Kinetic Monte Carlo Simulation of EB-PVD Film:Effects of Substrate Temperature

The 2D kinetic Monte Carlo (KMC) simulation was used to study the effects of different substrate temperatures on the microstruc-ture of Ni-Cr films in the process of deposition by the electron beam physical vapor deposition (EB-PVD). In the KMC model, substrate was assumed to be a “surface” of tight-packed rows, and the simulation includes two phenomena: adatom-surface collision and adatom diffusion. While the interaction between atoms was described by the embedded atom method, the jumping energy was calculated by the molecular static (MS) calculation. The initial location of the adatom was defined by the Momentum Scheme. The results reveal that there exists a critical substrate temperature which means that the lowest packing density and the highest surface roughness structure will be achieved when the temperature is lower than the smaller critical value, while the roughness of both surfaces and the void contents keep decreasing with the substrate temperature increasing until it reaches the higher critical value. The results also indicate that the critical substrate temperature rises as the deposition rate increases.     

Preparation, Growth Mechanisms and Characterizations of ZnSe Films via the Solvothermal Method

With diethylamine as a solvent, ZnSe films were formed on the Si substrate directly from zinc and selenium through the modified solvothermal method. The effects of holding temperature, deposition time and substrate surface treatment on the quality and morphologies of the ZnSe films were investigated. The growth mechanism of ZnSe films was proved to be a layer-nucleation growth process, which was tied in with the Stranski-Krastanov （SK） model. ZnSe films were identified by the X-ray diffraction pattern （XRD）, the scanning electron microscope （SEM）, the X-ray photoelectron spectroscope （XPS） and the photoluminescence （PL） techniques. The results indicate that the modified solvothermal method with diethylamine as a solvent is suitable to prepare high quality ZnSe films.     

Fabrication of Diamond-like Carbon Films by Ion Assisted Middle Frequency Unbalanced Magnetron Sputtering

Diamond-like carbon （DLC） films are deposited by the Hall ion source assisted by the mid-frequency unbalanced magnetron sputtering technique. The effects of the substrate voltage bias, the substrate temperature, the Hall discharging current and the argon/nitrogen ratio on the DLC film＇s performance were studied. The experimental results show that the film＇s surface roughness, the hardness and the Young＇s modulus increase firstly and then decrease with the bias voltage incrementally increases. Also when the substrate temperature rises, the surface roughness of the film varies slightly, but its hardness and Young＇s modulus firstly increase followed by a sharp decrease when the temperature surpassing 120 ℃. With the Hall discharging current incrementally rising, the hardness and Young＇s modulus of the film decrease and the surface roughness of the film on 316L stainless steel firstly decreased and then remains constant.     

Preparation,Growth Mechanisms and Characterizations of ZnSe Films via the Solvothermal Method

With diethylamine as a solvent, ZnSe films were formed on the Si substrate directly from zinc and selenium through the modified solvothermal method. The effects of holding temperature, deposition time and substrate surface treatment on the quality and morpholo-gies of the ZnSe films were investigated. The growth mechanism of ZnSe films was proved to be a layer-nucleation growth process, which was tied in with the Stranski-Krastanov (SK) model. ZnSe films were identified by the X-ray diffraction pattern (XRD), the scan-ning electron microscope (SEM), the X-ray photoelectron spectroscope (XPS) and the photoluminescence (PL) techniques. The results indicate that the modified solvothermal method with diethylamine as a solvent is suitable to prepare high quality ZnSe films.     

Fabrication of Diamond-like Carbon Films by Ion Assisted Middle Frequency Unbalanced Magnetron Sputtering

Diamond-like carbon (DLC) films are deposited by the Hall ion source assisted by the mid-frequency unbalanced magnetron sput-tering technique. The effects of the substrate voltage bias, the substrate temperature, the Hall discharging current and the argon/nitrogen ratio on the DLC film’s performance were studied. The experimental results show that the film’s surface roughness, the hardness and the Young’s modulus increase firstly and then decrease with the bias voltage incrementally increases. Also when the substrate temperature rises, the surface roughness of the film varies slightly, but its hardness and Young’s modulus firstly increase followed by a sharp decrease when the temperature surpassing 120 ℃. With the Hall discharging current incrementally rising, the hardness and Young’s modulus of the film decrease and the surface roughness of the film on 316L stainless steel firstly decreased and then remains constant.     

Plasma Niobium Surface Alloying of Pure Titanium and its Oxidation at 900℃

A niobium-modified layer on pure titanium surface was obtained by means of double glow plasma surface alloying technique. The modified layer was uniform, continuous, compact and well adhered to the substrate. The niobium composition in the modified layer decreased gradually from the surface to the substrate. The oxidation behavior of the niobium-modified layer was investigated and com- pared with the untreated surface at 900 ℃ for 100 h. Characterization of the layers was performed using X-ray diffraction and scanning electron microscope, respectively. The test results show that the oxidation behavior of pure titanium was improved by niobium alloying process. Niobium has a positive influence on the oxidation resistance.     

Luminescent Nanocrystalline Silicon Carbide Thin Film Deposited by Helicon Wave Plasma Enhanced Chemical Vapour Deposition

Hydrogenated nanocrystalline silicon carbide （SIC） thin films were deposited on the single-crystal silicon substrate using the helicon wave plasma enhanced chemical vapor deposition （HW-PECVD） technique. The influences of magnetic field and hydrogen dilution ratio on the structures of SiC thin film were investigated with the atomic force microscopy （AFM）, the Fourier transform infrared absorption （FTIR） and the transmission electron microscopy （TEM）. The results indicate that the high plasma activity of the helicon wave mode proves to be a key factor to grow crystalline SiC thin films at a relative low substrate temperature. Also, the decrease in the grain sizes from the level of microcrystalline to that of nanocrystalline can be achieved by increasing the hydrogen dilution ratios. Transmission electron microscopy measurements reveal that the size of most nanocrystals in the film deposited under the higher hydrogen dilution ratios is smaller than the doubled Bohr radius of 3C-SiC （approximately 5.4 nm）, and the light emission measurements also show a strong blue photoluminescence at the room temperature, which is considered to be caused by the quantum confinement effect of small-sized SiC nanocrystals.     

Simulation and experimental investigation on a dynamic lateral flow mode in trepanning electrochemical machining

An appropriate flow mode of electrolyte has a positive effect on process efficiency, surface roughness, and machining accuracy in the electrochemical machining(ECM) process. In this study, a new dynamic lateral flow mode, in which the electrolyte flows from the leading edge to the trailing edge, was proposed in trepanning ECM of a diffuser. Then a numerical model of the channel was set up and simulated by using computational fluid dynamics software. The result showed that the distribution of the flow field was comparatively uniform in the inter-electrode gap. Furthermore, a fixture was designed to realize this new flow mode and then corresponding experiments were carried out. The experimental results illustrated that the feeding rate of the cathode reached 2 mm/min, the best taper angle was about 0.4°, and the best surface roughness was up to Ra= 0.115 lm. It reflects that this flow mode is suitable and effective, and can also be applied to machining other complex structures in trepanning ECM.     

Numerical investigation of windage heating within shrouded rotor-stator cavity system with central inflow

The rotating disk surface temperature rise due to windage heating effect by numerically modeling the turbulent flow within a rotor-stator cavity which is available with a peripheral shroud and imposed through airflow was dealt with. The windage heating may be defined as viscous friction heating caused by relative velocity differences across the boundary layers between the fluid and the rotating disk surface. The kinetic energy dissipation process could transform the rotating shaft power into thermal heating. Commercial finite volume based solver, ANSYS/CFX was employed to numerically simulate this physical process by using the shear stress transport (SST) turbulence model. CFD results include the rotating disk surface temperature axial distribution and tangential velocity distribution of the fluid domain. The velocity difference between the result obtained by particle image velocimetry (PIV) experiments and CFD simulation are within 5%. The adiabatic disk temperature rise can be calculated by the tangential velocity of disk and fluid in large gap ratio and turbulent parameter. CFD temperature distribution results and those estimated via velocity differences are within 10%.     

Thermal shock damage behavior of CVD ZnS by oxygen propane flame：A numerical and experimental study

Chemical vapor deposition zinc sulfide （CVD ZnS） is widely used as an infrared window material to transmit infrared signals, keep the aerodynamic shape and protect its imaging system, which often suffers high temperature and complicated thermal stresses. The purpose of this paper is to investigate the thermal shock damage of CVD ZnS through a finite element method and oxygen propane flame experiments. The finite element model is developed to simulate the temperature and thermal stress fields by an oxygen propane flame. Then, the thermal shock experiments are performed to investigate the thermal shock damage behavior. The results show that the temperature rising rate of the shock surface is fast during the initial heating stage resulting in high thermal stress. After the thermal shock experiment, the scanning electron microscope （SEM） photographs shows that the shock surface of the specimen becomes rough and the microcracks occur in the thermal shock zone. Good agreements are achieved between the numerical solutions and the experimental results.     

Failure of EB-PVD Thermal Barrier Coatings Subjected to Thermo-Mechanical Loading

Thermal barrier coatings （TBCs） were developed to protect metallic blades and vanes working in turbo-engines. The two-layered structure TBCs, consisting of NiCoCrAlY bond coat and yttria stabilized zirconia （YSZ）, were deposited on a cylinder of superalloy substrate by the electron beam-physical vapor deposition （EB-PVD）. The failure mechanism of the TBCs was investigated with a thermo-mechanical fatigue testing system under the service condition similar to that for turbine blades. Non-destructive evaluation of the coated specimens was conducted through the impedance spectroscopy. It is found that the crack initiation mainly takes place on the top coat at the edge of the heated zones.     

Influences of milling and grinding on machined surface roughness and fatigue behavior of GH4169 superalloy workpieces

Surface topography of superalloy GH4169 workpieces machined by milling and grinding is different significantly. Meanwhile, surface roughness, as one of the main indicators of machined surface integrity, has a great influence on the fatigue behavior of workpieces. Based on analyzing the formation mechanism and characteristics of surface roughness utilizing different machining processes and parameters, the machined surface roughness curve can be decoupled into two parts utilizing frequency spectrum analysis, which are kinematic surface roughness curve and stochastic surface roughness curve. The kinematic surface roughness curve is influenced by machining process,parameters, geometry of the cutting tool or wheel, the maximum height of which is expressed as R'_z.By subtracting the kinematic part from the measurement curve, the stochastic surface roughness curve and its maximum height R'_zcan be obtained, which is influenced by the defects of cutting tool edge or abrasive grains, built-up edges(BUE), cracks, high frequency vibration and so on. On the other hand, the results of decoupling analysis of surface roughness curves indicate that Raand Rz values of milling GH4169 are 2–5 times and 1–3 times as high as those of grinding, while R'_zvalue of milling is 13.85%–37.7% as high as that of grinding. According to the results of fatigue life tests of specimens machined by milling and grinding, it can be concluded that fatigue behavior of GH4169 decreases with the increase of R'_zmonotonically, even utilizing different machining processes.     

Probe design for measuring total temperature of combustor outlet based on water cooling

To obtain the outlet temperature of combustor, a kind of high-temperature and water cooling thermocouple was designed. The main factors affecting the results of thermocouple measurement were analyzed after numerical simulation. Results showed that the high-temperature water cooling thermocouple can achieve high temperature measurement under the condition of 2400K. With the increase of the distance between the water cooling structure and the stagnation cover, the temperature measurement result was more accurate, and the increase in the area ratio of the inlet and outlet of the stagnation cover within a reasonable range can make the measurement results more accurate. The surface emissivity of the measuring point had a great influence on the radiation error. The pressure and flow rate of cooling water can be effectively reduced after adding zirconia coating onto the surface of the rake body.      

Luminescent Nanocrystalline Silicon Carbide Thin Film Deposited by Helicon Wave Plasma Enhanced Chemical Vapour Deposition

Hydrogenated nanocrystalline silicon carbide (SiC) thin films were deposited on the single-crystal silicon substrate using the heli-con wave plasma enhanced chemical vapor deposition (HW-PECVD) technique. The influences of magnetic field and hydrogen dilution ratio on the structures of SiC thin film were investigated with the atomic force microscopy (AFM), the Fourier transform infrared ab-sorption (FTIR) and the transmission electron microscopy (TEM). The results indicate that the high plasma activity of the helicon wave mode proves to be a key factor to grow crystalline SiC thin films at a relative low substrate temperature. Also, the decrease in the grain sizes from the level of microcrystalline to that of nanocrystalline can be achieved by increasing the hydrogen dilution ratios. Transmis-sion electron microscopy measurements reveal that the size of most nanocrystals in the film deposited under the higher hydrogen dilution ratios is smaller than the doubled Bohr radius of 3C-SiC (approximately 5.4 nm), and the light emission measurements also show a strong blue photoluminescence at the room temperature, which is considered to be caused by the quantum confinement effect of small-sized SiC nanocrystals.     

Effect of nickel introduced by electroplating on pyrocarbon deposition of carbon-fiber preforms

In order to improve the deposition rate and microstructure of pyrocarbon, nickel was introduced by electroplating on carbon fibers and used as a catalyst during the deposition of pyrocarbon at 1000 C using methane as a precursor gas. The distribution of nickel catalyst and the microstructure of pyrocarbon were characterized by scanning electron microscopy（SEM）, energy dispersive spectroscopy（EDS）, X-ray diffraction（XRD）, and Raman micro-spectrometry. Results show that nano-sized nickel particles could be well distributed on carbon fibers and the pyrocarbon deposited catalytically had a smaller d002 value and a higher graphitization degree compared with that without catalyst. In addition, the deposition rate of pyrocarbon in each hour was measured.The deposition rate of pyrocarbon in the first hour was more than 10 times when carbon cloth substrates were doped with nickel catalysts as compared to the pure carbon cloths. The pyrocarbon gained by rapid deposition may include two parts, which are generation directly on the nickel catalyst and formation with the carbon nanofibers as crystal nucleus.     

Experiment of Hall thruster plume effects on different ground experimental conditions

Reducing the influence of back-sputtering effect can effectively improve the accuracy of the measurement of the Hall thruster plume effect. Quartz crystal microbalance (QCM) was used to measure the deposition and sputtering distribution of HET-40 thruster plume on two different experimental conditions: case 1, using liquid nitrogen heat sinks and case 2, without using liquid nitrogen heat sinks. Meanwhile, X-ray photoelectron spectroscopy (XPS) was used to analyze the composition of the QCM surface after two experiments. The results of the two experiments showed that the sputtering rate under the condition of case 1 was slightly higher than case 2. Especially within the range of 90° to 110° relative to the thruster axis, case 1 experiment result showed sputtering effect, while case 2 experiment showed deposition effect. Through analysis of the experimental results, it can be found that using liquid nitrogen heat sink to reduce the temperature of the inner wall surface of vacuum chamber can effectively adsorb the particles sputtered by the plume and reduce the concentration of back-sputtering particles, leading to the above phenomenon.      

Interfacial Properties Modification of Carbon Fiber/ Polyarylacetylene Composites

This work was dedicated to performing surface oxidation and coating treatments on carbon fibers (CF) and investigating the changes of fiber surface properties after these treatments, including surface composition, relative volume of functional groups, and sur- face topography with X-ray photoelectron spectroscopy (XPS) and atom force microscopy (AFM) technology. The results show that, after oxidation treatments, interfacial properties between CF and non-polar polyarylacetylene (PAA) resin are remarkably modified by removing weak surface layers and increasing fiber surface roughness. Coating treatment by high char phenolic resin solution after oxida- tion makes interface of CF/PAA composites to be upgraded and the interfacial properties further bettered.     

High-temperature tribological behaviors of a Cr-Si co-alloyed layer on TA15 alloy

A Cr-Si co-alloyed layer was successfully deposited on TA15 alloy by the double glow plasma surface technology to improve its poor wear resistance at elevated temperature.The microstructure,composition,and phase structure of the layer were investigated by SEM,EDS,and XRD.The tribological behaviors of the Cr-Si co-alloyed layer at 20 ℃ and 500 ℃ were analyzed in details.The results indicated that the friction coefficient and wear rate of the Cr-Si coalloyed layer at 20 ℃ and 500 ℃ were much lower than those of the substrate,which was due to higher hardness and superior elastic modulus.This layer may become an approach to effectively improving the wear resistance of TA15 alloy at elevated temperature.     

Combustion efficiency test method in scramjet engine

A scramjet engine combustion efficiency measure system was designed.The combustion efficiency was measured by chromatography method,and the results of chromatography method were compared with those of temperature method.The results indicate that the combustion efficiency measured by chromatography method was 80.7%,lower than the combustion efficiency of 84.5%measured by temperature method;the combustion efficiency could be measured more precisely by chromatogram method than by temperature method.The combustion efficiency measure system based on chromatogram method can work well,and thus can be used to measure the combustion efficiency of scramjet engine.     

Effect of temperature on corrosion behavior of 3003 aluminum alloy in ethylene glycol–water solution

The effect of temperature on the corrosion behavior of 3003 aluminum alloy in ethylene glycol–water solution was investigated by potentiodynamic polarization and electrochemical impedance spectroscopy(EIS) techniques. The surface characterization was observed and determined by scanning electron microscopy(SEM), atomic force microscopy(AFM) and energy dispersive spectrometer(EDS). The results demonstrate that the anodic aluminum dissolution and the cathodic oxygen reduction were accelerated by the increased temperature. However, as temperature was over60 °C, the solubility and concentration of oxygen decreased, resulting in the inhibition of cathodic reaction. The cathodic reaction rate of 3003 aluminum alloy rose to the maximum at 60 °C. The Warburg impedance in Nyquist diagram diminished and then was replaced by a negative capacitance caused by the absorption of intermediate corrosion product on electrode. On the other hand,after potentiodynamic measurements, 3003 aluminum alloy suffered pitting corrosion. The dissolution of aluminum alloy around secondary phase particles expanded both horizontally and vertically.