Room temperature deposition of functional ceramic films on low-cost metal substrate

Khansur, Neamul H.; Eckstein, Udo; Benker, Lisa; Deisinger, Ulrike; Merle, Benoit; Webber, Kyle G.

doi:10.1016/j.ceramint.2018.06.027

Cited by 46 publications

(49 citation statements)

References 35 publications

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“…Film deposition parameters are listed in Table . Details describing the AD process can be found in previous works . The NaCl coating was washed using distilled water to obtain the post‐deposited substrate (Post‐AD).…”

Section: Experimental Methodologymentioning

confidence: 99%

Revealing the effects of aerosol deposition on the substrate‐film interface using NaCl coating

Khansur

Eckstein

et al. 2019

J Am Ceram Soc

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Aerosol deposition is a feasible method of fabricating dense ceramic films at room temperature by the impact consolidation of submicron‐sized particles on ceramic, metal, glass, and polymer substrates at a rapid rate. Despite the potential usefulness of the aerosol deposition process, there are issues, such as deposition mechanisms and structure of the film‐substrate interface, that are not well understood. We have used complementary structural and microstructural analysis to capture the state of the substrate surface after the aerosol deposition process. The results reveal that modification of the substrate surface by the ejected submicron‐sized particles is essential for the formation of anchoring layer, thereby, a change in internal residual stress state and surface free energy of the substrate is required to deposit film using AD process. Our analysis also suggests that the adhesion between the metal substrate and ceramic particles is possibly contributed by both physical bonding and mechanical interlocking.

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Section: Experimental Methodologymentioning

confidence: 99%

Revealing the effects of aerosol deposition on the substrate‐film interface using NaCl coating

Khansur

Eckstein

et al. 2019

J Am Ceram Soc

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“…Both Si–O–Si centroid and Nd‐max values as well as the densification ratios estimated for the film have an unexpected trend along the depth profile. Indeed, the maximum values are not at the substrate‐film interface as observed for other AD films . A further contribution must be considered before further interpretation: the spatial resolution.…”

Section: Discussionmentioning

confidence: 84%

“…The linear variation observed, more than showing a gradient within the AD film, can be simply interpreted as a sampling artifact between a homogeneous AD film and the substrate glass. The previous study on a ceramic film deposited on a metallic substrate showed that the internal residual stress gradient profile along the film thickness is maximum at the ceramic film‐metal substrate interface . By analogy, an increase in density could be expected at the base of the AD film.…”

Section: Discussionmentioning

confidence: 87%

“…The micrometer‐sized powder was used to coat the glass substrate using N 2 as the carrier gas. Details of the AD equipment and film processing can be found in our previous works . Film deposition parameters are listed in Table .…”

Section: Experimental Methodsmentioning

confidence: 99%

“…Another noteworthy characteristic of AD films is the development of significant internal residual stress. Using various techniques, a number of investigations have characterized the internal residual stresses in AD films, where biaxial compressive stresses from approximately 0.5 to 14 GPa have been reported . A synchrotron x‐ray microdiffraction study was able to characterize the internal residual stress through the thickness of an AD‐processed BaTiO 3 ceramic film on a steel substrate, showing a stress gradient .…”

Section: Introductionmentioning

confidence: 99%

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Determining the local pressure during aerosol deposition using glass memory

et al. 2019

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Aerosol deposition (AD) is a dynamic loading process that can be envisioned as a shock wave loading, necessitating the consideration of the elastic/plastic response of solid materials. Due to the dynamic nature of this process, however, experimental determination of the local pressures during the deposition process is difficult. This work addresses this by investigating the compression and subsequent structure modification of a silicate glass after room‐temperature AD on a silicate glass substrate with Raman spectroscopy. Clear structural changes in the short‐ and middle‐range order of the silicate glass were observed, both as intertetrahedral angle distribution and as ring statistic. Therefore, the AD induced permanent densification of the glass, equivalent, in a hydrostatic approximation, to a minimal pressure of 10.5 ± 1.5 GPa during the film deposition process. Furthermore, the analysis of the Nd3+ photoluminescence of the 4F3/2 − 4I9/2 transition provided complementary information on the glass network modifications occurring during film formation. More than a pure hydrostatic densification, the AD seems to present a very intense shear deformation. This work opens up the perspective of evaluating the mechanical response of film‐substrate and of the particles themselves, and provides critical information on the mechanisms responsible for the AD film formation.

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What Happens during Thermal Post‐Treatment of Powder Aerosol Deposited Functional Ceramic Films? Explanations Based on an Experiment‐Enhanced Literature Survey

et al. 2020

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Powder aerosol deposition (PAD) is a unique ceramic spray coating method that produces dense and well‐adhering thick‐films directly at room temperature, without requiring any heating or sintering. After the successful film formation, mechanical film properties like hardness or plasma resistance are remarkably good. However, when it comes to electrical properties like permittivity or electrical conductivity, the nanocrystalline structure of PAD films combined with high internal strains deteriorates partly the characteristic properties. The electrical conductivity may already be present within the as‐deposited films. However, it is mostly lowered by several orders of magnitude. Therefore, a thermal post‐deposition annealing is oftentimes required. In this work, electrically conducting films produced by powder aerosol deposition are surveyed based on published data. Their microstructural and electrical behavior during the post‐deposition annealing treatment is summarized and reasons for the lowered electrical conductivity are identified. Additionally, the processes taking place during annealing, which eventually allow to regain bulk‐like functional properties, are examined. A universal annealing behavior is found that leads to a quantitative recommendation for the suitable film annealing temperatures to regain the electrical conductivities.

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Room temperature deposition of functional ceramic films on low-cost metal substrate

Cited by 46 publications

References 35 publications

Revealing the effects of aerosol deposition on the substrate‐film interface using NaCl coating

Revealing the effects of aerosol deposition on the substrate‐film interface using NaCl coating

Determining the local pressure during aerosol deposition using glass memory

What Happens during Thermal Post‐Treatment of Powder Aerosol Deposited Functional Ceramic Films? Explanations Based on an Experiment‐Enhanced Literature Survey

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