David P. Adams

Micromilling of metal alloys with focused ion beam-fabricated tools

Abstract This work combines focused ion beam sputtering and ultra-precision machining as a first step in fabricating metal alloy microcomponents. Micro-end mills having ∼25 μm diameters are made by sputtering cobalt M42 high-speed steel and C2 micrograin tungsten carbide tool blanks. A 20 keV focused gallium ion beam is used to define a number of cutting edges and tool end clearance. Cutting edge radii of curvature are less than or equal to 0.1 μm. Micro-end mill tools having 2, 4 and 5 cutting edges successfully machine millimeter long trenches in 6061-T4 aluminum, brass, 4340 steel and polymethyl methacrylate. Machined trench widths are approximately equal to the tool diameters, and surface roughnesses (Ra) at the bottom of micromachined features are ∼200 nm. Microtools are robust and operate for more than 6 h without fracture. Results from ultra-precision machining aluminum alloy at feed rates as high as 50 mm/minute and an axial depth of 1.0 μm are included.

Microgrooving and microthreading tools for fabricating curvilinear features

This paper presents techniques for fabricating microscopic, curvilinear features in a variety of workpiece materials. Micro-grooving and micro-threading tools having cutting widths as small as 13 {micro}m are made by focused ion beam sputtering and used for ultra-precision machining. Tool fabrication involves directing a 20 keV gallium beam at polished cylindrical punches made of cobalt M42 high-speed steel or C2 tungsten carbide to create a number of critically aligned facets. Sputtering produces rake facets of desired angle and cutting edges having radii of curvature equal to 0.4 {micro}m. Clearance for minimizing frictional drag of a tool results from a particular ion beam/target geometry that accounts for the sputter yield dependence on incidence angle. It is believed that geometrically specific cutting tools of this dimension have not been made previously. Numerically controlled, ultra-precision machining with micro-grooving tools results in a close match between tool width and feature size. Microtools are used to machine 13 {micro}m wide, 4 {micro}m deep, helical grooves in polymethyl methacrylate and 6061 Al cylindrical workplaces. Micro-grooving tools are also used to fabricate sinusoidal cross-section features in planar metal samples.

Selective area growth of metal nanostructures

Nanometer‐scale metal lines are fabricated onto Si(100) substrates by scanning tunneling microscope (STM) based lithography and subsequent chemical vapor deposition. An STM tip is first used to define areas for metal layer growth by electron stimulated desorption of adsorbed hydrogen. Exposure to Fe(CO)5 at 275 °C results in preferential deposition of Fe onto Si dangling bond sites (i.e., depassivated areas defined by the STM tip), while the monohydride resist remains intact in surrounding areas. Fe metal lines with widths ∼10 nm are constructed using this selective‐area, autocatalytic growth technique.

Pulsed laser ignition of reactive multilayer films

Nanostructured Al∕Pt multilayer films were ignited by single pulse irradiation from a Ti:sapphire femtosecond laser system. Critical ignition fluences (0.9–22J∕cm2) required to initiate a self-propagating reaction were quantified for different multilayer designs. Multilayers with smaller bilayer thickness required relatively lower fluence for ignition. Ignition threshold fluence was also found to be 1.4–3.6 times higher for Al-capped multilayers than for Pt-capped multilayers. Ablation threshold fluences were measured for Al (860±70mJ∕cm2) and Pt (540±50mJ∕cm2) and related to the observed difference in ignition fluences for Al- and Pt-capped multilayers.

Direct observation of spinlike reaction fronts in planar energetic multilayer foils

Propagating reactions in initially planar cobalt/aluminum exothermic multilayer foils have been investigated using high-speed digital photography. Real-time observations of reactions indicate that unsteady (spinlike) reaction propagation leads to the formation of highly periodic surface morphologies with length scales ranging from 1 μm to 1 mm. The characteristics of propagating spinlike reactions and corresponding reacted foil morphologies depend on the bilayer thickness of multilayer foils.

Rare-earth transition-metal intermetallic compounds produced via self-propagating, high-temperature synthesis

Several binary intermetallic compounds—each containing a rare-earth (RE) element paired with a transition metal (TM)—were prepared by self-propagating, high-temperature synthesis (SHS). Thin multilayers, composed of alternating Sc or Y (RE element) and Ag, Cu, or Au (TM), were first deposited by direct current magnetron sputtering. Once the initially distinct layers were stimulated and caused to mix, exothermic reactions propagated to completion. X-ray diffraction revealed that Sc/Au, Sc/Cu, Y/Au, and Y/Cu multilayers react in vacuum to form single-phase, cubic B2 structures. Multilayers containing Ag and a RE metal formed cubic B2 (RE)Ag and a minority (RE)Ag 2 phase. The influence of an oxygen-containing environment on the reaction dynamics and the formation of phase were investigated, providing evidence for the participation of secondary combustion reactions during metal-metal SHS. High-speed photography demonstrated reaction propagation speeds that ranged from 0.1–40.0 m/s (dependent on material system and foil design). Both steady and spin-like reaction modes were observed.

Nanosecond laser induced ignition thresholds and reaction velocities of energetic bimetallic nanolaminates

Thresholds for optically igniting self-propagating reactions are quantified for energetic Ni/Ti, Co/Al, and Al/Pt nanolaminates, where smaller enthalpy material pairs required larger laser ignition fluences. The threshold fluences (J/cm2) for ignition by 30 ns laser pulses focused to ∼8 μm spot size varied from 720 to 15 000 J/cm2 for Ni/Ti, 8.6 to 380 J/cm2 for Co/Al, and 3.2 to 27 J/cm2 for Al/Pt. Conversely, smaller enthalpy nanolaminates exhibited reduced steady-state propagation speeds ranging from 0.05 to 0.9 m/s for Ni/Ti, 0.6 to 8.5 m/s for Co/Al, and 24 to 73 m/s for Al/Pt. Increasing the laser spot diameter tenfold reduced the ignition threshold fluence by as much as two orders of magnitude.

The Effect of Substrate Microstructure on the Heat-Affected Zone Size in Sn-Zn Alloys Due to Adjoining Ni-Al Reactive Multilayer Foil Reaction

The rapid release of energy from reactive multilayer foils can create extreme local temperature gradients near substrate materials. In order to fully exploit the potential of these materials, a better understanding of the interaction between the substrate or filler material and the foil is needed. Specifically, this work investigates how variations in local properties within the substrate (i.e. differences between properties in constituent phases) can affect heat transport into the substrate. This can affect the microstructural evolution observed within the substrate, which may affect the final joint properties. The effect of the initial substrate microstructure on microstructural evolution within the heat-affected zone is evaluated experimentally in two Sn-Zn alloys and numerical techniques are utilized to inform the analysis.

Morphology evolution on diamond surfaces during ion sputtering.

We have conducted an extensive study of the evolution of surface morphology of single crystal diamond surfaces during sputtering by 20keV Ga+ and Ga++H2O. We observe the formation of well-ordered ripples on the surface for angles of incidence between 40 and 70°. We have also measured sputter yields as a function of angle of incidence, and ripple wavelength and amplitude dependence on angle of incidence and ion fluence. Smooth surface morphology is observed for 70°. The formation and evolution of well-ordered surface ripples is well characterized by the model of Bradley and Harper, where sputter-induced roughening is balanced by surface transport smoothing. Smoothing is consistent with an ion-induced viscous relaxation mechanism. Ripple amplitude saturates at high ion fluence, confirming the effect of nonlinear processes. Differences between Ga+ and Ga++H2O in ripple wavelength, amplitude, and time to saturation of amplitude are consis...

Polarization dependent formation of femtosecond laser-induced periodic surface structures near stepped features

Laser-induced periodic surface structures (LIPSS) are formed near 110 nm-tall Au microstructured edges on Si substrates after single-pulse femtosecond irradiation with a 150 fs pulse centered near a 780 nm wavelength. We investigate the contributions of Fresnel diffraction from step-edges and surface plasmon polariton (SPP) excitation to LIPSS formation on Au and Si surfaces. For certain laser polarization vector orientations, LIPSS formation is dominated by SPP excitation; however, when SPP excitation is minimized, Fresnel diffraction dominates. The LIPSS orientation and period distributions are shown to depend on which mechanism is activated. These results support previous observations of the laser polarization vector influencing LIPSS formation on bulk surfaces.