iab project abstract/description form · 2019. 9. 10. · -general protective coatings for the...

IAB PROJECT ABSTRACT/DESCRIPTION FORM INVESTIGATORS: Prof. Jyotirmoy Mazumder (Primary), Joonghan Shin (Participant)

ABSTRACT/DESCRIPTION: Multi-energy processing can be applied for novel thin film deposition, synthesis of new phase of materials, enhancement of film growth rate, efficient removal of materials and other applications. Our approach is to use multi-energy source to perform different functions, ablation and heat treatment, to get the desired materials. Potential application can be found in a wide range of fields, both in the military and commercial sectors. Benefits from some of the developed techniques will also have applications in the area of diagnostics and materials analysis PROGRESS TO DATE: - Ni superalloy film deposition experiment under L9 Daguchi DOE - Investigation of microstructure and growth behavior of the Ni superalloy films with XRD (X-ray diffraction) and SEM. - Investigation of effects of the process parameters on the process. - Investigation of film growth behavior in cavities

BENEFITS TO MEMBERS (Achieved and Anticipated) This research will open up new avenues for hard and protective coatings at a lower temperature which is useful for both aerospace industry and ground transportation industry. Moreover, in conjunction with the single crystal deposition work one can explore co-deposition of superalloy and TBC leading to more robust fabrication technique for components for high temperature use. The basic research will lead to fundamental understanding of thin coating of ceramic and metal by laser ablation by plasma diagnostics during the process and post analysis to determine structure property relationship. The proposed project will support research training for graduate students at the two institutions participating in the proposed research effort. The universities will be able to provide a more comprehensive educational experience for the students and students will be able to develop research skills and gain valuable experience in both basic science and the engineering application of new technologies. This off-campus experience will broaden their knowledge and provide opportunities for collaboration and technology transfer.

MILESTONES - Process parameters for homoepitaxial Ni superalloy film deposition were found. - Experimental parameters to give a main effect on the process were found. - Comparison of film growth behavior between on smooth and rough (cavity regions) surface was implemented.

NSF I/UCRC BOARD MEETING May 2007NSF I/UCRC BOARD MEETING May 2007

Center for Lasers and plasmas for Advanced Manufacturing

Thin film production by multi energyprocessing based on pulsed laser de

position technique

JoonghanJoonghan Shin and Shin and JyotiJyoti MazumderMazumder


ContentsContents

PART Ⅰ: Background and Motivation of the project

- Multi energy processing

- Impact and Benefits

PART Ⅱ: Some achievements of the project

- Ni-base superalloy film deposition

- Investigation of microstructure and growth behavior of the films with XRD (X-ray diffraction) and SEM.

- Investigation of the film growth behavior in cavities

PART Ⅲ: Future work


Background and motivation of the project -1Background and motivation of the project -1

Multi energy processingMulti energy processing

- Good quality film (smooth, large uniformity, good stoichiometry and mechanical properties)

- Increase of film growth rate

Substrate

Laser1

α β

Laser2

Target

Plume/Plasma

Electric field

Heat

Expected results

Use advantages result from combination of multi energy sources(Reduce chance of splashing, enhancedexcitation and expansion of plume plasma, attraction and acceleration of ionparticles)


Background and motivation of the project -3Background and motivation of the project -3

Technical impact and BenefitsTechnical impact and Benefits

- Several technological benefits in the areasof hard and corrosion protective coatingsfor mechanical components

- Potential application in the military / commercialsectors and in the area of diagnostics / materials analysis

- High quality film (smooth, large uniformity, goodstoichiometry and thermo-mechanical properties)

- Increase of film growth rate / provide control for the development of new phase of materials


Some achievements of the projectSome achievements of the project

Ni base superalloy film deposition experiment was carried out under the L9 Daguchi DOE (4 parameters and 3 levels)to investigate effects of the each process parameter on the process.

- Investigation of microstructure and growth behavior of the films with XRD (X-ray diffraction) and SEM.

- Investigation of the film growth behavior in cavities

Updated ones

Previous ones

1. Characterization study of YSZ film (Film surface morphology, mechanical properties)

2. Experimental investigation of the effect of the electric field assisted PLD process on the collection rate


Potential applications- General protective coatings for the components used under the extreme environment (high temperature, hot corrosion and oxidation, wear)- A bond coat in the thermal barrier coating (TBC) system

Ni based super-alloy film deposition-1Ni based super-alloy film deposition-1

The result of 2500 h low altitude sea flight service on an uncoated and NiAl coated blade turbine blade, from Eskner M., PhD thesis, Royal Institute of Technology, Stockholm, 2004

UncoatedUncoated Ni-Al coatedNi-Al coated


Experimental setup for PLD processing with substrate heating systemExperimental setup for PLD processing with substrate heating system

Substrate holder and heating system assemblySubstrate holder and heating system assembly

Vacuumchamber

Pumpsystem

Powersupply

+

-~V

Beam Target

Substrateholder /heatingsystemassembly

Electric feedthrough

Heater

Single crystalNi super-alloysubstrate

Thermocouple

Electrical connection parts



Design of experiment (DOE)Design of experiment (DOE)

1233L9

3123L8

2313L7

2132L6

1322L5

3212L4

3331L3

2221L2

1111L1

DCBA

Taguchi method : 4 parameters / 3 levels

20

120

3

900

2

10

90

2

850

1 3

4B (Pulse energy fluence, J/cm^2)

30D (Pulse repetition rate, Hz)

150C (Deposition time, min)

950A (Temp, ℃)

Level

Parameter

DOE matrix



XRD analysis of the films


Temperature increase

Pulse energy increase



Group1: 850 ℃

Group2: 900 ℃

Group3: 950 ℃

- Films deposited under different conditions show the XRDpatterns of the stronger polycrystalline characteristic assubstrate temperature and pulse energy increase


SEM images of the film cross sectionsSEM images of the film cross sections

L1 L5L8

Film Film

Substrate SubstrateSubstrate

Film

Substrate / filminterface

γ

γ’

Single crystal film

γ’

γγ

γ’

γ: Ni matrix, γ’: coherent and ordered Ni3Al precipitation


AFM analysis of SC Ni superalloy film

Roughness (rms) : 9.76nmHeight difference : 20~30nm


10

30

20

20

10

30

30

20

10

Pulse repetition rate (Hz)

111204950L9

10903950L8

51502950L7

61504900L6

6903900L5

41202900L4

41504850L3

21203850L2

1902850L1

ResponseDeposition time (min)

Pulse energy(J/cm^2)

Temperature(℃)

- Response 1 : when a film shows same peak pattern ( (100) and (200) Ni3Al ) as thatof SC substrate

- Add additional counts to response whenever other film growth direction is found

Definition of the response in the process

Analysis of the effect of each process parameter



Mea

n of

resp

onse

for i

ndiv

idua

l pro

cess

par

amet

er

Process parameter

Mea

n of

sig

nal t

o no

ise

ratio

for i

ndiv

idua

l pro

cess

par

amet

er

Process parameter

- According to statistical calculation with the defined response of the process, it was found thattemperature and pulse energy are variables to give significant effect on the process.Deposition time and pulse repetition rate are variables to give relatively small influence onthe process ( steeper slope means more significant effect )

- It was also found that 850 ℃, 2J/cm^2, 90min, 20Hz are variables to give high signal to noise ratioof the process (smaller minus value is better S/N ratio, points enclosed by circles)

Analysis of the effect of each process parameter



Film deposition in cavityFilm deposition in cavity

Cavity area Smooth areaγ

γ’

Scratch by diamond saw

Etch treated film surface

Film deposition condition : L1



~150um

Smooth area

Film

substrate

substrate

FilmFilm

substrate

SEM images of the film cross section in cavities



~300um

Film

Film

Filmsubstrate

substrate

substrate

Ni based super-alloy film Ni based super-alloy film deposition-12deposition-12

SEM images of the film cross section in cavities


Future workFuture work

Experimental work for multi energy process

- Preparation of experimental setup for Electric field assistedand dual beam process

- Investigate film properties: smoothness, particle density,mechanical properties

- Microstructure analysis of films

- Film growth rate measurement / Spectroscopic study

iab project abstract/description form · 2019. 9. 10. · -general protective coatings for the...

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