thin film coating
DESCRIPTION
Its a presentation at CSIR CGCRI on thin film coating using ultrasonic sprayTRANSCRIPT
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Thin Film CoatingUsing
Ultrasonic Spray Nozzles
Manoj D. Bhataria([email protected])
Inventys Research Company Pvt. Ltd.Particle Science
503-504, Keshava, Bandra-Kurla Complex, Bandra (East), Mumbai 400051
AOFC 2015CGCRI, Kolkata
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 1 / 21
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Outline of this Presentation
1 What is a Thin Film?Some definitions of Thin FilmsDeposition Techniques
2 Ultrasonic AtomisationUltrasonic and LiquidsOperation of an Ultrasonic NozzleConstruction of an Ultrasonic Nozzle
3 ApplicationsPEM Fuel CellCoating MethodsFC Coating Comparison
4 ConclusionAdvantages of Ultrasonic SprayReferences
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 2 / 21
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Outline of this Presentation
1 What is a Thin Film?Some definitions of Thin FilmsDeposition Techniques
2 Ultrasonic AtomisationUltrasonic and LiquidsOperation of an Ultrasonic NozzleConstruction of an Ultrasonic Nozzle
3 ApplicationsPEM Fuel CellCoating MethodsFC Coating Comparison
4 ConclusionAdvantages of Ultrasonic SprayReferences
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 2 / 21
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Outline of this Presentation
1 What is a Thin Film?Some definitions of Thin FilmsDeposition Techniques
2 Ultrasonic AtomisationUltrasonic and LiquidsOperation of an Ultrasonic NozzleConstruction of an Ultrasonic Nozzle
3 ApplicationsPEM Fuel CellCoating MethodsFC Coating Comparison
4 ConclusionAdvantages of Ultrasonic SprayReferences
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 2 / 21
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Outline of this Presentation
1 What is a Thin Film?Some definitions of Thin FilmsDeposition Techniques
2 Ultrasonic AtomisationUltrasonic and LiquidsOperation of an Ultrasonic NozzleConstruction of an Ultrasonic Nozzle
3 ApplicationsPEM Fuel CellCoating MethodsFC Coating Comparison
4 ConclusionAdvantages of Ultrasonic SprayReferences
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 2 / 21
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What is a Thin Film?
PC Magazine Encyclopedia
A thin film is a microscopically thin layer of material that is deposited ontoa metal, ceramic, semiconductor or plastic base.
Wikipedia
A thin film is a layer of material ranging from fractions of a nanometer(mono-layer) to several micrometers in thickness.
Smith
Thin film technology involves deposition of individual molecules or atoms,whereas thick film technology involves deposition of particles.
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 3 / 21
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What is a Thin Film?
PC Magazine Encyclopedia
A thin film is a microscopically thin layer of material that is deposited ontoa metal, ceramic, semiconductor or plastic base.
Wikipedia
A thin film is a layer of material ranging from fractions of a nanometer(mono-layer) to several micrometers in thickness.
Smith
Thin film technology involves deposition of individual molecules or atoms,whereas thick film technology involves deposition of particles.
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 3 / 21
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What is a Thin Film?
PC Magazine Encyclopedia
A thin film is a microscopically thin layer of material that is deposited ontoa metal, ceramic, semiconductor or plastic base.
Wikipedia
A thin film is a layer of material ranging from fractions of a nanometer(mono-layer) to several micrometers in thickness.
Smith
Thin film technology involves deposition of individual molecules or atoms,whereas thick film technology involves deposition of particles.
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 3 / 21
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What is Thin?
Foll
A film is thin if its thickness is in some order of magnitude smaller thansome intrinsic length scale of the system we are considering.
Example
For a flat surface of the dimension dx dy and a layer of dz on it.The layer would be classified as thin, if
dz dx , dy .
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 4 / 21
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What is Thin?
Foll
A film is thin if its thickness is in some order of magnitude smaller thansome intrinsic length scale of the system we are considering.
Example
For a flat surface of the dimension dx dy and a layer of dz on it.The layer would be classified as thin, if
dz dx , dy .
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 4 / 21
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What is Thin?
Foll
A film is thin if its thickness is in some order of magnitude smaller thansome intrinsic length scale of the system we are considering.
Example
For a flat surface of the dimension dx dy and a layer of dz on it.The layer would be classified as thin, if
dz dx , dy .
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 4 / 21
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What is a Film?
Foll
A film should be solid
Adherance to the substrate
Uniformity over the substrate (thickness)
Homogenity of the coating (composition)
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 5 / 21
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What is a Film?
Foll
A film should be solid
Adherance to the substrate
Uniformity over the substrate (thickness)
Homogenity of the coating (composition)
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 5 / 21
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What is a Film?
Foll
A film should be solid
Adherance to the substrate
Uniformity over the substrate (thickness)
Homogenity of the coating (composition)
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 5 / 21
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What is a Film?
Foll
A film should be solid
Adherance to the substrate
Uniformity over the substrate (thickness)
Homogenity of the coating (composition)
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 5 / 21
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Deposition Techniques
Chemical
PlatingI Dip Coating, Electroplating, etc
Chemical Solution DepositionI Sol-Gels, etc
Chemical Vapour DepositionI MOCVD, PECVD, ALD, etc
Physical
Spray DepositionI Ultrasonic nozzle, Electrospray, etc
Physical Vapour DepositionI Evaporative
MBE, etcI Sputtering
PLD, Arc-PVD, etc
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 6 / 21
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Deposition Techniques
Chemical
PlatingI Dip Coating, Electroplating, etc
Chemical Solution DepositionI Sol-Gels, etc
Chemical Vapour DepositionI MOCVD, PECVD, ALD, etc
Physical
Spray DepositionI Ultrasonic nozzle, Electrospray, etc
Physical Vapour DepositionI Evaporative
MBE, etcI Sputtering
PLD, Arc-PVD, etc
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 6 / 21
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Progress of this Presentation
1 What is a Thin Film?Some definitions of Thin FilmsDeposition Techniques
2 Ultrasonic AtomisationUltrasonic and LiquidsOperation of an Ultrasonic NozzleConstruction of an Ultrasonic Nozzle
3 ApplicationsPEM Fuel CellCoating MethodsFC Coating Comparison
4 ConclusionAdvantages of Ultrasonic SprayReferences
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 7 / 21
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What is Ultrasonic Atomisation?
Figure: A Typical Ultrasonic Bath1
1Sono-tek Corp., USA
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 8 / 21
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What is Ultrasonic Atomisation?
Making the Wave
1 When liquid is added to a resonating nozzle,waves are formed on the atomizing surface
2 Increasing the power causes the wave peaks toget so high that droplets fall off the tips of thewave.
3 These droplets have a mathematically definablesize.
4 Notice also that less of the atomizing surface isused (for a given flow rate).
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 9 / 21
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What is Ultrasonic Atomisation?
Making the Wave
1 When liquid is added to a resonating nozzle,waves are formed on the atomizing surface
2 Increasing the power causes the wave peaks toget so high that droplets fall off the tips of thewave.
3 These droplets have a mathematically definablesize.
4 Notice also that less of the atomizing surface isused (for a given flow rate).
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 9 / 21
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What is Ultrasonic Atomisation?
Making the Wave
1 When liquid is added to a resonating nozzle,waves are formed on the atomizing surface
2 Increasing the power causes the wave peaks toget so high that droplets fall off the tips of thewave.
3 These droplets have a mathematically definablesize.
4 Notice also that less of the atomizing surface isused (for a given flow rate).
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 9 / 21
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What is Ultrasonic Atomisation?
Making the Wave
1 When liquid is added to a resonating nozzle,waves are formed on the atomizing surface
2 Increasing the power causes the wave peaks toget so high that droplets fall off the tips of thewave.
3 These droplets have a mathematically definablesize.
4 Notice also that less of the atomizing surface isused (for a given flow rate).
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 9 / 21
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What is Ultrasonic Atomisation?
Figure: Close-ups of a Crest2
2Sono-tek Corp., USA
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 10 / 21
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Some Maths
Wavelength of Capillary Waves
C =(8sf 2
)1/3where, C = wavelength of the capillary wave,s = surface tension of the liquid, = density of the liquid andf = frequency of the vibration.
Number Mean Drop Diameter
dN,0.5 = 0.34 (8sf 2
)1/3where, dN,0.5 = that diameter, in a sample of Ndrops, for which half of the drops are smaller than,and the other half larger than dN,0.5
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 11 / 21
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An Ultrasonic Nozzle
Figure: Construction of an Ultrasonic Nozzle 3
3Sono-tek Corp., USA
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 12 / 21
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Progress of this Presentation
1 What is a Thin Film?Some definitions of Thin FilmsDeposition Techniques
2 Ultrasonic AtomisationUltrasonic and LiquidsOperation of an Ultrasonic NozzleConstruction of an Ultrasonic Nozzle
3 ApplicationsPEM Fuel CellCoating MethodsFC Coating Comparison
4 ConclusionAdvantages of Ultrasonic SprayReferences
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 13 / 21
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Components of a PEM Fuel Cell
Figure: Components of a PEM fuel cell 4
Coated Components of a PEM Fuel Cell
Membrane
Gas Diffusion Layer
Bipolar Plate4E. G. & G. Technical Services, Inc., Fuel Cell Handbook, Department of Energy, USA, 2004.
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 14 / 21
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Coating Methods
Figure: Area Fill Figure: Inward Spiral
Ultrasonic Coating Methods
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 15 / 21
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Coating Methods
Figure: Area Fill Figure: Inward Spiral
Ultrasonic Coating Methods
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 15 / 21
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Comparison of Coatings
Figure: SEM images of Hand Painted and Screen Painted GDEsManoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 16 / 21
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Comparison of Coatings
Figure: SEM images of Ultrasonic Nozzle Coated GDEsManoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 17 / 21
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Comparison of Coatings
Peak PowerPt. Loading Hand Painted Ultrasonic Spray0.40 mg/cm2 1.7 W /mg 1.7 W /mg
0.15 mg/cm2 3.5 W /mg 4.5 W /mg
0.05 mg/cm2 9.8 W /mg 10.9 W /mg
Peak Power Comparison5
(Hand Painted and Ultrasonic Spray Coated GDEs)
5Millington, B., et al, A novel method for preparing proton exchange membrane fuel cell electrodes by the
ultrasonic-spray technique, Journal of Power Sources, 196, 8500-8508, 2011.
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 18 / 21
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Progress of this Presentation
1 What is a Thin Film?Some definitions of Thin FilmsDeposition Techniques
2 Ultrasonic AtomisationUltrasonic and LiquidsOperation of an Ultrasonic NozzleConstruction of an Ultrasonic Nozzle
3 ApplicationsPEM Fuel CellCoating MethodsFC Coating Comparison
4 ConclusionAdvantages of Ultrasonic SprayReferences
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 19 / 21
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Advantages of Ultrasonic Spray Nozzles
Ultrasonic nozzles are proven with all common coating materials
Waste reduction from 20% 75%
Controllable droplet size
Excellent repeatability
Ultrasonic nozzle are non-clogging
Scalability from R&D to high volume production lines
Deagglomeration of catalysts increases active surface area, resultingin reduction of expensive platinum use
Excellent stiction (high durability of coatings)
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 20 / 21
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References
1 Sono-tek Inc, http://www.sono-tek.com
2 Berger, H., Ultrasonic Liquid Atomisation : Theory and applications,PHP, Hyde Park, NY, 1998.
3 E. G. & G. Technical Services, Inc., Fuel Cell Handbook, Departmentof Energy, USA, 2004.
4 Senthil Kumar, A., Development of a Novel Light Weight BipolarPlate System for Polymer Electrolyte Fuel Cells, M.Tech. Thesis,Dept. of Energy Science & Engineering, IIT Bombay, Mumbai, 2009.
5 Hoffman, C. J. and Walczyk, D. F., Development of a PEM Fuel CellElectrode Coating Testbed, Proceedings of the ASME 2010 EighthInternational Fuel Cell Science, Engineering and TechnologyConference, FuelCell2010, Brooklyn, New York, 2010.
6 Millington, B., et al, A novel method for preparing proton exchangemembrane fuel cell electrodes by the ultrasonic-spray technique,Journal of Power Sources, 196, 8500-8508, 2011.
Manoj D. Bhataria (Inventys) Thin Film Coating 12/Mar/2015 21 / 21
What is a Thin Film?Some definitions of Thin FilmsDeposition Techniques
Ultrasonic AtomisationUltrasonic and LiquidsOperation of an Ultrasonic NozzleConstruction of an Ultrasonic Nozzle
ApplicationsPEM Fuel CellCoating MethodsFC Coating Comparison
ConclusionAdvantages of Ultrasonic SprayReferences