Publications

As composites gain wider acceptance in all sectors of the economy, new methodologies must be developed to increase their cost effectiveness in manufacturing. The neoteric Resin Infusion between Double Flexible Tooling (RIDFT) process is undergoing modifications to improve its cost-effectiveness by developing methodologies for in-mold coating and the incorporation of UV curing. In-mold coating is desired by the composites industry since it eliminates the current paint process, which is not only laborious and time consuming, but expensive, and presents safety issues. Two methodologies (paint films and coinfusion) for implementing in-mold coating were investigated. It was demonstrated that thermoformable paint films could be used to produce coated RIDFTed components. Coinfusion was also successfully implemented. This work also investigated the feasibility of designing and incorporating a Cure on Demand system into the RIDFT process, using ultraviolet (UV) light for the curing of composite laminates. The objective was to develop a process for the RIDFT that would eliminate or reduce the inflexibility in the current production process, resulting in shortened production cycle times. UV-cured laminates were produced at a fraction of the time required to produce catalyst-cured laminates. Mechanical and material characterization tests were performed on each of the UV-cured laminates produced. The results were referenced against those obtained for laminates produced using a catalyst curing system to determine their overall quality. The UV-cured laminates, after undergoing tensile and rheological thermal tests, were found to have mechanical and material properties comparable, or in a few instances slightly better, than that of thermally cured laminates.

Less toxic, storable, hypergolic propellants are desired to replace nitrogen tetroxide (NTO) and hydrazine in certain applications. Hydrogen peroxide is a very attractive replacement oxidizer, but finding acceptable replacement fuels is more challenging. The focus of this investigation is to find fuels that have short hypergolic ignition delays, high specific impulse, and desirable storage properties. The resulting hypergolic fuel/oxidizer combination would be highly desirable for virtually any high energy-density applications such as small but powerful gas generating systems, attitude control motors, or main propulsion. These systems would be implemented on platforms ranging from guided bombs to replacement of environmentally unfriendly existing systems to manned space vehicles.

Biomanufacturing has the potential to be one of the defining technologies in the upcoming century. Research, development, and applications in the fields of biotechnology, bioengineering, biodetection, biomaterials, biocomputation and bioenergy will have dramatic impact on both the products we are able to create, and the ways in which we create them. In this report, we examine current research trends in biotechnology, identify key areas where biomanufacturing will likely be a major contributing field, and report on recent developments and barriers to progress in key areas.

Magnesium vanadates are potentially important catalytic materials for the conversion of alkanes to alkenes via oxidative dehydrogenation. However, little is known about the active sites at which the catalytic reactions take place. It may be possible to obtain a significant increase in the catalytic efficiency if the effects of certain material properties on the surface reactions could be quantified and optimized through the use of appropriate preparation techniques. Given that surface reactivity is often dependent upon surface structure and that the atomic level structure of the active sites in these catalysts is virtually unknown, we desire thin film samples consisting of a single magnesium vanadate phase and a well defined crystallographic orientation in order to reduce complexity and simplify the study of active sites. This report describes the use of reactive RF sputter deposition to fabricate very highly oriented, stoichiometric Mg{sub 3}(VO{sub 4}){sub 2} thin films, and subsequent studies of the reactivity of these films under reaction conditions typically found during oxidative dehydrogenation. We demonstrate that the synthesis methods employed do in fact result in stoichiometric films with the desired crystallographic orientation, and that the chemical behavior of the films closely approximates that of bulk, high surface area Mg{sub 3}(VO{sub 4}){sub 2} powders. We further use these films to demonstrate the effects of oxygen vacancies on chemical behavior, demonstrate that surface composition can vary significantly under reaction conditions, and obtain the first evidence for structure sensitivity in Mg{sub 3}(VO{sub 4}){sub 2} catalysts.

Abstract not provided.

Thermionic energy conversion in a microminiature format shows potential as a viable, high efficiency, on-chip power source. Microminiature thermionic converters (MTC) with inter-electrode spacings on the order of microns are currently being prototyped and evaluated at Sandia. The remaining enabling technology is the development of low work function materials and processes than can be integrated into these converters. In this report, the authors demonstrate a method of incorporating thin film emitters into converters using rf sputtering. They find that the resultant films possess a minimum work function of 1.2 eV. Practical energy conversion is hindered by surface work function non-uniformity. They postulate the source of this heterogeneity to be a result of limited bulk and surface transport of barium. Several methods are proposed for maximizing transport, including increased film porosity and the use of metal terminating layers. They demonstrate a novel method for incorporating film porosity based on metal interlayer coalescence.

Magnesium vanadates are potentially important catalytic materials for the conversion of alkanes to alkenes via oxidative dehydrogenation. However, little is known about the active sites at which the catalytic reactions take place. It may be possible to obtain a significant increase in the catalytic efficiency if the effects of certain material properties on the surface reactions could be quantified and optimized through the use of appropriate preparation techniques. Given that surface reactivity is often dependent upon surface structure and that the atomic level structure of the active sites in these catalysts is virtually unknown, we desire thin film samples consisting of a single magnesium vanadate phase and a well defined crystallographic orientation in order to reduce complexity and simplify the study of active sites. We report on the use of reactive RF sputter deposition to fabricate very highly oriented, stoichiometric Mg{sub 3}(VO{sub 4}){sub 2} thin films for use in these surface analysis studies. Deposition of samples onto amorphous substrates resulted in very poor crystallinity. However, deposition of Mg{sub 3}(VO{sub 4}){sub 2} onto well-oriented, lattice-matched thin film ''seed'' layers such as Ti(0001), Au(111), or Pt(111) resulted in very strong preferential (042) crystallographic orientation (pseudo-hexagonal oxygen planes parallel to the substrate). This strong preferential growth of the Mg{sub 3}VO{sub 4}{sub 2} suggests epitaxial (single-crystal) growth of this mixed metal oxide on the underlying metal seed layer. The effects of the seed layer material, deposition temperature, and post-deposition reactive treatments on thin film properties such as stoichiometry, crystallographic orientation, and chemical interactions will be discussed.

Deposition parameters were found to have a marked effect on piezoelectric response of reactive radio frequency (RF) sputtered AlN thin films. The authors observed peizoelectric response values ranging from {minus}3.5 to +4.2 pm/V for 1 {micro}m thick AlN films deposited onto Ti/Ru electrode stacks. An investigation of the effects of deposition parameters, in particular the nature of the Ru/AlN interface, was conducted. The lag time between deposition of adjacent thin film layers appeared to have the greatest affect on the value of the piezoelectric response. This suggests that chemical reaction occurring on the Ru thin film surface is responsible for changing an important thin film property such as dipole orientation within the overlying AlN thin film.

Uncooled pyroelectric IR imaging systems, such as night vision goggles, offer important strategic advantages in battlefield scenarios and reconnaissance surveys. Until now, the current technology for fabricating these devices has been limited by low throughput and high cost which ultimately limit the availability of these sensor devices. We have developed and fabricated an alternative design for pyroelectric IR imaging sensors that utilizes a multilayered thin film deposition scheme to create a monolithic thin film imaging element on an active silicon substrate for the first time. This approach combines a thin film pyroelectric imaging element with a thermally insulating SiO{sub 2} aerogel thin film to produce a new type of uncooled IR sensor that offers significantly higher thermal, spatial, and temporal resolutions at a substantially lower cost per unit. This report describes the deposition, characterization and optimization of the aerogel thermal isolation layer and an appropriate pyroelectric imaging element. It also describes the overall integration of these components along with the appropriate planarization, etch stop, adhesion, electrode, and blacking agent thin film layers into a monolithic structure. 19 refs., 8 figs., 6 tabs.

There has been little systematic study of the cause of dead (inactive) layers in II-VI phosphors used in thin film electroluminescent devices. This paper discusses preparation and characterization of rf sputter deposited Eu-doped Sr sulfide (SrS:Eu) thin films for use in a study to determine the cause of the dead layer. (The dead layer`s behavior is likely influenced by thin film composition, crystallinity, and microstructure.) We have deposited SrS:Eu thin films in a repeatable, consistent manner and have characterized properties such as composition, crystallinity, and microstructure as well as photoluminescent (PL) and electroluminescent behavior. The composition was determined using Rutherford backscattering spectrometry and electron microprobe analysis. XRD was used to assess crystalline orientation and grain size, SEM to image thin film microstructure. Measuring the PL decay after subnanosecond laser excitation in the lowest absorption band of the dopant allowed direct measurement of the dopant luminescence efficiency.

Sputter deposition of ZnS:Mn/SrS:Ce multilayered broad-band ``white`` emission thin film electroluminescent (TFEL) stacks has been investigated. To date, deposition of these multilayers has been limited to vacuum evaporation techniques and atomic layer epitaxy, both of which require two different substrate temperatures for growth of high quality ZnS and SrS. This repeated thermal cycling during multilayer deposition can induce stress, defects, and interdiffusion with adversely affect EL performance. Sputter deposition of ZnS and SrS produces high quality TFELs for a wider range of substrate temperatures. Both materials can be sputter deposited at a common temperature (300-350{degrees}C) which eliminates the need for thermal cycling and increases manufacturability. Luminance outputs from sputter deposited ZnS and SrS thin films are comparable to those from evaporated films, making sputtering an attractive alternative deposition technique for these materials. We report on the effects of sputter deposition parameters including chamber pressure, substrate temperature, and H2S process gas partial pressure on the resultant composition and morphology of ZnS:Mn and SrS:Ce thin films and multilayers. Their EL performance was evaluated and correlated to composition and morphology.