Coating and Thin Film Materials for Energy, Aerospace, Environment and Biological Applications: Advanced Coating and Thin Films
Sponsored by: TMS Surface Engineering Committee, TMS Thin Films and Interfaces Committee
Program Organizers: Jing Zhang, Indiana University – Purdue University Indianapolis; Yeon-Gil Jung, Korea Institute of Ceramic Engineering & Technology; Albert Feuerstein, Praxair Surface Technologies, Inc. (retired); Raymond Sinatra, Rolls-Royce Corporation (retired); Li Li, Rolls-Royce Corporation

Tuesday 2:00 PM
November 3, 2020
Room: Virtual Meeting Room 27
Location: MS&T Virtual

Session Chair: Jing Zhang, Indiana University - Purdue University Indianapolis; Yeon-Gil Jung, Changwon National University; Albert Feuerstein, Praxair Surface Technologies (retired); Raymond Sinatra, Rolls-Royce Corporation (retired); Li Li, Rolls-Royce Corporation

2:00 PM
Rapid, Selective, Ambient Growth and Optimization of Copper Benzene-1,3,5-Tricarboxylate (Cu−BTC) Metal−organic Framework Thin Films on a Conductive Metal Oxide for Sensing Applications: Scott Crawford¹; Ki-Joong Kim¹; Yang Yu¹; Paul Ohodnicki¹; ¹National Energy Technology Laboratory
    Metal−organic frameworks (MOFs) exhibit tremendous promise in sensing applications. However, the incorporation of MOFs onto sensing platforms such as optical fibers requires thin film growth techniques that are high-quality, scalable, and manufacturable. Here, a facile, rapid strategy to grow copper benzene-1,3,5-tricarboxylate (Cu−BTC) MOF thin films using the plasmonic substrate aluminum-doped zinc oxide (AZO) as a seed layer is demonstrated. The AZO templates Cu−BTC growth, with MOF formation only occurring on the AZO layer, allowing growth chemicals to be recycled. A dense Cu-BTC film is obtained within 10 minutes at room temperature, circumventing energy-intensive heating steps and long reaction times. We demonstrate that variables including the copper precursor anion, solvent conditions, and pH can systematically fine-tune both the packing density and size of the MOF crystals on AZO. The technique described here is rapid and applicable to a variety of substrates, providing a robust strategy for incorporating MOFs into sensing devices

2:20 PM
Forming Al Tab to Cu Busbar Joints Using Low Pressure Cold Spray Process: Volf Leshchynsky¹; Roman Maev¹; Thomas Brackett²; James Boileau²; Brian Robert²; Emil Strumban¹; ¹IDIR; ²Ford
    Lithium-ion battery packs are increasingly used in electric vehicles. Each pack consists of modules comprised of a number of pouch cells electrically linked within a module via tab-to-busbar interconnects. Copper is used for busbars, while tabs are often made of thin aluminum foil. Forming mechanically strong, low resistance tab-to-busbar joints of dissimilar metals presents a challenge, since the currently used ultrasonic welding produces brittle intermetallic compounds in the joint interface. Low Pressure Cold Spray (LPCS) is a method allowing for the below melting point material buildup. The main objective of the work was to prove the feasibility of forming LPCS-based Al tab to Cu busbar joints and study their mechanical and microstructural characteristics. Different Al-Zn and Cu-Zn powder composition have been tested. High current resistance of the joints was evaluated. Lap shear tests were performed to establish a correlation between the electrical resistance and the mechanical strength of the joints.

2:40 PM
Molecular Dynamics Simulation of Mechanical and Tribological Properties of AlCoCrFe High Entropy Alloy Coatings on Aluminum Substrate: Xuehui Yang¹; Jian Zhang¹; Dan Koo¹; Bong-Gu Kim²; Heesung Park²; Yeon-Gil Jung²; Jing Zhang¹; ¹Indiana University - Purdue University Indianapolis; ²Changwon National University
    High-Entropy Alloys (HEAs) are single-phase-disordered solid solution alloys with multiple principal elements. HEAs present superior thermodynamic stability and mechanical properties, which lead to the potential applications in structural, aerospace and energy industries. In this work, we present a molecular dynamics model to simulate the mechanical and tribological properties of AlCoCrFe HEA coating on aluminum substrate. Using the simulated nanoindentation and tribology tests, the Young’s modulus and coefficient of friction of the HEA are derived. Compared to pure aluminum substrate, HEA coating demonstrates a higher Young’s modulus and a lower coefficient of friction, which is consistent with experimental observation.

3:00 PM
Modeling Ceramic Coating Removal Process Using Smoothed Particle Hydrodynamics Method: Jian Zhang¹; Sugrim Sagar¹; Dan Koo¹; Hyun-Hee Choi²; Yeon-Gil Jung²; Heesung Park²; Jing Zhang¹; ¹Indiana University - Purdue University Indianapolis; ²Changwon National University
    A smoothed particle hydrodynamics (SPH) based model to simulate the coating removal process using water jet is developed. The effects of water jet impact angle and velocity on the zirconia coating are studied. In addition, the temperature evolution during the removal process is evaluated. The results show that the coating removal rate increases with incident angle and impact velocity. The simulated profiles of removed coating are in good agreement with experimental observations.

3:20 PM
Aerosol Cold Spray and Sintering of Hydroxyapatite Coatings: Volf Leshchynsky¹; Roman Maev¹; Ahmed Elseddawy¹; Emil Strumban¹; Joanna Chojnacka¹; Dariusz Garbiecz¹; ¹IDIR
    A new method of aerosol cold spray (ACS) associated with following sintering is tried for Hydroxyapatite (HA) coating deposition on the pet implants. While aerosol cold spray technology has matured during the last decade, the complex effects of ceramic deposition parameters on porosity, mechanical properties and microstructure are unclear. The physical modelling of the structure formation processes is difficult because of lack of some technology parameters knowledge to enable a better fundamental understanding of both ACS and sintering process parameters. In this presentation, a new ACS apparatus is used to examine the ACS process. Sintering of coatings is made by two methods (spark plasma sintering and furnace sintering). Establishment and validation of the HA coating structure formation mechanisms is provided through experimental measurements which demonstrate the opportunities of new technology and its ability to provide considerable improvements of the HA deposition onto pet implants.

3:40 PM
Advanced Coatings for Passive Mitigation of Spacecraft Charging: Danny Liu¹; Joshua Boman²; Matthew Lyle²; Dan Wang¹; JR Dennison²; Timothy Hall¹; Maria Inman¹; ¹Faraday Technology Inc; ²Utah State University
    Spacecraft charging has been recognized as an important consideration for spacecraft design and occurs due to charged particle interactions between space plasmas and the spacecraft. When parts of the spacecraft experience differential charging relative to one another, resulting in a potential which exceeds the breakdown potentials, discharge arcing may occur and irreversibly damage spacecraft components. One solution towards avoiding discharge arcing is to incorporate coatings to facilitate autonomous or passive electron emission. By enabling charge dissipation between the various components at modest potential differences, discharge arcing may be prevented. In this work, a graphene-based composite coating was developed and demonstrated high electron yields over a wide range of incident electron energies. Decoration of the coating with various metals (alkali, alkaline earth, transition) offered significant improvements in the electron yield (290% increase over the undecorated coating) and substantially extended the range (~9 times) of incident electron energies between crossover points.