Pb-Zr-Ti-O (PZT) perovskites span a large solid-solution range and have found widespread use due to their piezoelectric and ferroelectric properties that also span a large range. Crystal structure analysis via Rietveld refinement facilitates materials analysis via the extraction of the structural parameters. These parameters, often obtained as a function of an additional dimension (e.g., pressure), can help to diagnose materials response within a use environment. Often referred to as in-situ studies, these experiments provide an abundance of data. Viewing structural changes due to applied pressure conditions can give much-needed insight into materials performance. However, challenges exist for viewing/presenting results when the details are inherently three-dimensional (3D) in nature. For PZT perovskites, the use of polyhedra (e.g., Zr/Ti-O6 octahedra) to view bonding/connectivity is beneficial; however, the visualization of the octahedra behavior with pressure dependence is less easily demonstrated due to the complexity of the added pressure dimension. We present a more intuitive visualization by projecting structural data into virtual reality (VR). We employ previously published structural data for Pb0.99(Zr0.95Ti0.05)0.98Nb0.02O3 as an exemplar for VR visualization of the PZT R3c crystal structure between ambient and 0.62 GPa pressure. This is accomplished via our in-house CAD2VR™ software platform and the new CrystalVR plugin. The use of the VR environment enables a more intuitive viewing experience, while enabling on-the-fly evaluation of crystal data, to form a detailed and comprehensive understanding of in-situ datasets. Discussion of methodology and tools for viewing are given, along with how recording results in video form can enable the viewing experience.
Refractory complex concentrated alloys are an emerging class of materials that attracts attention due to their stability and performance at high temperatures. In this study, we investigate the variations in the mechanical and thermal properties across a broad compositional space for the refractory MoNbTaTi quaternary using high-throughput ab-initio calculations and experimental characterization. For all the properties surveyed, we note a good agreement between our modeling predictions and the experimentally measured values. We reveal the particular role of molybdenum (Mo) to achieve high strength when in high concentration. We trace the origin of this phenomenon to a shift from metallic to covalent bonding when the Mo content is increased. Additionally, a mechanistic, dislocation-based description of the yield strength further explains such high strength due to a combination of high bulk and shear moduli, accompanied by the relatively small size of the Mo atom compared to the other atoms in the alloy. Our analysis of the thermodynamics properties shows that regardless of the composition, this class of quaternary alloys shows good stability and low sensitivity to temperature. Taken together, these results pave the way for the design of new high-performance refractory alloys beyond the equimolar composition found in high-entropy alloys.
The electric discharge across a varistor granule filled air gap under a fast-rising voltage pulse was investigated for surge protection applications. The effects of temperature and pressure on the arc and the electrical conduction were analyzed by the characteristic changes in voltage waveforms triggered by a fast-rising high voltage pulse. In addition to the gap size, experimental results show that competing mechanisms among arc conduction, conduction through the varistor granule network, thermionic emission from Joule heating at granule-to-granule contact points, and the magnitude of the switching voltage dictate the maximum surge protection voltage for the filled air gap. Experimental evidence indicated that accumulated degradation was created at small contact points between varistor granules by repetitive assaults from longer duration, high voltage pulses. The uniqueness of using varistor over other dielectric granules in an air gap for surge protection is identified and discussed.
Electric discharge across an air gap can be self-healing, providing a unique capability for repetitive, fast, high-voltage/current switching applications through arc conduction. Furthermore, incorporating dielectric granules in the air gap stimulates gas ionization, which lowers the breakdown voltage and narrows breakdown voltage distribution, thereby enabling engineered surge protection from multiple lightning strikes on aerospace vehicles and sensitive solid-state electronics in critical systems. This study investigates the effect of the permittivity of dielectric granules, gap filling, surface roughness, and metal work function on fast-rising, high-voltage breakdowns. In addition to the air gap width, these factors play important roles in gas ionization, field concentration, and initiation of electrical discharge and arcing. Therefore, they could potentially be used to control and narrow operational breakdown voltages for practical applications. Additionally, a modified Langevin-Debye model is developed to correlate the breakdown voltage and the permittivity of the dielectric filler. These investigations identify and highlight key underpinning mechanisms governing the gas discharge behavior across a dielectric filled air gap during voltage surge events.
This report documents an effort to improve the energy resolution for a thallium doped cesium iodide (CsI:T1) scintillator paired with a spectrum matching photomultiplier tube (PMT). A comparison of the differences in the pulse height spectra from thallium doped (CsI:T1) and sodium doped (CsI:Na) single crystals with PMTs of different spectrum responses was performed. Results show that energy resolution of the detector only improves 0.5% at room temperature when these scintillators are coupled with a spectrum matching PMT. Based on a spectrum matching PMT, the best results for energy resolution are 7.39% and 7.88% for CsI:T1 and CsI:Na scintillators, respectively. The improvement is primarily attributed to the increase of photon statistics from the increase of photons (N) being detected in the spectrum matching PMT. Other factors, such as optical quantum yield and non-proportionality of the CsI:T1 and CsI:Na crystals, that can affect the energy resolution were also studied and reported. The results indicate that although the use of a spectrum matching PMT enhances the photon statistics, it also exacerbates the nonproportionality response. Consequently, a promised improvement on energy resolution due solely to photon statistics was not fully realized.
TlBr can surpass CZT as the leading semiconductor for γ- A nd X-radiation detection. Unfortunately, the optimum properties of TlBr quickly decay when an operating electrical field is applied. Quantum mechanical studies indicated that if this property degradation comes from the conventional mechanism of ionic migration of vacancies, then an unrealistically high vacancy concentration is required to account for the rapid aging of TlBr seen in experiments. In this work, we have applied large scale molecular dynamics simulations to study the effects of dislocations on ionic migration of TlBr crystals under electrical fields. We found that electrical fields can drive the motion of edge dislocations in both slip and climb directions. These combined motions eject enormous vacancies in the dislocation trail. Both dislocation motion and a high vacancy concentration can account for the rapid aging of the TlBr detectors. These findings suggest that strengthening methods to pin dislocations should be explored to increase the lifetimes of TlBr crystals.
It has been widely believed that crystalline TlBr can surpass CdZnTe to become the leading semiconductor for γ- and X- radiation detection. The major hurdle to this transition is the rapid aging of TlBr under the operating electrical field. Here, while ionic migration of vacancies has been traditionally the root cause for property degradation, quantum mechanical calculations indicated that the vacancy concentration needed to cause the observed aging must be orders of magnitude higher than the usual theoretical estimate. Recent molecular dynamics simulations and X-ray diffract ion experiments have shown that electrical fields can drive the motion of edge dislocations in both slip and climb directions. Furthermore, these combined motions eject a large number of vacancies. Both dislocation mot ion and vacancy ejection can account for the rapid aging of the TlBr detectors. Based on these new discoveries, the present work applies molecular dynamics simulations to “develop” aging-resistant TlBr crystals by inhibiting dislocation motions.
A preliminary finite-element model has been developed using the ALEGRA-FE code for explosive driven depoling of a PZT 95/5 ferroelectric generator. The ferroelectric material is characterized using hysteresis-loop and hydrostatic depoling tests. These characteristics are incorporated into ALEGRA-FE simulations that model the explosive drive mechanism and shock environment in the material leading to depoling, as well as the ferroelectric response and the behavior of a coupled circuit. The ferroelectric-to-antiferroelectric phase transition is captured, producing an output voltage pulse that matches experimental data to within 10% in rise time, and to within about 15% for the final voltage. Both experimental and modeled pulse magnitudes are less than the theoretical maximum output of the material. Observations from materials characterization suggest that unmodeled effects such as trapped charge in the stored FEG material may have influenced the experimentally observed output.
Various versions of deep borehole nuclear waste disposal have been proposed in the past in which effective sealing of a borehole after waste emplacement is generally required. In a high temperature disposal mode, the sealing function will be fulfilled by melting the ambient granitic rock with waste decay heat or an external heating source, creating a melt that will encapsulate waste containers or plug a portion of the borehole above a stack of the containers. However, there are certain drawbacks associated with natural materials, such as high melting temperatures, inefficient consolidation, slow crystallization kinetics, the resulting sealing materials generally being porous with low mechanical strength, insufficient adhesion to waste container surface, and lack of flexibility for engineering controls. In this study, we showed that natural granitic materials can be purposefully engineered through chemical modifications to enhance the sealing capability of the materials for deep borehole disposal. The present work systematically explores the effect of chemical modification and crystallinity (amorphous vs. crystalline) on the melting and crystallization processes of a granitic rock system. The approach can be applied to modify granites excavated from different geological sites. Several engineered granitic materials have been explored which possess significantly lower processing and densification temperatures than natural granites. Those new materials consolidate more efficiently by viscous flow and accelerated recrystallization without compromising their mechanical integrity and properties.
The powder-bed laser additive manufacturing (AM) process is widely used in the fabrication of three-dimensional metallic parts with intricate structures, where kinetically controlled diffusion and microstructure ripening can be hindered by fast melting and rapid solidification. Therefore, the microstructure and physical properties of parts made by this process will be significantly different from their counterparts produced by conventional methods. This work investigates the microstructure evolution for an AM fabricated AlSi10Mg part from its nonequilibrium state toward equilibrium state. Special attention is placed on silicon dissolution, precipitate formation, collapsing of a divorced eutectic cellular structure, and microstructure ripening in the thermal annealing process. These events alter the size, morphology, length scale, and distribution of the beta silicon phase in the primary aluminum, and changes associated with elastic properties and microhardness are reported. The relationship between residual stress and silicon dissolution due to changes in lattice spacing is also investigated and discussed.
TlBr has the properties to become the leading radiation detection semiconductor. It has not yet been deployed due to a short lifetime of only hours to weeks. While the rapid structural deteriorations must come from ionic conduction under operating electrical fields, detailed aging mechanisms have not been understood. As a result, progress to extend lifetime has been limited despite extensive studies in the past. We have developed new atomistic simulation capabilities to enable study of ionic conduction under electrical fields. Our combined simulations and experiments indicate that dislocations in TlBr climb under electrical fields. This climb is the root cause for structural deterioration. Hence, we discovered new strengthening methods to reduce aging. Our new atomistic simulation approach can have broader impact on other Sandia programs including battery research. Our project results in 4 publications, a new invention, new LAMMPS capabilities, solution to mission relevant materials, and numerous presentations.
TlBr crystals have superior radiation detection properties; however, their properties degrade in the range of hours to weeks when an operating electrical field is applied. To account for this rapid degradation using the widely-accepted vacancy migration mechanism, the vacancy concentration must be orders of magnitude higher than any conventional estimates. The present work has incorporated a new analytical variable charge model in molecular dynamics (MD) simulations to examine the structural changes of materials under electrical fields. Our simulations indicate that dislocations in TlBr move under electrical fields. This discovery can lead to new understanding of TlBr aging mechanisms under external fields.
TlBr is promising for g- and x- radiation detection, but suffers from rapid performance degradation under the operating external electric fields. To enable molecular dynamics (MD) studies of this degradation, we have developed a Stillinger-Weber type of TlBr interatomic potential. During this process, we have also addressed two problems of wider interests. First, the conventional Stillinger-Weber potential format is only applicable for tetrahedral structures (e.g., diamond-cubic, zinc-blende, or wurtzite). Here we have modified the analytical functions of the Stillinger-Weber potential so that it can now be used for other crystal structures. Second, past modifications of interatomic potentials cannot always be applied by a broad community because any new analytical functions of the potential would require corresponding changes in the molecular dynamics codes. Here we have developed a polymorphic potential model that simultaneously incorporates Stillinger-Weber, Tersoff, embedded-atom method, and any variations (i.e., modified functions) of these potentials. As a result, we have implemented this polymorphic model in MD code LAMMPS, and demonstrated that our TlBr potential enables stable MD simulations under external electric fields.
Elpasolite scintillators are a large family of halides which includes compounds reported to meet the NA22 program goals of <3% energy resolution at 662 keV1. This work investigated the potential to produce quality elpasolite compounds and alloys of useful sizes at reasonable cost, through systematic experimental and computational investigation of crystal structure and properties across the composition space. Discovery was accelerated by computational methods and models developed previously to efficiently identify cubic members of the elpasolite halides, and to evaluate stability of anion and cation exchange alloys.
An ideal 3He detector replacement for the near- to medium-term future will use materials that are easy to produce and well understood, while maintaining thermal neutron detection efficiency and gamma rejection close to the 3He standard. Toward this end, we investigated the use of standard alkali halide scintillators interfaced with 6Li and read out with photomultiplier tubes (PMTs). Thermal neutrons are captured on 6Li with high efficiency, emitting high-energy and triton (3H) reaction products. These particles deposit energy in the scintillator, providing a thermal neutron signal; discrimination against gamma interactions is possible via pulse shape discrimination (PSD), since heavy particles produce faster pulses in alkali halide crystals. We constructed and tested two classes of detectors based on this concept. In one case 6Li is used as a dopant in polycrystalline NaI; in the other case a thin Li foil is used as a conversion layer. In the configurations studied here, these systems are sensitive to both gamma and neutron radiation, with discrimination between the two and good energy resolution for gamma spectroscopy. We present results from our investigations, including measurements of the neutron efficiency and gamma rejection for the two detector types. We also show a comparison with Cs2LiYCl6:Ce (CLYC), which is emerging as the standard scintillator for simultaneous gamma and thermal neutron detection, and also allows PSD. We conclude that 6Li foil with CsI scintillating crystals has near-term promise as a thermal neutron detector in applications previously dominated by 3He detectors. The other approach, 6Li-doped alkali halides, has some potential, but require more work to understand material properties and improve fabrication processes.
This work was funded by the U.S. Department of Energy Office of Nonproliferation Research to develop elpasolite materials, with an emphasis on high-atomic-number rare-earth elpasolites for gamma-ray spectrometer applications. Low-cost, high-performance gamma-ray spectrometers are needed for detection of nuclear proliferation. Cubic materials, such as some members of the elpasolite family (A2BLnX6; Ln-lanthanide and X-halogen), hold promise due to their high light output, proportionality, and potential for scale-up. Using both computational and experimental studies, a systematic investigation of the compositionstructureproperty relationships of these high-atomic-number elpasolite halides was performed. The results reduce the barrier to commercialization of large single crystals or transparent ceramics, and will facilitate economical scale-up of elpasolites for high-sensitivity gamma-ray spectroscopy.
Ceramic based nanocomposites have recently demonstrated the ability to provide enhanced permittivity, increased dielectric breakdown strength, and reduced electromechanical strain making them potential materials systems for high energy density applications. A systematic characterization and optimization of barium titanate and PLZT based nanoparticle composites employing a glass or polymer matrix to yield a high energy density component will be presented. This work will present the systematic characterization and optimization of barium titanate and lead lanthanum zirconate titanate nanoparticle based ceramics. The nanoparticles have been synthesized using solution and pH-based synthesis processing routes and employed to fabricate polycrystalline ceramic and nanocomposite based components. The dielectric/ferroelectric properties of these various components have been gauged by impedance analysis and electromechanical response and will be discussed.
A2BLnX6 elpasolites (A, B: alkali; Ln: lanthanide; X: halogen), LaBr3 lanthanum bromide, and AX alkali halides are three classes of the ionic compound crystals being explored for {gamma}-ray detection applications. Elpasolites are attractive because they can be optimized from combinations of four different elements. One design goal is to create cubic crystals that have isotropic optical properties and can be grown into large crystals at lower costs. Unfortunately, many elpasolites do not have cubic crystals and the experimental trial-and-error approach to find the cubic elpasolites has been prolonged and inefficient. LaBr3 is attractive due to its established good scintillation properties. The problem is that this brittle material is not only prone to fracture during services, but also difficult to grow into large crystals resulting in high production cost. Unfortunately, it is not always clear how to strengthen LaBr3 due to the lack of understanding of its fracture mechanisms. The problem with alkali halides is that their properties decay rapidly over time especially under harsh environment. Here we describe our recent progress on the development of atomistic models that may begin to enable the prediction of crystal structures and the study of fracture mechanisms of multi-element compounds.
Attractive for numerous technological applications, ferroelectronic oxides constitute an important class of multifunctional compounds. Intense experimental efforts have been made recently in synthesizing, processing and understanding ferroelectric nanostructures. This work will present the systematic characterization and optimization of barium titanate and lead lanthanum zirconate titanate nanoparticle based ceramics. The nanoparticles have been synthesized using several solution and pH-based synthesis processing routes and employed to fabricate polycrystalline ceramic and nanocomposite based components. The dielectric and ferroelectric properties of these various components have been gauged by impedance analysis and electromechanical response and will be discussed.
Structural phase transformations between ferroelectric (FE), antiferroelectric (AFE), and paraelectric (FE) phases are frequently observed in the zirconia-rich phase region on the lead zirconate-titanate (PZT) phase diagram. Since the free energy difference among these phases is small, phase transformation can be easily induced by temperature, pressure and electric field. These induced transformation characteristics have been used for many practical applications. This study focuses on a hydrostatic pressure induced FE-to-AFE phase transformation in a tin modified PZT ceramic (PSZT). The relative phase stability between FE and AFE phases is determined by the dielectric permittivity measurement as a function of temperature from -60 C to 125 C. A pressure-temperature phase diagram for the PSZT system will be presented.
The development of more reliable scintillator materials can significantly advance the gamma-ray detection technology. Scintillator materials such as lanthanum halides (e.g., LaBr{sub 3}, CsBr{sub 3}), elpasolites (e.g., Cs{sub 2}LiLaBr{sub 6}, Cs{sub 2}NaLaBr{sub 6}, and Cs{sub 2}LiLaI{sub 6}), and alkali halides (e.g., CsI, NaI) are extremely brittle. The fracture of the materials is often a problem causing the failure of the devices. Lanthanum halides typically have a hexagonal crystal structure. These materials have highly anisotropic thermal and mechanical properties, and therefore they are likely to fracture under cyclic thermal and mechanical loading conditions. For example, fracture of lanthanum halides is known to occur in the field. Fracture during synthesis also complicates the growth of large lanthanum halide single crystals needed for sensitive radiation detection, and accounts for the high production cost of these materials. Elpasolites can have both cubic and non-cubic crystal structures depending on the constituent elements and composition of the compounds. This provides an opportunity to design cubic elpasolites with more isotropic properties and therefore improved mechanical performances. However, the design of an optimized cubic elpasolite crystal remains elusive because there is a tremendous number of possible elpasolites and the design criterion for cubic crystals is not clear. Alkali halides have cubic crystal structures. Consequently, large CsI and NaI crystals have been grown and used in devices. However, these materials suffer from an aging problem, i.e., the properties decay rapidly over time especially under harsh environment. Unfortunately, the fundamental mechanisms of this aging have not been understood and the path to improve the alkali halide-based scintillators is not developed. Clearly, improved scintillator materials can be achieved via strengthened/toughened lanthanum halides, optimized cubic elpasolites, or new alkali halide-based crystals that are more resistant to aging. Without a fundamental understanding of the atomic origins of the mechanical and the thermodynamic properties of materials, past experimental efforts to develop improved scintillator materials have been prolonged. Here we report our recent progress on the development of atomistic models that can be used to accelerate the discovery of new scintillator materials with improved properties. First, we have developed a novel embedded-ion method interatomic potential approach that analytically addresses the variable charge interactions between atoms in ionic compound material systems. Based on this potential, molecular dynamics simulations have been used to study the mechanical properties of LaBr3 including slip systems, dislocation core structures, and material strength. We have also developed an atomistic model that can already be used to predict crystal structures and to derive crystal stability rules for alkali halides. This model is under further development for prediction of crystal structures of elpasolites. These efforts will facilitate the design of better scintillator materials.
This late start RTBF project started the development of barium titanate (BTO)/glass nanocomposite capacitors for future and emerging energy storage applications. The long term goal of this work is to decrease the size, weight, and cost of ceramic capacitors while increasing their reliability. Ceramic-based nanocomposites have the potential to yield materials with enhanced permittivity, breakdown strength (BDS), and reduced strain, which can increase the energy density of capacitors and increase their shot life. Composites of BTO in glass will limit grain growth during device fabrication (preserving nanoparticle grain size and enhanced properties), resulting in devices with improved density, permittivity, BDS, and shot life. BTO will eliminate the issues associated with Pb toxicity and volatility as well as the variation in energy storage vs. temperature of PZT based devices. During the last six months of FY09 this work focused on developing syntheses for BTO nanoparticles and firing profiles for sintering BTO/glass composite capacitors.
Nanocrystalline and nanostructured materials offer unique microstructure-dependent properties that are superior to coarse-grained materials. These materials have been shown to have very high hardness, strength, and wear resistance. However, most current methods of producing nanostructured materials in weapons-relevant materials create powdered metal that must be consolidated into bulk form to be useful. Conventional consolidation methods are not appropriate due to the need to maintain the nanocrystalline structure. This research investigated new ways of creating nanocrystalline material, new methods of consolidating nanocrystalline material, and an analysis of these different methods of creation and consolidation to evaluate their applicability to mesoscale weapons applications where part features are often under 100 {micro}m wide and the material's microstructure must be very small to give homogeneous properties across the feature.
Thermal properties of niobium-modified PZT95/5(1.8Nb) and PSZT ceramics used for the ferroelectric power supply have been studied from -100 C to 375 C. Within this temperature range, these materials exhibit ferroelectric-ferroelectric and ferroelectric-paraelectric phase transformations. The thermal expansion coefficient, heat capacity, and thermal diffusivity of different phases were measured. Thermal conductivity and Grueneisen constant were calculated at several selected temperatures between -60 C and 100 C. Results show that thermal properties of these two solid solutions are very similar. Phase transformations in these ceramics possess first order transformation characteristics including thermal hysteresis, transformational strain, and enthalpy change. The thermal strain in the high temperature rhombohedral phase region is extremely anisotropic. The heat capacity for both materials approaches to 3R (or 5.938 cal/(g-mole*K)) near room temperature. The thermal diffusivity and the thermal conductivity are quite low in comparison to common oxide ceramics, and are comparable to amorphous silicate glass. Furthermore, the thermal conductivity of these materials between -60 C and 100 C becomes independent of temperature and is sensitive to the structural phase transformation. These phenomena suggest that the phonon mean free path governing the thermal conductivity in this temperature range is limited by the lattice dimensions, which is in good agreement with calculated values. Effects of small compositional changes and density/porosity variations in these ceramics on their thermal properties are also discussed. The implications of these transformation characteristics and unusual thermal properties are important in guiding processing and handling procedures for these materials.
To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of representative Newtonian viscosity is dependent on the amount of heating of the initially room temperature mold. An early 3D transient model shows that the initial design of the distributor is sub-optimal. However, these simulations take several months to run on 4 processors of an HP workstation using a preconditioner/solver combination of ILUT/GMRES with fill factors of 3 and PSPG stabilization. Therefore, several modifications to the distributor geometry and orientations of the vents and molds have been investigated using much faster 3D steady-state simulations. The pressure distribution for these steady-state calculations is examined for three different distributor designs to see if this can indicate which geometry has the superior design. The second modification, with a longer distributor, is shown to have flatter, more monotonic isobars perpendicular to the flow direction indicating a better filling process. The effects of the distributor modifications, as well as effects of the mold orientation, have also been examined with laboratory experiments in which the flow of a viscous Newtonian oil entering transparent molds is recorded visually. Here, the flow front is flatter and voids are reduced for the second geometry compared to the original geometry. A horizontal orientation, as opposed to the planned vertical orientation, results in fewer voids. Recently, the Navier-Stokes equations have been stabilized with the Dohrman-Bochev PSPP stabilization method, allowing us to calculate transient 3D simulations with computational times on the order of days instead of months. Validation simulations are performed and compared to the experiments. Many of the trends of the experiments are captured by the level set modeling, though quantitative agreement is lacking mainly due to the high value of the gas phase viscosity necessary for numerical stability, though physically unrealistic. More correct trends are predicted for the vertical model than the horizontal model, which is serendipitous as the actual mold is held in a vertical geometry. The full, transient mold filling calculations indicate that the flow front is flatter and voids may be reduced for the second geometry compared to the original geometry. The validated model is used to predict mold filling for the actual process with the material properties for the PZT paste, the original distributor geometry, and the mold in a vertical orientation. This calculation shows that voids may be trapped at the four corners of the mold opposite the distributor.
Solid solutions of lead-based perovskites are the backbone materials of the piezoelectric components for transducer, actuator, and resonator applications. These components, typically small in size, are fabricated from large sintered ceramic slugs using grinding and lapping processes. These operations increase manufacturing costs and produce a large hazardous waste stream, especially when component size decreases. To reduce costs and hazardous wastes associated with the production of these components, an injection molding technique is being investigated to replace the machining processes. The first step in the new technique is to compound an organic carrier with a ceramic powder. The organic carrier is a thermoplastic based system composed of a main carrier, a binder, and a surfactant. Understanding the rheology of the compounded material is necessary to minimize the creation of defects such as voids or cavities during the injection-molding process. An experiment was performed to model the effects of changes in the composition and processing of the material on the rheological behavior. Factors studied included: the surfactant of the organic carrier system, the solid loading of the compounded material, and compounding time. The effects of these factors on the viscosity of the material were investigated.
The microstructure and mechanical properties of niobium-modified lead zirconate titanate (PNZT) 95/5 ceramics, where 95/5 refers to the ratio of lead zirconate to lead titanate, were evaluated as a function of lead (Pb) stoichiometry. Chemically-prepared PNZT 95/5 is produced at Sandia National Laboratories by the Ceramics and Glass Processing Department (14154) for use as voltage elements in ferroelectric neutron generator power supplies. PNZT 95/5 was prepared according to the nominal formulation of Pb{sub 0.991+x}(Zr{sub 0.955}Ti{sub 0.045}){sub 0.982}Nb{sub 0.018}O{sub 3+x}, where x (-0.0274 {approx}< x {approx}< 0.0297) refers to the mole fraction of Pb and O that deviated from the stoichiometric value. The Pb concentrations were determined from calcined powders; no adjustments were made to Pb compositions due to weight loss during sintering. The microstructure (second phases, fracture mode and grain size) varied appreciably with Pb stoichiometry, whereas the mechanical properties (hardness, fracture toughness, strength and Weibull parameters) exhibited modest variation. Specimens deficient in Pb, 2.74% (x = -0.0274) and 2.15% (x = -0.02150), had a high area fraction of a zirconia (ZrO{sub 2}) second phase on the order of 0.02. As the Pb content in solid solution increased the ZrO{sub 2} content decreased; no ZrO{sub 2} was observed for the specimen containing 2.97% excess Pb (x = 0.0297). Over the range of Pb stoichiometry most specimens fractured predominately transgranularly; however, 2.97% Pb excess PNZT 95/5 fractured predominately intergranularly. No systematic changes in hardness or Weibull modulus were observed as a function of Pb content. Fracture toughness decreased slightly from 1.8 MPa{center_dot}m{sup 1/2} for Pb deficient specimens to 1.6 MPa{center_dot}m{sup 1/2} for specimens with excess Pb. Although there are microstructural differences with changes in Pb content, the mechanical properties did not vary substantially. However, the average failure stress and fracture toughness for PNZT 95/5 containing 2.97% excess Pb decreased slightly. It is expected that additional increases in Pb content would result in further mechanical property degradation. The decrease in mechanical properties for the 2.97% Pb excess ceramics could be the result of a weaker PbO-rich grain boundary phase present in the material. If better mechanical properties are desired, it is recommended that PNZT 95/5 ceramics are processed by a method whereby any excess Pb is depleted from the final sintered ceramic so that near-stoichiometric values of Pb concentration are reached. Otherwise, a PbO-rich grain boundary phase may exist in the ceramic which could potentially be detrimental to the mechanical properties of PNZT 95/5 ceramics.
The goal of this project was to identify a viable, non-destructive methodology for the detection of cracks in electrically poled piezoelectric ceramics used in neutron generator power supply units. The following methods were investigated: Impedance Spectroscopy, Scanning Acoustic Microscopy, Lock-in Thermography, Photo-acoustic Microscopy, and Scanned Vicinal Light. In addition to the exploration of these techniques for crack detection, special consideration was given to the feasibility of integrating these approaches to the Automatic Visual Inspection System (AVIS) that was developed for mapping defects such as chips, pits and voids in piezoelectric ceramic components. Scanned Vicinal Light was shown to be the most effective method of automatically detecting and quantifying cracks in ceramic components. This method is also very effective for crack detection in other translucent ceramics.
The hydrostatically induced ferroelectric(FE)-to-antiferroelectric(AFE) phase transformation for chemically prepared niobium modified PZT 95/5 ceramics was studied as a function of density and pore former type (Lucite or Avicel). Special attention was placed on the effect of different pore formers on the charge release behavior associated with the FE-to-AFE phase transformation. Within the same density range (7.26 g/cm3 to 7.44 g/cm3), results showed that ceramics prepared with Lucite pore former exhibit a higher bulk modulus and a sharper polarization release behavior than those prepared with Avicel. In addition, the average transformation pressure was 10.7% greater and the amount of polarization released was 2.1% higher for ceramics with Lucite pore former. The increased transformation pressure was attributed to the increase of bulk modulus associated with Lucite pore former. Data indicated that a minimum volumetric transformational strain of -0.42% was required to trigger the hydrostatically induced FE-to-AFE phase transformation. This work has important implications for increasing the high temperature charge output for neutron generator power supply units.
We used a regeneratively amplified Ti:sapphire femtosecond laser to create optical birefringence in an isotropic glass medium. Between two crossed polarizers, regions modified by the femtosecond laser show bright transmission with respect to the dark background of the isotropic glass. This observation immediately suggests that these regions possess optical birefringence. The angular dependence of transmission through the laser-modified region is consistent with that of an optically birefringent material. Laser-induced birefringence is demonstrated in different glasses, including fused silica and borosilicate glass. Experimental results indicate that the optical axes of laser-induced birefringence can be controlled by the polarization direction of the femtosecond laser. The amount of laser-induced birefringence depends on the pulse energy level and number of accumulated pulses.
The polarization reversal process in a rhombohedral ferroelectric ceramic material was investigated using field-induced strain measurements and texture development. Special attention was focused on the difference in the field-induced strains between the first quarter cycle and subsequent loading conditions. Results show that the initial field-induced strain is about twelve times greater than the subsequent strain, which immediately suggests that mechanisms involved in these conditions during the polarization reversal process are different. The difference in the magnitude of field-induced strain is discussed in terms of 180 degree and non-180 degree domain reorientation processes.
Meso-scale manufacturing processes are bridging the gap between silicon-based MEMS processes and conventional miniature machining. These processes can fabricate two and three-dimensional parts having micron size features in traditional materials such as stainless steels, rare earth magnets, ceramics, and glass. Meso-scale processes that are currently available include, focused ion beam sputtering, micro-milling, micro-turning, excimer laser ablation, femtosecond laser ablation, and micro electro discharge machining. These meso-scale processes employ subtractive machining technologies (i.e., material removal), unlike LIGA, which is an additive meso-scale process. Meso-scale processes have different material capabilities and machining performance specifications. Machining performance specifications of interest include minimum feature size, feature tolerance, feature location accuracy, surface finish, and material removal rate. Sandia National Laboratories is developing meso-scale mechanical components and actuators which require meso-scale parts fabricated in a variety of materials. Subtractive meso-scale manufacturing processes expand the functionality of meso-scale components and complement silicon based MEMS and LIGA technologies.
Chemically prepared Pb(Zr0.95Ti0.05)O3 (PZT 95/5) ceramics were fabricated with a range of different porosity levels, while grain size was held constant, by systematic additions of added organic pore former (Avicel). Use of Avicel in amounts ranging from 0 to 4.0 wt% resulted in fired ceramic densities that ranged from 97.3% to 82.3%. Hydrostatic-pressure-induced ferroelectric (FE) to antiferroelectric (AFE) phase transformations were substantially more diffuse and occurred at lower hydrostatic pressures with increasing porosity. An ∼12 MPa decrease in hydrostatic transformation pressure per volume percent added porosity was observed. The decrease in transformation pressure with decreasing density was quantitatively consistent with the calculated macroscopic stress required to achieve a specific volumetric macrostrain (0.40%). This strain was equivalent to experimentally measured macrostrain for FE-to-AFE transformation. The macroscopic stress levels were calculated using measured bulk modulus values that decreased from 84 to 46 GPa as density decreased from 97.3% to 82.3%. Good agreement between calculated and measured values of FE-to-AFE transformation stress was obtained for ceramics fired at 1275° and 1345°C.
Meso-scale manufacturing processes are bridging the gap between silicon-based MEMS processes and conventional miniature machining. These processes can fabricate two and three-dimensional parts having micron size features in traditional materials such as stainless steels, rare earth magnets, ceramics, and glass. Meso-scale processes that are currently available include, focused ion beam sputtering, micro-milling, micro-turning, excimer laser ablation, femto-second laser ablation, and micro electro discharge machining. These meso-scale processes employ subtractive machining technologies (i.e., material removal), unlike LIGA, which is an additive meso-scale process. Meso-scale processes have different material capabilities and machining performance specifications. Machining performance specifications of interest include minimum feature size, feature tolerance, feature location accuracy, surface finish, and material removal rate. Sandia National Laboratories is developing meso-scale electro-mechanical components, which require meso-scale parts that move relative to one another. The meso-scale parts fabricated by subtractive meso-scale manufacturing processes have unique tribology issues because of the variety of materials and the surface conditions produced by the different meso-scale manufacturing processes.
This report summarizes materials issues associated with advanced micromachines development at Sandia. The intent of this report is to provide a perspective on the scope of the issues and suggest future technical directions, with a focus on computational materials science. Materials issues in surface micromachining (SMM), Lithographic-Galvanoformung-Abformung (LIGA: lithography, electrodeposition, and molding), and meso-machining technologies were identified. Each individual issue was assessed in four categories: degree of basic understanding; amount of existing experimental data capability of existing models; and, based on the perspective of component developers, the importance of the issue to be resolved. Three broad requirements for micromachines emerged from this process. They are: (1) tribological behavior, including stiction, friction, wear, and the use of surface treatments to control these, (2) mechanical behavior at microscale, including elasticity, plasticity, and the effect of microstructural features on mechanical strength, and (3) degradation of tribological and mechanical properties in normal (including aging), abnormal and hostile environments. Resolving all the identified critical issues requires a significant cooperative and complementary effort between computational and experimental programs. The breadth of this work is greater than any single program is likely to support. This report should serve as a guide to plan micromachines development at Sandia.
A substantial decrease in hydrostatic ferroelectric (FE) to antiferroelectric (AFE) transformation pressure was measured for Pb(Zr{sub 0.949}Ti{sub 0.051}){sub 0.989}Nb{sub 0.0182}O{sub 3} ceramics with decreasing grain size. The 150 MPa decrease in hydrostatic FE to AFE transformation pressure over the grain size range of 8.5 {micro}m to 0.7{micro}m was shown to be consistent with enhanced internal stress with decreasing grain size. Further, the Curie Point decreased and the dielectric constant measured at 25 C increased with decreasing grain size. All three properties: dielectric constant magnitude, Curie point shift and FE to AFE phase transformation pressure were shown to be semi-quantitatively consistent with internal stress differences on the order of 100 MPa. Calculations of Curie point shifts from the Clausius-Clapeyron equation, using internal stress levels derived from the hydrostatic depoling characteristics, were consistent with measured values.
Embedded resistor circuits have been generated with the use of a Micropen system Ag conductor paste (DuPont 6142D), a new experimental resistor ink from DuPont (E84005-140), and Low Temperature Co-fired Ceramic (LTCC) green tape (DuPont A951). Sample circuits were processed under varying peak temperature ranges (835 C-875 C) and peak soak times (10 min-720 min). Resistors were characterized by SEM, TEM, EDS, and high-temperature XRD. Results indicate that devitrification of resistor glass phase to Celcian, Hexacelcian, and a Zinc-silicate phase occurred in the firing ranges used (835-875 C) but kinetics of divitrification vary substantially over this temperature range. The resistor material appears structurally and chemically compatible with the LTCC. RuO{sub 2} grains do not significantly react with the devitrifying matrix material during processing. RuO{sub 2} grains coarsen significantly with extended time and temperature and the electrical properties appear to be strongly affected by the change in RuO{sub 2} grain size.
In October 1996, an interdisciplinary team began a three-year LDRD project to study the plasma processes of reactive ion etching and plasma-enhanced chemical vapor deposition on large-area silicon devices. The goal was to develop numerical models that could be used in a variety of applications for surface cleaning, selective etching, and thin-film deposition. Silicon solar cells were chosen as the experimental vehicle for this project because an innovative device design was identified that would benefit from immediate performance improvement using a combination of plasma etching and deposition processes. This report presents a summary of the technical accomplishments and conclusions of the team.
Chemically prepared Pb(Zr{sub 0.951}Ti{sub 0.949}){sub 0.982}Nb{sub 0.018}O{sub 3} ceramics were fabricated that were greater than 95% dense for sintering temperatures as low as 925 C. Achieving high density at low firing temperatures permitted isolation of the effects of grain size, from those due to porosity, on both dielectric and pressure induced transformation properties. Specifically, two samples of similar high density, but with grain sizes of 0.7 {micro}m and 8.5 {micro}m, respectively, were characterized. The hydrostatic ferroelectric (FE) to antiferroelectric (AFE) transformation pressure was substantially less (150 MPa) for the lower grain size material than for the larger grain size material. In addition, the dielectric constant increased and the Curie temperature decreased for the sample with lower grain size. All three properties: dielectric constant magnitude, Curie point shift, and FE to AFE phase transformation pressure were shown to be semi-quantitatively consistent with internal stress levels on the order of 100 MPa.
The electrical properties were investigated for ruthenium oxide based devitrifiable resistors embedded within low temperature co-fired ceramics. Special attention was given to the processing conditions and their affects on resistance and temperature coefficient of resistance (TCR). Results indicate that the conductance for these buried resistors is limited by tunneling of charge carriers through the thin glass layer between ruthenium oxide particles. A modified version of the tunneling barrier model is proposed to more accurately account for the microstructure ripening observed during thermal processing. The model parameters determined from curve fitting show that charging energy (i.e., the energy required for a charge carrier to tunnel through the glass barrier) is strongly dependent on particle size and particle-particle separation between ruthenium oxide grains. Initial coarsening of ruthenium oxide grains was found to reduce the charging energy and lower the resistance. However, when extended ripening occurs, the increase in particle-particle separation increases the charging energy, reduces the tunneling probability and gives rise to a higher resistance. The trade-off between these two effects results an optimum microstructure with a minimum resistance and TCR. Furthermore, the TCR of these resistors has been shown to be governed by the magnitude of the charging energy. Model parameters determined by our analysis appear to provide quantitative physical interpretations to the microstructural change in the resistor, which in turn, are controlled by the processing conditions.
High temperature XRD has been employed to monitor the devitrification of Dupont 951 low temperature co-fired ceramic (LTCC) and Dupont E84005 resistor ink. The LTCC underwent devitrification to an anorthite phase in the range of 835-875 C with activation energy of 180 kJ/mol as calculated from kinetic data. The resistor paste underwent devitrification in the 835-875 C range forming monoclinic and hexagonal celcian phases plus a phase believed to be a zinc-silicate. RuO{sub 2} appeared to be stable within this devitrified resistor matrix. X-ray radiography of a co-fired circuit indicated good structural/chemical compatibility between the resistor and LTCC.