compared to dry interfaces, highlighting its role as an effective liquid medium for stabilizing surface charge and improving interfacial electron transport in DC-TENG systems. Full article

A comparative investigation of the corrosion behavior evolution of 15%SiCp/Al-Cu-Mg aluminum matrix composites (AMC) subjected to different heat treatments in a salt spray environment containing 5wt% NaCl was performed. Metallographic microscopy was used to observe the surface morphology of the corroded materials. Field-emission transmission electron microscopy (TEM) and scanning electron microscopy (SEM) were used for microstructural evaluation and elemental analysis of the samples. Polarization curves and electrochemical impedance spectroscopy (EIS) were also employed to investigate the corrosion performance of the particle-reinforced aluminum matrix composites under different heat treatments. The test results indicate that, in addition to the influence of various grain boundary precipitates and electrochemical inhomogeneities between the precipitate-free zone (PFZ) and the aluminum matrix, differences in electrochemical properties between the SiC reinforcement particles and the aluminum alloy matrix are also a primary factor contributing to the corrosion of the aluminum-based composites in a 5wt% NaCl salt spray environment. Microstructural observations and electrochemical testing of AMC specimens at different corrosion stages indicate that under-aged samples exhibit relatively higher intergranular corrosion susceptibility. Under prolonged exposure to a salt spray environment, the over-aged specimen exhibited more pronounced galvanic corrosion phenomena, specifically, a significant decrease in Charge transfer resistance (R_ct) values and an increase in CPE values. R_ct results indicate that naturally aged AMC exhibits higher corrosion resistance than artificially aged AMC. With increased salt spray corrosion time, varying degrees of crevice corrosion occurred at the Al–SiC interface in all heat-treated samples. Full article

This study evaluated how the addition of 5 wt% bioactive glass and 15 wt% short glass fibers to EQUIA Forte HT affects the microhardness, micromorphology, and elemental composition of demineralized dentin. Class I cavities in 28 human third molars were demineralized with 37% phosphoric acid and restored with: (1) Filtek Universal composite, (2) EQUIA Forte HT, (3) EQUIA Forte HT + 5wt% BAG, or (4) EQUIA Forte HT + 15wt% short glass fibers. After 4 weeks of storage in phosphate-buffered saline at 37 °C, the teeth were cut in half, obtaining two samples from each tooth (n = 14). Vickers microhardness (HV0.1) was measured on demineralized dentin 50–100 μm apical to the restoration interface. Representative specimens (n = 2) were examined using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). Data were analyzed with one-way ANOVA (α = 0.05). Unmodified EQUIA Forte HT showed the highest mean dentin microhardness recovery (25.06 ± 1.42 HV0.1), followed by composite (17.31 ± 0.66 HV0.1), BAG-modified (23.74 ± 1.37 HV0.1) and fiber-reinforced (22.15 ± 1.06 HV0.1) groups (p < 0.001, all pairwise comparisons p ≤ 0.039). Glass hybrids showed prominent Ca/P peaks; modified groups had elevated Si (BAG) and Al (fibers). SEM revealed smoother surfaces with fewer cracks in modified materials. Unmodified EQUIA Forte HT produced the highest short-term microhardness recovery, while BAG and fiber additions altered surface morphology and elemental composition but slightly reduced early hardness. Full article

First-principles calculations based on density functional theory (DFT) are performed to investigate the interfacial properties and fracture behavior of 3C-SiC(111)/Al(111) and 4H-SiC(0001)/Al(111) interfaces. To mitigate surface effects through adequate slab thickness, the interface models are constructed by positioning a seven-layer Al(111) slab atop eight-layer 3C-SiC(111) and 14-layer 4H-SiC(0001) slabs, respectively. Accounting for the distinct surface terminations and stacking sequences of each polytype, six interface configurations are established: C-top, -center, and -hollow; Si-top, -center, and -hollow. Based on the simulation results of surface energy, work of separation, and electron density distribution, the C-top configuration yields the most stable SiC/Al interface structure, exhibiting the highest work of separation. The ultimate tensile strengths of the C-top interfaces are 6.603 GPa (3C-SiC/Al) and 6.851 GPa (4H-SiC/Al), with corresponding tensile strains of 10% and 12%, respectively. Tensile fracture initiates exclusively within the Al slab for all C-top interfaces, but at distinct atomic layers: fracture occurs between the second and third Al layers (Al2–Al3) for 3C-SiC/Al; and between the first and second Al layers (Al1–Al2) for 4H-SiC/Al. This distinction reflects the influence of different interfacial configurations on the bonding strength between aluminum atomic layers. In summary, an atomic-scale investigation of the interfacial properties and fracture behavior of SiC/Al interfaces provides critical insights for the design and fabrication of novel ceramic/metal composites. Full article

The exploration of new materials with stable molten calcium–magnesium–aluminum-silicate (CMAS) resistance at elevated temperatures is of great significance to the development of advanced aero-engines. In the present study, Al₂O_3−xGd₂O₃ (x = 5, 10, 20, 30 mol.%) ceramic samples were prepared by the high-temperature solid-state synthesis method. The thermochemical reaction behavior, reaction products, and growth kinetics of the reaction layer for the ceramics with molten CMAS at 1300 °C were investigated. The results reveal that the primary reaction products between Al₂O_3−xGd₂O₃ ceramics and molten CMAS are anorthite (CaAl₂Si₂O₈), gehlenite (Ca₂Al(AlSi)O₇), spinel (MgAl₂O₄), and Gd-apatite (Ca₂Gd₈(SiO₄)₆O₂). In the initial reaction stage, a dense double-layer reaction layer composed of anorthite and spinel is formed at the ceramic/CMAS interface, while its growth rate decreases with increasing reaction time. Increasing the Gd₂O₃ doping content inhibits the growth of the reaction layer and enhances the CMAS penetration resistance of Al₂O_3−xGd₂O₃ ceramics. The mechanism is discussed systematically. Full article