Advances in Surface Engineering: Session II
Sponsored by: TMS Surface Engineering Committee
Program Organizers: Rajeswaran Radhakrishnan, Faraday Technology Inc; Timothy Hall, Faraday Technology Inc; Michael Roach, University of Mississippi Medical Center; Sandip Harimkar, Oklahoma State University; Tushar Borkar, Cleveland State University; Rajeev Gupta, North Carolina State University; Bharat Jasthi, South Dakota School of Mines & Technology
Tuesday 8:00 AM
October 11, 2022
Room: 328
Location: David L. Lawrence Convention Center
Session Chair: Rajeswaran Radhakrishnan, Faraday Technology, Inc
8:00 AM
Control of Tin Coating Properties Using Pulse and Pulse Reverse Electrodeposition: Holly Garich1; Tim Hall1; Brian Skinn1; Danny Liu1; 1Faraday Technology, Inc.
Use of tin coatings is industrially important in the fabrication of electronics, corrosion protection in automotive sectors and in lithium-ion batteries. The scalability of electrodeposition, in which metallic films are formed from application of an electric current, makes it an industrially important process. In the present work, use of pulse electrodeposition is used to control the properties of pure tin deposits for applications including printed circuit board fabrication and novel battery structures. Properties including stress, grain size, crystallographic texture and morphology are controlled through use of pulse and pulse reverse electrodeposition processes in simple methanesulfonic acid electrolytes. Thermal cycling and high temperature humidity storage tests have been conducted to assess the propensity for whisker formation in these tin deposits, and further, dense and uniform tin coatings covering high surface area copper substrates has been demonstrated for novel battery applications.
8:20 AM
Graded Coatings of IN 625 Alloy Reinforced with Ni3Al Precipitates Processed In-situ: Viviane Mazur1; Ana Sofia d'Oliveira2; Maurício Mazur3; 1Universidade Tecnológica Federal do Paraná; 2Universidade Federal do Paraná; 3Universidade Estadual de Ponta Grossa
Hardfacing coatings take advantage of multilayer deposition to minimize negative impacts of dilution on substrate. This study takes a step further using multilayer to mitigate dilution and also impose a compositional gradient, adding functionality to hardfacing coating. Smooth and sharp multilayered graded IN625 coatings were processed by Plasma Transferred Arc using powder mixtures of Ni and Al (Ni+25wt.%Al), aiming to impose compositional gradients in IN625 without compromising weldability and simultaneously gain oxidation resistance. Sharp gradients were obtained depositing 80wt.%(Ni+Al) on top of IN625 layer, while smooth gradients were obtained with increasing Ni+Al content in five layers (10, 20, 40, 80wt.%) added to IN625. Results shows in-situ synthesis of Ni3Al precipitates and absence of cracks, confirming that weldability was not compromised. Coating hardness and oxidation resistance were improved with the imposed gradient. Different mechanisms of strengthening were observed and are related to the with Al content in the powder mixtures.
8:40 AM
Irreversible Bonding of Polymer-based Microfluidic Systems to Support Biological Experiments on the International Space Station (ISS): Annaliza Perez-Torres1; Paul Kuehl1; Shelby Giza1; Molly Sullivan1; 1Space Tango
Polymers are appealing substrate materials for microfluidic systems, including various benefits in developing low-mass and low-cost reusable devices to support biological experiments in the International Space Station (ISS). While much research focuses on the rapid manufacturing of thermoplastic microfluidic components, sealing these microfluidic devices to create enclosed microchannels allows biological experiments to function on the ISS. In this study, we use mechanical etching and chemical treatments such as aminopropyltriethoxysilane (APTES) and 3-glycidoxypropyltrimethoxysilane (GLYMO) to treat the surfaces of the Polyether ether ketone (PEEK) and Polydimethylsiloxane (PDMS). The microfluidic structures are bonded using biocompatible thermal and UV curable glues, which can hold pressures up to 21 psi. The changes in surface properties will be characterized using different techniques, and we validate the biocompatibility of the bonded materials according to ISO 10993.
9:00 AM
Multiscale Surface Structure Formation on Fused Silica by Ultrafast Lasers: Kewei Li1; Xin Zhao1; 1Clemson University
Glass materials integrated with advanced functions, such as anti-fogging and self-cleaning functions, are urgently demanded in applications such as eyeglasses, goggles, and windows. Surface morphology is essential for determining surface functions, such as wettability. The ultrafast pulsed laser is a promising tool for generating surface structures and subsequently controlling the surface functionality. In the case of glass, however, the formation mechanisms of different structures and their influence on surface wettability remain unknown. This study investigates the formation of micro/nano-surface structures on fused silica by ultrafast laser irradiation, and their impacts on surface wettability. The effects of laser fluence, overlapping ratio, and repetition rate on the structure morphology are studied. Different processing conditions permit the formation of different types of structures, which are enabled by different underlying mechanisms. Surface wetting qualities vary depending on the structure type. The relationship is established between laser parameters, surface structures, surface roughness, and surface wettability.
9:20 AM
The Impact of Viscosity on Coating Atomization Patterns and Paint Lay Down: Michael Bonner1; 1Saint Clair Systems, Inc.
For any manufacturing environment that involves painting, the paint process is the most expensive process in the plant. It is the most expensive to build and operate, and accounts for more rework and scrap than any other department. Setting up a new part or paint color is a tedious process. Checking the result of this process requires painting parts, running them through the cure process, then spending countless hours inspecting each part to determine if the process was successful. Each defect can require hours or even days to resolve. In this study, in cooperation with CFAN, a manufacturer of high-tech composite jet engine turbine blades we utilized the SprayVision System to analyze the impact of temperature-based viscosity variations on spray application performance.The results demonstrate how easy it is to generate inconsistency in an otherwise carefully controlled process.
9:50 AM
Surface Modification of Ti-6Al-4V for Dust Adhesion Mitigation in Lunar Environment: Lopamudra Das1; Samuel Hocker2; Brodan Richter2; Christopher Wohl2; 1National Institute of Aerospace; 2NASA Langley Research Center
Materials selected for successful lunar exploration must endure the harsh lunar environment and be resilient toward lunar dust interactions. Lunar dust is chemically reactive, jagged, abrasive, electrostatically charged, and strongly adheres to surfaces causing contamination and component failure. The titanium alloy, Ti-6Al-4V, is widely used in aerospace applications due to its high strength, low density, and excellent corrosion resistance. It is a potential structural material for many lunar surface missions. Developing Ti-6Al-4V surfaces to passively mitigate lunar dust adhesion contributes to an enduring presence on the lunar surface. In this study, several topographies were generated on Ti-6Al-4V surfaces using traditional abrasive polishing and novel laser processing techniques. Lunar dust simulant adhesion was determined using controlled vibration. Surface characterization results suggest that dust mitigation properties are correlated with surface topography. This indicates that tailored topographical modification may enable Ti-6Al-4V surfaces to exhibit dust adhesion mitigating properties for lunar and space applications.