WorldWideScience

Sample records for silicon manufacturing process

  1. Low energy production processes in manufacturing of silicon solar cells

    Science.gov (United States)

    Kirkpatrick, A. R.

    1976-01-01

    Ion implantation and pulsed energy techniques are being combined for fabrication of silicon solar cells totally under vacuum and at room temperature. Simplified sequences allow very short processing times with small process energy consumption. Economic projections for fully automated production are excellent.

  2. Silicon Chemical Vapor Deposition Process Using a Half-Inch Silicon Wafer for Minimal Manufacturing System

    Science.gov (United States)

    Li, Ning; Habuka, Hitoshi; Ikeda, Shin-ichi; Hara, Shiro

    A chemical vapor deposition reactor for producing thin silicon films was designed and developed for achieving a new electronic device production system, the Minimal Manufacturing, using a half-inch wafer. This system requires a rapid process by a small footprint reactor. This was designed and verified by employing the technical issues, such as (i) vertical gas flow, (ii) thermal operation using a highly concentrated infrared flux, and (iii) reactor cleaning by chlorine trifluoride gas. The combination of (i) and (ii) could achieve a low heating power and a fast cooling designed by the heat balance of the small wafer placed at a position outside of the reflector. The cleaning process could be rapid by (iii). The heating step could be skipped because chlorine trifluoride gas was reactive at any temperature higher than room temperature.

  3. Reduction of breakage losses in silicon-cell processing - Investigations towards an optimization of manufacturing processes

    Energy Technology Data Exchange (ETDEWEB)

    Beinert, J.; Kordisch, H.; Kuebler, R.; Koenczoel, L.; Kleer, G. [Fraunhofer-Institut fueur Werkstoffmechanik, Freiburg (Germany)

    2004-07-01

    For the optimization of silicon cell manufacturing processes with respect to a reduction of breakage losses an integral concept was developed and applied in industrial manufacturing lines. The concept consists on a combination of different approaches. Measurements of the cell strength after specific manufacturing processes reveal, whether these processes induce or reduce damaging. The damage and crack formation and evolution history is investigated by fractographic and microscopic inspections of original cells broken during manufacturing. Fracture relevant processes are analysed by experiments and by numerical modelling in order to determine the acting mechanical or thermomechanical loadings. Numerical simulations by means of finite element analyses help to optimise the processes, because the influencing process parameters can be varied in the computer. Testing methods such as acoustic techniques or proof-tests are applied for the early detection and elimination of cells which are not able to survive further processing. By a combination of the results of these approaches the causes of breakage losses can be localised, analysed and deleted. (orig.)

  4. Plasma monitoring and PECVD process control in thin film silicon-based solar cell manufacturing

    Directory of Open Access Journals (Sweden)

    Gabriel Onno

    2014-02-01

    Full Text Available A key process in thin film silicon-based solar cell manufacturing is plasma enhanced chemical vapor deposition (PECVD of the active layers. The deposition process can be monitored in situ by plasma diagnostics. Three types of complementary diagnostics, namely optical emission spectroscopy, mass spectrometry and non-linear extended electron dynamics are applied to an industrial-type PECVD reactor. We investigated the influence of substrate and chamber wall temperature and chamber history on the PECVD process. The impact of chamber wall conditioning on the solar cell performance is demonstrated.

  5. Achievement report for fiscal 1997 on developing a silicon manufacturing process with reduced energy consumption. Investigation and research on analyzing practical application of a technology to manufacture solar cell silicon raw materials; 1997 nendo energy shiyo gorika silicon seizo process kaihatsu. Taiyo denchi silicon genryo seizo gijutsu no jitsuyoka kaiseki ni kansuru chosa kenkyu

    Energy Technology Data Exchange (ETDEWEB)

    NONE

    1998-03-01

    This paper describes the achievement in fiscal 1997 of analyzing practical application of a technology to manufacture solar cell silicon raw materials. Silicon consumption for solar cells in fiscal 1997 has increased to 2000-ton level, and the supply has been very tight. For drastic improvement in the demand and supply situation, development of SOG-Si manufacturing technology and its early practical application are desired. The development of the NEDO mass-production technology using melting and refining has completed constructing the process facilities in fiscal 1998, and will enter the stage of operational research. However, insufficiency in the basic data about behavior of impurities is inhibiting the development. In the substrate manufacturing technology, discussions have shown progress on use of diversifying silicons outside the standard by using the electromagnetic casting process. For slicing and processing the substrates, development of a high-performance slicing equipment and automatic rough rinsing machine is under way. Properties required on silicon raw materials vary considerably widely because of difference in cell making systems and conditions, which is attributable to unknown impurity behavior. When 1GW production is assumed, the cell module manufacturing cost is calculated as 137 yen/W, for which low-cost mass production for its realization, slicing productivity enhancement, and cost reduction are required. The paper also describes site surveys in overseas countries. (NEDO)

  6. Environmentally benign silicon solar cell manufacturing

    Energy Technology Data Exchange (ETDEWEB)

    Tsuo, Y.S. [National Renewable Energy Lab., Golden, CO (United States); Gee, J.M. [Sandia National Labs., Albuquerque, NM (United States); Menna, P. [National Agency for New Technologies Energy and Environment, Portici (Italy); Strebkov, D.S.; Pinov, A.; Zadde, V. [Intersolarcenter, Moscow (Russian Federation)

    1998-09-01

    The manufacturing of silicon devices--from polysilicon production, crystal growth, ingot slicing, wafer cleaning, device processing, to encapsulation--requires many steps that are energy intensive and use large amounts of water and toxic chemicals. In the past two years, the silicon integrated-circuit (IC) industry has initiated several programs to promote environmentally benign manufacturing, i.e., manufacturing practices that recover, recycle, and reuse materials resources with a minimal consumption of energy. Crystalline-silicon solar photovoltaic (PV) modules, which accounted for 87% of the worldwide module shipments in 1997, are large-area devices with many manufacturing steps similar to those used in the IC industry. Obviously, there are significant opportunities for the PV industry to implement more environmentally benign manufacturing approaches. Such approaches often have the potential for significant cost reduction by reducing energy use and/or the purchase volume of new chemicals and by cutting the amount of used chemicals that must be discarded. This paper will review recent accomplishments of the IC industry initiatives and discuss new processes for environmentally benign silicon solar-cell manufacturing.

  7. The Characteristics of Seebeck Coefficient in Silicon Nanowires Manufactured by CMOS Compatible Process

    Directory of Open Access Journals (Sweden)

    Choi Sung-Jin

    2010-01-01

    Full Text Available Abstract Silicon nanowires are patterned down to 30 nm using complementary metal-oxide-semiconductor (CMOS compatible process. The electrical conductivities of n-/p-leg nanowires are extracted with the variation of width. Using this structure, Seebeck coefficients are measured. The obtained maximum Seebeck coefficient values are 122 μV/K for p-leg and −94 μV/K for n-leg. The maximum attainable power factor is 0.74 mW/m K2 at room temperature.

  8. Photovoltaic Czochralski silicon manufacturing technology improvements

    Science.gov (United States)

    Jester, T.

    1995-03-01

    This report describes work performed under a three-year, three-phase, cost-share contract to demonstrate significant cost reductions and improvements in manufacturing technology. The objective of the program is to reduce costs in photovoltaic manufacturing by approximately 10% per year. The work was focused in three main areas: (1) silicon crystal growth and thin wafer technology; (2) silicon cell processing; and (3) silicon module fabrication and environmental, safety, and health issues. During this reporting period, several significant improvements were achieved. The crystal growing operation improved significantly with an increase in growth capacity due to larger crucibles, higher polysilicon packing density, and high pull speeds. Wafer processing with wire saws progressed rapidly, and the operation is completely converted to wire saw wafer processing. The wire saws yield almost 50% more wafers per inch in production, thus improving manufacturing volume by 50% without any additional expense in crystal growth. Cell processing improvements focused on better understanding the contact paste and firing processes. Module designs for lower material and labor costs began with the focus on a new junction box, larger modules with larger cells, and a less costly framing technique. In addition, chlorofluorocarbon (CFC) usage was completely eliminated in the Siemens manufacturing facility during this period, resulting in significant reductions in the cost of caustic waste treatment.

  9. Silicon processing for photovoltaics II

    CERN Document Server

    Khattak, CP

    2012-01-01

    The processing of semiconductor silicon for manufacturing low cost photovoltaic products has been a field of increasing activity over the past decade and a number of papers have been published in the technical literature. This volume presents comprehensive, in-depth reviews on some of the key technologies developed for processing silicon for photovoltaic applications. It is complementary to Volume 5 in this series and together they provide the only collection of reviews in silicon photovoltaics available.The volume contains papers on: the effect of introducing grain boundaries in silicon; the

  10. Silicon web process development

    Science.gov (United States)

    Duncan, C. S.; Seidensticker, R. G.; Mchugh, J. P.; Skutch, M. E.; Driggers, J. M.; Hopkins, R. H.

    1981-01-01

    The silicon web process takes advantage of natural crystallographic stabilizing forces to grow long, thin single crystal ribbons directly from liquid silicon. The ribbon, or web, is formed by the solidification of a liquid film supported by surface tension between two silicon filaments, called dendrites, which border the edges of the growing strip. The ribbon can be propagated indefinitely by replenishing the liquid silicon as it is transformed to crystal. The dendritic web process has several advantages for achieving low cost, high efficiency solar cells. These advantages are discussed.

  11. Silicon production process evaluations

    Science.gov (United States)

    1982-05-01

    Engineering design of the third distillation column in the process was accomplished. The initial design is based on a 94.35% recovery of dichlorosilane in the distillate and a 99.9% recovery of trichlorosilane in the bottoms. The specified separation is achieved at a reflux ratio of 15 with 20 trays (equilibrium stages). Additional specifications and results are reported including equipment size, temperatures and pressure. Specific raw material requirements necessary to produce the silicon in the process are presented. The primary raw materials include metallurgical grade silicon, silicon tetrachloride, hydrogen, copper (catalyst) and lime (waste treatment). Hydrogen chloride is produced as by product in the silicon deposition. Cost analysis of the process was initiated during this reporting period.

  12. Silicon-Film{trademark} Solar Cells by a Flexible Manufacturing System

    Energy Technology Data Exchange (ETDEWEB)

    Culik, J. S.; Rand, J. A.; Bai, Y.; Bower, J. R.; Cummings, J. R.; Goncharovsky, I.; Jonczyk, R.; Sims, P. E.; Hall, R. B.; Barnett, A. M.

    1999-09-13

    AstroPower is developing a manufacturing process for Silicon-Film{trademark} solar cell production under the Photovoltaic Manufacturing Technology (PVMaT) cost-share program. This document reports on results from the first phase of a three-phase effort. Progress is reported on developing new procedures and equipment for in-line wet-chemical processes, metallization processes, sheet fabrication, solar cell processing, module assembly, solar cell testing, metallurgical-grade silicon purification, and recycling of Silicon-Film{trademark} sheet materials. Future concepts and goals for the Silicon-Film{trademark} process are also discussed.

  13. Achievement Report for fiscal 1997 on developing a silicon manufacturing process with reduced energy consumption. Development of technology to manufacture high quality solar cell silicon substrates; 1997 nendo energy shiyo gorika silicon seizo process kaihatsu. Kohinshitsu taiyo denchiyo silicon kiban seizo gijutsu no kaihatsu

    Energy Technology Data Exchange (ETDEWEB)

    NONE

    1998-03-01

    It is intended to establish an energy saving type mass production technology to manufacture solar cell substrates by using the electromagnetic casting process. This paper describes the achievements in fiscal 1997. Preliminary experiments were performed for high-performance slicing processing and post-slicing rinsing to reduce the cost by enhancing productivity in the slicing process. Since there is a problem of mixing of contaminating raw materials due to diversification in raw materials, resistance and impurity concentration must be determined on each raw material as the materials for the Czochralski method. Then, the raw materials are sorted out referring to the determination results, and they can be used for the electromagnetic casting process upon optimizing them. As a result of having sliced an ingot of 15-cm square with a length of 40 cm by using a mass-production wire saw, an accuracy of 22.8 {mu}m was attained as intra-face variance when the required cutting time was 476 minutes and the substrate thickness is 348 {mu}, thus having obtained prospect for achieving the standard. Development was made on a water jetting rough cleaning machine to separate and remove slurries (oil and grinding particles) from the substrates after slicing, and an arm robot to accommodate substrates into cassettes, which provided processing velocity of 9 second per substrate. A problem of raising the speed remains to be solved. (NEDO)

  14. Novel Manufacturing Process for Unique Mixed Carbide Refractory Composites Project

    Data.gov (United States)

    National Aeronautics and Space Administration — This STTR Phase I project will establish the feasibility of an innovative manufacturing process to fabricate a range of unique hafnium/silicon based carbide...

  15. Beryllium Manufacturing Processes

    Energy Technology Data Exchange (ETDEWEB)

    Goldberg, A

    2006-06-30

    This report is one of a number of reports that will be combined into a handbook on beryllium. Each report covers a specific topic. To-date, the following reports have been published: (1) Consolidation and Grades of Beryllium; (2) Mechanical Properties of Beryllium and the Factors Affecting these Properties; (3) Corrosion and Corrosion Protection of Beryllium; (4) Joining of Beryllium; (5) Atomic, Crystal, Elastic, Thermal, Nuclear, and other Properties of Beryllium; and (6) Beryllium Coating (Deposition) Processes and the Influence of Processing Parameters on Properties and Microstructure. The conventional method of using ingot-cast material is unsuitable for manufacturing a beryllium product. Beryllium is a highly reactive metal with a high melting point, making it susceptible to react with mold-wall materials forming beryllium compounds (BeO, etc.) that become entrapped in the solidified metal. In addition, the grain size is excessively large, being 50 to 100 {micro}m in diameter, while grain sizes of 15 {micro}m or less are required to meet acceptable strength and ductility requirements. Attempts at refining the as-cast-grain size have been unsuccessful. Because of the large grain size and limited slip systems, the casting will invariably crack during a hot-working step, which is an important step in the microstructural-refining process. The high reactivity of beryllium together with its high viscosity (even with substantial superheat) also makes it an unsuitable candidate for precision casting. In order to overcome these problems, alternative methods have been developed for the manufacturing of beryllium. The vast majority of these methods involve the use of beryllium powders. The powders are consolidated under pressure in vacuum at an elevated temperature to produce vacuum hot-pressed (VHP) blocks and vacuum hot-isostatic-pressed (HIP) forms and billets. The blocks (typically cylindrical), which are produced over a wide range of sizes (up to 183 cm dia. by 61

  16. PV Cz silicon manufacturing technology improvements

    Science.gov (United States)

    Jester, T.

    1995-09-01

    This describes work done in the final phase of a 3-y, 3-phase contract to demonstrate cost reductions and improvements in manufacturing technology. The work focused on near-term projects in the SSI (Siemens Solar Industries) Czochralski (Cz) manufacturing facility in Camarillo, CA; the final phase was concentrated in areas of crystal growth, wafer technology, and environmental, safety, and health issues. During this period: (1) The crystal-growing operation improved with increased growth capacity; (2) Wafer processing with wire saws continued to progress; the wire saws yielded almost 50 percent more wafers per inch in production. The wire saws needs less etching, too; (3) Cell processing improvements focused on better handling and higher mechanical yield. The cell electrical distribution improved with a smaller standard deviation in the distribution; and (4) Module designs for lower material and labor costs continued, with focus on a new junction box, larger modules with larger cells, and less costly framing techniques. Two modules demonstrating these cost reductions were delivered during this phase.

  17. Impurity doping processes in silicon

    CERN Document Server

    Wang, FFY

    1981-01-01

    This book introduces to non-experts several important processes of impurity doping in silicon and goes on to discuss the methods of determination of the concentration of dopants in silicon. The conventional method used is the discussion process, but, since it has been sufficiently covered in many texts, this work describes the double-diffusion method.

  18. High Efficiency, Low Cost Solar Cells Manufactured Using 'Silicon Ink' on Thin Crystalline Silicon Wafers

    Energy Technology Data Exchange (ETDEWEB)

    Antoniadis, H.

    2011-03-01

    Reported are the development and demonstration of a 17% efficient 25mm x 25mm crystalline Silicon solar cell and a 16% efficient 125mm x 125mm crystalline Silicon solar cell, both produced by Ink-jet printing Silicon Ink on a thin crystalline Silicon wafer. To achieve these objectives, processing approaches were developed to print the Silicon Ink in a predetermined pattern to form a high efficiency selective emitter, remove the solvents in the Silicon Ink and fuse the deposited particle Silicon films. Additionally, standard solar cell manufacturing equipment with slightly modified processes were used to complete the fabrication of the Silicon Ink high efficiency solar cells. Also reported are the development and demonstration of a 18.5% efficient 125mm x 125mm monocrystalline Silicon cell, and a 17% efficient 125mm x 125mm multicrystalline Silicon cell, by utilizing high throughput Ink-jet and screen printing technologies. To achieve these objectives, Innovalight developed new high throughput processing tools to print and fuse both p and n type particle Silicon Inks in a predetermined pat-tern applied either on the front or the back of the cell. Additionally, a customized Ink-jet and screen printing systems, coupled with customized substrate handling solution, customized printing algorithms, and a customized ink drying process, in combination with a purchased turn-key line, were used to complete the high efficiency solar cells. This development work delivered a process capable of high volume producing 18.5% efficient crystalline Silicon solar cells and enabled the Innovalight to commercialize its technology by the summer of 2010.

  19. Green manufacturing processes and systems

    Energy Technology Data Exchange (ETDEWEB)

    Davim, J. Paulo (ed.) [Aveiro Univ. (Portugal). Dept. of Mechanical Engineering, Campus Universitario de Santiago

    2013-02-01

    This book provides the recent advances on green manufacturing processes and systems for modern industry. Chapter 1 provides information on sustainable manufacturing through environmentally-friendly machining. Chapter 2 is dedicated to environmentally-friendly machining: vegetable based cutting fluids. Chapter 3 describes environmental-friendly joining of tubes. Chapter 4 contains information on concepts, methods and strategies for zero-waste in manufacturing. Finally, chapter 5 is dedicated to the application of hybrid MCDM approach for selecting the best tyre recycling process.

  20. Quality management of manufacturing process based on manufacturing execution system

    Science.gov (United States)

    Zhang, Jian; Jiang, Yang; Jiang, Weizhuo

    2017-04-01

    Quality control elements in manufacturing process are elaborated. And the approach of quality management of manufacturing process based on manufacturing execution system (MES) is discussed. The functions of MES for a microcircuit production line are introduced conclusively.

  1. Manufacturing technology for contacts to silicon carbide

    Directory of Open Access Journals (Sweden)

    Kudryk Ya.Ya.

    2013-02-01

    Full Text Available The authors classified the results of investigations of resistivity of ohmic contacts to silicon carbide made without any semiconductor surface modification. A set of contacts with better parameters were analysed. From the results of this analysis, some recommendations were made concerning optimal contact-forming layers for p- and n-SiC types of 4H, 6H, 3C, 15R, 21R polytypes.

  2. Manufacturing processes 4 forming

    CERN Document Server

    Klocke, Fritz

    2013-01-01

    This book provides essential information on metal forming, utilizing a practical distinction between bulk and sheet metal forming. In the field of bulk forming, it examines processes of cold, warm and hot bulk forming, as well as rolling and a new addition, the process of thixoforming. As for the field of sheet metal working, on the one hand it deals with sheet metal forming processes (deep drawing, flange forming, stretch drawing, metal spinning and bending). In terms of special processes, the chapters on internal high-pressure forming and high rate forming have been revised and refined. On the other, the book elucidates and presents the state of the art in sheet metal separation processes (shearing and fineblanking). Furthermore, joining by forming has been added to the new edition as a new chapter describing mechanical methods for joining sheet metals. The new chapter “Basic Principles” addresses both sheet metal and bulk forming, in addition to metal physics, plastomechanics and computational basics; ...

  3. Silicon nanowire device and method for its manufacture

    Science.gov (United States)

    Okandan, Murat; Draper, Bruce L.; Resnick, Paul J.

    2017-01-03

    There is provided an electronic device and a method for its manufacture. The device comprises an elongate silicon nanowire less than 0.5 .mu.m in cross-sectional dimensions and having a hexagonal cross-sectional shape due to annealing-induced energy relaxation.

  4. Bench-Scale Silicone Process for Low-Cost CO{sub 2} Capture. Manufacturing Plan for Aminosilicone-based CO{sub 2} Absorption Material

    Energy Technology Data Exchange (ETDEWEB)

    Vogt, Kirkland

    2013-02-01

    A commercially cost effective manufacturing plan was developed for GAP-1m, the aminosilicone-based part of the CO{sub 2} capture solvent described in DE-FE0007502, and the small-scale synthesis of GAP-1m was confirmed. The plan utilizes a current intermediate at SiVance LLC to supply the 2013-2015 needs for GE Global Research. Material from this process was supplied to GE Global Research for evaluation and creation of specifications. GE Global Research has since ordered larger quantities (60 liters) for the larger scale evaluations that start in first quarter, 2013. For GE’s much larger future commercial needs, an improved, more economical pathway to make the product was developed after significant laboratory and literature research. Suppliers were identified for all raw materials.

  5. MITLL Silicon Integrated Photonics Process: Design Guide

    Science.gov (United States)

    2015-07-31

    MIT Lincoln Laboratory Silicon Integrated Photonics Process Design Guide Revision 2015:1a (31 July 2015) Comprehensive Design...Government. Rev.: 2015:1a (18 June 2015) i MITLL Silicon Integrated Photonics Process Comprehensive Design Guide ... Silicon Integrated Photonics Process Comprehensive Design Guide 16  Deep Etch for Fiber Coupling (DEEP_ETCH

  6. Solar silicon via the Dow Corning process

    Science.gov (United States)

    Hunt, L. P.; Dosaj, V. D.

    1979-01-01

    Technical feasibility for high volume production of solar cell-grade silicon is investigated. The process consists of producing silicon from pure raw materials via the carbothermic reduction of quartz. This silicon was then purified to solar grade by impurity segregation during Czochralski crystal growth. Commercially available raw materials were used to produce 100 kg quantities of silicon during 60 hour periods in a direct arc reactor. This silicon produced single crystalline ingot, during a second Czochralski pull, that was fabricated into solar cells having efficiencies ranging from 8.2 percent to greater than 14 percent. An energy analysis of the entire process indicated a 5 month payback time.

  7. Wind Turbine Manufacturing Process Monitoring

    Energy Technology Data Exchange (ETDEWEB)

    Waseem Faidi; Chris Nafis; Shatil Sinha; Chandra Yerramalli; Anthony Waas; Suresh Advani; John Gangloff; Pavel Simacek

    2012-04-26

    To develop a practical inline inspection that could be used in combination with automated composite material placement equipment to economically manufacture high performance and reliable carbon composite wind turbine blade spar caps. The approach technical feasibility and cost benefit will be assessed to provide a solid basis for further development and implementation in the wind turbine industry. The program is focused on the following technology development: (1) Develop in-line monitoring methods, using optical metrology and ultrasound inspection, and perform a demonstration in the lab. This includes development of the approach and performing appropriate demonstration in the lab; (2) Develop methods to predict composite strength reduction due to defects; and (3) Develop process models to predict defects from leading indicators found in the uncured composites.

  8. Silicon-Based Anode and Method for Manufacturing the Same

    Science.gov (United States)

    Yushin, Gleb Nikolayevich (Inventor); Luzinov, Igor (Inventor); Zdyrko, Bogdan (Inventor); Magasinski, Alexandre (Inventor)

    2017-01-01

    A silicon-based anode comprising silicon, a carbon coating that coats the surface of the silicon, a polyvinyl acid that binds to at least a portion of the silicon, and vinylene carbonate that seals the interface between the silicon and the polyvinyl acid. Because of its properties, polyvinyl acid binders offer improved anode stability, tunable properties, and many other attractive attributes for silicon-based anodes, which enable the anode to withstand silicon cycles of expansion and contraction during charging and discharging.

  9. High Volume Manufacturing of Silicon-Film Solar Cells and Modules; Final Subcontract Report, 26 February 2003 - 30 September 2003

    Energy Technology Data Exchange (ETDEWEB)

    Rand, J. A.; Culik, J. S.

    2005-10-01

    The objective of the PV Manufacturing R&D subcontract was to continue to improve AstroPower's technology for manufacturing Silicon-Film* wafers, solar cells, and modules to reduce costs, and increase production yield, throughput, and capacity. As part of the effort, new technology such as the continuous back metallization screen-printing system and the laser scribing system were developed and implemented. Existing processes, such as the silicon nitride antireflection coating system and the fire-through process were optimized. Improvements were made to the statistical process control (SPC) systems of the major manufacturing processes: feedstock preparation, wafer growth, surface etch, diffusion, and the antireflection coating process. These process improvements and improved process control have led to an increase of 5% relative power, and nearly 15% relative improvement in mechanical and visual yield.

  10. Highly Manufacturable Deep (Sub-Millimeter) Etching Enabled High Aspect Ratio Complex Geometry Lego-Like Silicon Electronics

    KAUST Repository

    Ghoneim, Mohamed T.

    2017-02-01

    A highly manufacturable deep reactive ion etching based process involving a hybrid soft/hard mask process technology shows high aspect ratio complex geometry Lego-like silicon electronics formation enabling free-form (physically flexible, stretchable, and reconfigurable) electronic systems.

  11. Accuracy of freeform manufacturing processes

    NARCIS (Netherlands)

    Gubbels, G.P.H.; Venrooy, B.W.H.; Henselmans, R.

    2009-01-01

    The breakthrough of freeform optics is limited by manufacturing and metrology technology. However, today's manufacturing machines like polishing robots and diamond turning machines are accurate enough to produce good surface quality, so the question is how accurate can a freeform be produced. To

  12. News: Good chemical manufacturing process criteria

    Science.gov (United States)

    This news column covers topics relating to manufacturing criteria, machine to machine technology, novel process windows, green chemistry indices, business resilience, immobilized enzymes, and Bt crops.

  13. Silicon-Film(TM) Solar Cells by a Flexible Manufacturing System: Final Report, 16 April 1998 -- 31 March 2001

    Energy Technology Data Exchange (ETDEWEB)

    Rand, J.

    2002-02-01

    This report describes the overall goal to engineer and develop flexible manufacturing methods and equipment to process Silicon-Film solar cells and modules. Three major thrusts of this three-year effort were to: develop a new larger-area (208 mm x 208 mm) Silicon-Film solar cell, the APx-8; construct and operate a new high-throughput wafer-making system; and develop a 15-MW single-thread manufacturing process. Specific technical accomplishments from this period are: Increase solar cell area by 80%, increase the generation capacity of a Silicon-Film wafer-making system by 350%, use a new in-line HF etch system in solar cell production, design and develop an in-line NaOH etch system, eliminate cassettes in solar cell processing, and design a new family of module products.

  14. Fundamentals of semiconductor manufacturing and process control

    CERN Document Server

    May, Gary S

    2006-01-01

    A practical guide to semiconductor manufacturing from process control to yield modeling and experimental design Fundamentals of Semiconductor Manufacturing and Process Control covers all issues involved in manufacturing microelectronic devices and circuits, including fabrication sequences, process control, experimental design, process modeling, yield modeling, and CIM/CAM systems. Readers are introduced to both the theory and practice of all basic manufacturing concepts. Following an overview of manufacturing and technology, the text explores process monitoring methods, including those that focus on product wafers and those that focus on the equipment used to produce wafers. Next, the text sets forth some fundamentals of statistics and yield modeling, which set the foundation for a detailed discussion of how statistical process control is used to analyze quality and improve yields. The discussion of statistical experimental design offers readers a powerful approach for systematically varying controllable p...

  15. Improved Methods for Production Manufacturing Processes in Environmentally Benign Manufacturing

    Directory of Open Access Journals (Sweden)

    Yan-Yan Wang

    2011-09-01

    Full Text Available How to design a production process with low carbon emissions and low environmental impact as well as high manufacturing performance is a key factor in the success of low-carbon production. It is important to address concerns about climate change for the large carbon emission source manufacturing industries because of their high energy consumption and environmental impact during the manufacturing stage of the production life cycle. In this paper, methodology for determining a production process is developed. This methodology integrates process determination from three different levels: new production processing, selected production processing and batch production processing. This approach is taken within a manufacturing enterprise based on prior research. The methodology is aimed at providing decision support for implementing Environmentally Benign Manufacturing (EBM and low-carbon production to improve the environmental performance of the manufacturing industry. At the first level, a decision-making model for new production processes based on the Genetic Simulated Annealing Algorithm (GSAA is presented. The decision-making model considers not only the traditional factors, such as time, quality and cost, but also energy and resource consumption and environmental impact, which are different from the traditional methods. At the second level, a methodology is developed based on an IPO (Input-Process-Output model that integrates assessments of resource consumption and environmental impact in terms of a materials balance principle for batch production processes. At the third level, based on the above two levels, a method for determining production processes that focus on low-carbon production is developed based on case-based reasoning, expert systems and feature technology for designing the process flow of a new component. Through the above three levels, a method for determining the production process to identify, quantify, assess, and optimize the

  16. Broadband Nonlinear Signal Processing in Silicon Nanowires

    DEFF Research Database (Denmark)

    Yvind, Kresten; Pu, Minhao; Hvam, Jørn Märcher

    The fast non-linearity of silicon allows Tbit/s optical signal processing. By choosing suitable dimensions of silicon nanowires their dispersion can be tailored to ensure a high nonlinearity at power levels low enough to avoid significant two-photon abso We have fabricated low insertion...

  17. Additive Manufacturing of Silicon Carbide-Based Ceramic Matrix Composites: Technical Challenges and Opportunities

    Science.gov (United States)

    Singh, Mrityunjay; Halbig, Michael C.; Grady, Joseph E.

    2016-01-01

    Advanced SiC-based ceramic matrix composites offer significant contributions toward reducing fuel burn and emissions by enabling high overall pressure ratio (OPR) of gas turbine engines and reducing or eliminating cooling air in the hot-section components, such as shrouds, combustor liners, vanes, and blades. Additive manufacturing (AM), which allows high value, custom designed parts layer by layer, has been demonstrated for metals and polymer matrix composites. However, there has been limited activity on additive manufacturing of ceramic matrix composites (CMCs). In this presentation, laminated object manufacturing (LOM), binder jet process, and 3-D printing approaches for developing ceramic composite materials are presented. For the laminated object manufacturing (LOM), fiber prepreg laminates were cut into shape with a laser and stacked to form the desired part followed by high temperature heat treatments. For the binder jet, processing optimization was pursued through silicon carbide powder blending, infiltration with and without SiC nano powder loading, and integration of fibers into the powder bed. Scanning electron microscopy was conducted along with XRD, TGA, and mechanical testing. Various technical challenges and opportunities for additive manufacturing of ceramics and CMCs will be presented.

  18. Flat-plate solar array project: Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

    Science.gov (United States)

    1983-01-01

    The process technology for the manufacture of semiconductor-grade silicon in a large commercial plant by 1986, at a price less than $14 per kilogram of silicon based on 1975 dollars is discussed. The engineering design, installation, checkout, and operation of an Experimental Process System Development unit was discussed. Quality control of scaling-up the process and an economic analysis of product and production costs are discussed.

  19. Features of the Manufacturing Vision Development Process

    DEFF Research Database (Denmark)

    Dukovska-Popovska, Iskra; Riis, Jens Ove; Boer, Harry

    2005-01-01

    This paper discusses the key features of the process of Manufacturing Vision Development, a process that enables companies to develop their future manufacturing concept. The basis for the process is a generic five-phase methodology (Riis and Johansen, 2003) developed as a result of ten years...... of action research. The methodology recommends wide participation of people from different hierarchical and functional positions, who engage in a relatively short, playful and creative process and come up with a vision (concept) for the future manufacturing system in the company. Based on three case studies...... of companies going through the initial phases of the methodology, this research identified the key features of the Manufacturing Vision Development process. The paper elaborates the key features by defining them, discussing how and when they can appear, and how they influence the process....

  20. Fabrication of Microcomponents by Electrochemical Manufacturing: Advanced Feed-Through Metallisation on Silicon and Nickel Micromechanical Resonators

    DEFF Research Database (Denmark)

    Tang, Peter Torben; Heschel, Matthias; Ravnkilde, Jan Tue

    2000-01-01

    -lithography, silicon substrates and other processes traditionally associated with microelectronics. By replacing ceramic materials, in some parts of a MEMS structure, with metal - and introducing electrochemical manufacturing - the production costs can be significantly reduced. This will be illustrated by two very...... different MEMS component examples: An example uses electrochemical manufacturing to form multiple feed-though wires of copper (similar to printed circuit boards, but much smaller and on tree-dimensional surfaces) from one side of a silicon wafer to the other. In this example tin bumps for flip-chip bonding......, as well as nickel/gold pads for conductive adhesive bonding, are also deposited by electroplating. The second example is a simple, inexpensive, low-temperature electroplating process for fabrication of released, stress-free nickel comb resonators. Since the manufacturing sequence only involves low...

  1. Manufacturing processes 2 grinding, honing, lapping

    CERN Document Server

    Klocke, Fritz

    2009-01-01

    Presents a view of the most common machining and non-machining manufacturing processes. This volume describes the characteristics of abrasive tools, their design and manufacturing, followed by the fundamentals of grinding fluids. It also discusses grinding of different materials (steel, cast iron, hard and brittle materials, nickel and titanium).

  2. Ultra-precision processes for optics manufacturing

    Science.gov (United States)

    Martin, William R.

    1991-12-01

    The Optics MODIL (Manufacturing Operations Development and Integration Laboratory) is developing advanced manufacturing technologies for fabrication of ultra precision optical components, aiming for a ten-fold improvement in precision and a shortening of the scheduled lead time. Current work focuses on diamond single point turning, ductile grinding, ion milling, and in/on process metrology.

  3. Recent Developments in Abrasive Hybrid Manufacturing Processes

    Directory of Open Access Journals (Sweden)

    Ruszaj Adam

    2017-06-01

    Full Text Available Recent dynamic development of abrasive hybrid manufacturing processes results from application of a new difficult for machining materials and improvement of technological indicators of manufacturing processes already applied in practice. This tendency also occurs in abrasive machining processes which are often supported by ultrasonic vibrations, electrochemical dissolution or by electrical discharges. In the paper we present the review of new results of investigations and new practical applications of Abrasive Electrodischarge (AEDM and Electrochemical (AECM Machining.

  4. High aspect ratio micro tool manufacturing for polymer replication using mu EDM of silicon, selective etching and electroforming

    DEFF Research Database (Denmark)

    Tosello, Guido; Bissacco, Giuliano; Tang, Peter Torben

    2008-01-01

    Mass fabrication of polymer micro components with high aspect ratio micro-structures requires high performance micro tools allowing the use of low cost replication processes such as micro injection moulding. In this regard an innovative process chain, based on a combination of micro electrical...... discharge machining (mu EDM) of a silicon substrate, electroforming and selective etching was used for the manufacturing of a micro tool. The micro tool was employed for polymer replication by means of the injection moulding process....

  5. Method of reusably sealing a silicone rubber vacuum bag to a mold for composite manufacture

    Science.gov (United States)

    Steinbach, John (Inventor)

    1989-01-01

    A silicone rubber vacuum bag for use in composite article manufacture is reusably sealed to a mold, without mechanical clamping means. The mold-mating portion of the bag is primed with a silicone rubber adhesive, which is cured thereto, and a layer of semiadhesive sealer is applied between the primed mold-mating portion of the bag and the mold.

  6. DECOMPOSITION OF MANUFACTURING PROCESSES: A REVIEW

    Directory of Open Access Journals (Sweden)

    N.M.Z.N. Mohamed

    2012-06-01

    Full Text Available Manufacturing is a global activity that started during the industrial revolution in the late 19th century to cater for the large-scale production of products. Since then, manufacturing has changed tremendously through the innovations of technology, processes, materials, communication and transportation. The major challenge facing manufacturing is to produce more products using less material, less energy and less involvement of labour. To face these challenges, manufacturing companies must have a strategy and competitive priority in order for them to compete in a dynamic market. A review of the literature on the decomposition of manufacturing processes outlines three main processes, namely: high volume, medium volume and low volume. The decomposition shows that each sub process has its own characteristics and depends on the nature of the firm’s business. Two extreme processes are continuous line production (fast extreme and project shop (slow extreme. Other processes are in between these two extremes of the manufacturing spectrum. Process flow patterns become less complex with cellular, line and continuous flow compared with jobbing and project. The review also indicates that when the product is high variety and low volume, project or functional production is applied.

  7. Manufacturing Vision Development – Process and Dialogue

    DEFF Research Database (Denmark)

    Dukovska-Popovska, Iskra

    This Ph.D. project has been conducted in the context of PRODUCTION+5 methodology for devel¬oping manufacturing visions for companies, and related to Experimental Laboratory for Production. Both have been established in the Center for Industrial Production. The empirical parts of the research...... involve case studies of three companies that are part of the MCD-process. The cases primarily are focusing on the process and the dialogue dur¬ing the manufacturing vision development....

  8. Process improvement in nuclear fuel manufacturing

    Energy Technology Data Exchange (ETDEWEB)

    Gueldner, R.; Osseforth, E.; Hoff, A. [Siemens Advanced Nuclear Fuels, D-49811 Lingen (Germany)

    1998-07-01

    Higher burnups and more demanding in-pile conditions require not only advanced product designs but also higher process capabilities in nuclear fuel manufacturing. This can only be achieved by implementation of advanced technologies and systematic application of statistical process control methods. Examples of process improvements established at different manufacturing areas within Advanced Nuclear Fuels GmbH are given. In the mid term perspective adequate processes and reliable products shall give a sound basis to substitute numerous order specific product examinations by efficient order independent process supervision to the largest possible extent. (author)

  9. An Improved Manufacturing Approach for Discrete Silicon Microneedle Arrays with Tunable Height-Pitch Ratio.

    Science.gov (United States)

    Wang, Renxin; Wang, Wei; Li, Zhihong

    2016-10-09

    Silicon microneedle arrays (MNAs) have been widely studied due to their potential in various transdermal applications. However, discrete MNAs, as a preferred choice to fabricate flexible penetrating devices that could adapt curved and elastic tissue, are rarely reported. Furthermore, the reported discrete MNAs have disadvantages lying in uniformity and height-pitch ratio. Therefore, an improved technique is developed to manufacture discrete MNA with tunable height-pitch ratio, which involves KOH-dicing-KOH process. The detailed process is sketched and simulated to illustrate the formation of microneedles. Furthermore, the undercutting of convex mask in two KOH etching steps are mathematically analyzed, in order to reveal the relationship between etching depth and mask dimension. Subsequently, fabrication results demonstrate KOH-dicing-KOH process. {321} facet is figured out as the surface of octagonal pyramid microneedle. MNAs with diverse height and pitch are also presented to identify the versatility of this approach. At last, the metallization is realized via successive electroplating.

  10. Engineering in the Manufacturing Process

    Science.gov (United States)

    1993-03-01

    process configurations," Computers & Industrial Engineering , 21:1-4, 1991, p. 41. "A survey of major approaches for accelerating new product development...Parsaei, Ibrahim N. Imam and All K. Kamrani, "An integrated cost estimating system for concurrent engineering environment," Computers & Industrial Engineering , 21

  11. Silicon analog components device design, process integration, characterization, and reliability

    CERN Document Server

    El-Kareh, Badih

    2015-01-01

    This book covers modern analog components, their characteristics, and interactions with process parameters. It serves as a comprehensive guide, addressing both the theoretical and practical aspects of modern silicon devices and the relationship between their electrical properties and processing conditions. Based on the authors’ extensive experience in the development of analog devices, this book is intended for engineers and scientists in semiconductor research, development and manufacturing. The problems at the end of each chapter and the numerous charts, figures and tables also make it appropriate for use as a text in graduate and advanced undergraduate courses in electrical engineering and materials science.

  12. Processes for manufacture of products from plants

    DEFF Research Database (Denmark)

    2010-01-01

    Disclosed herein is a process for inhibiting browning of plant material comprising adding a chelating agent to a disrupted plant material and adjusting the pH to a value of 2.0 to 4.5. Processes for manufacture of soluble and insoluble products from a plant material are also disclosed. Soluble...

  13. Oxygen defect processes in silicon and silicon germanium

    KAUST Repository

    Chroneos, A.

    2015-06-18

    Silicon and silicon germanium are the archetypical elemental and alloy semiconductor materials for nanoelectronic, sensor, and photovoltaic applications. The investigation of radiation induced defects involving oxygen, carbon, and intrinsic defects is important for the improvement of devices as these defects can have a deleterious impact on the properties of silicon and silicon germanium. In the present review, we mainly focus on oxygen-related defects and the impact of isovalent doping on their properties in silicon and silicon germanium. The efficacy of the isovalent doping strategies to constrain the oxygen-related defects is discussed in view of recent infrared spectroscopy and density functional theory studies.

  14. Ultrafast Nonlinear Signal Processing in Silicon Waveguides

    DEFF Research Database (Denmark)

    Oxenløwe, Leif Katsuo; Mulvad, Hans Christian Hansen; Hu, Hao

    2012-01-01

    We describe recent demonstrations of exploiting highly nonlinear silicon waveguides for ultrafast optical signal processing. We describe wavelength conversion and serial-to-parallel conversion of 640 Gbit/s data signals and 1.28 Tbit/s demultiplexing and all-optical sampling....

  15. Silicon photonics integrated circuits: a manufacturing platform for high density, low power optical I/O's.

    Science.gov (United States)

    Absil, Philippe P; Verheyen, Peter; De Heyn, Peter; Pantouvaki, Marianna; Lepage, Guy; De Coster, Jeroen; Van Campenhout, Joris

    2015-04-06

    Silicon photonics integrated circuits are considered to enable future computing systems with optical input-outputs co-packaged with CMOS chips to circumvent the limitations of electrical interfaces. In this paper we present the recent progress made to enable dense multiplexing by exploiting the integration advantage of silicon photonics integrated circuits. We also discuss the manufacturability of such circuits, a key factor for a wide adoption of this technology.

  16. Reduction of the environmental impacts in crystalline silicon module manufacturing

    NARCIS (Netherlands)

    Alsema, E.A.|info:eu-repo/dai/nl/073416258; de Wild-Schoten, M.J.

    2007-01-01

    In this paper we review the most important options to reduce environmental impacts of crystalline silicon modules. We investigate which are the main barriers for implementation of the measure. Finally we review which measures to reduce environmental impacts could also lead to a cost reduction.

  17. Precision laser processing for micro electronics and fiber optic manufacturing

    Science.gov (United States)

    Webb, Andrew; Osborne, Mike; Foster-Turner, Gideon; Dinkel, Duane W.

    2008-02-01

    The application of laser based materials processing for precision micro scale manufacturing in the electronics and fiber optic industry is becoming increasingly widespread and accepted. This presentation will review latest laser technologies available and discuss the issues to be considered in choosing the most appropriate laser and processing parameters. High repetition rate, short duration pulsed lasers have improved rapidly in recent years in terms of both performance and reliability enabling flexible, cost effective processing of many material types including metal, silicon, plastic, ceramic and glass. Demonstrating the relevance of laser micromachining, application examples where laser processing is in use for production will be presented, including miniaturization of surface mount capacitors by applying a laser technique for demetalization of tracks in the capacitor manufacturing process and high quality laser machining of fiber optics including stripping, cleaving and lensing, resulting in optical quality finishes without the need for traditional polishing. Applications include telecoms, biomedical and sensing. OpTek Systems was formed in 2000 and provide fully integrated systems and sub contract services for laser processes. They are headquartered in the UK and are establishing a presence in North America through a laser processing facility in South Carolina and sales office in the North East.

  18. Microeconomics of process control in semiconductor manufacturing

    Science.gov (United States)

    Monahan, Kevin M.

    2003-06-01

    Process window control enables accelerated design-rule shrinks for both logic and memory manufacturers, but simple microeconomic models that directly link the effects of process window control to maximum profitability are rare. In this work, we derive these links using a simplified model for the maximum rate of profit generated by the semiconductor manufacturing process. We show that the ability of process window control to achieve these economic objectives may be limited by variability in the larger manufacturing context, including measurement delays and process variation at the lot, wafer, x-wafer, x-field, and x-chip levels. We conclude that x-wafer and x-field CD control strategies will be critical enablers of density, performance and optimum profitability at the 90 and 65nm technology nodes. These analyses correlate well with actual factory data and often identify millions of dollars in potential incremental revenue and cost savings. As an example, we show that a scatterometry-based CD Process Window Monitor is an economically justified, enabling technology for the 65nm node.

  19. Large-Scale PV Module Manufacturing Using Ultra-Thin Polycrystalline Silicon Solar Cells: Annual Subcontract Report, 1 October 2003--30 September 2004

    Energy Technology Data Exchange (ETDEWEB)

    Wohlgemuth, J.; Narayanan, M.

    2005-03-01

    The major objectives of this program are to continue the advancement of BP Solar polycrystalline silicon manufacturing technology. The program includes work in the following areas: Efforts in the casting area to increase ingot size, improve ingot material quality, and improve handling of silicon feedstock as it is loaded into the casting stations; developing wire saws to slice 100- m-thick silicon wafers on 290- m centers; developing equipment for demounting and subsequent handling of very thin silicon wafers; developing cell processes using 100- m-thick silicon wafers that produce encapsulated cells with efficiencies of at least 15.4% at an overall yield exceeding 95%; expanding existing in-line manufacturing data reporting systems to provide active process control; establishing a 50-MW (annual nominal capacity) green-field Mega-plant factory model template based on this new thin polycrystalline silicon technology; facilitating an increase in the silicon feedstock industry's production capacity for lower-cost solar-grade silicon feedstock.

  20. Large-Scale PV Module Manufacturing Using Ultra-Thin Polycrystalline Silicon Solar Cells: Final Subcontract Report, 1 April 2002--28 February 2006

    Energy Technology Data Exchange (ETDEWEB)

    Wohlgemuth, J.; Narayanan, M.

    2006-07-01

    The major objectives of this program were to continue advances of BP Solar polycrystalline silicon manufacturing technology. The Program included work in the following areas. (1) Efforts in the casting area to increase ingot size, improve ingot material quality, and improve handling of silicon feedstock as it is loaded into the casting stations. (2) Developing wire saws to slice 100-..mu..m-thick silicon wafers on 290-..mu..m-centers. (3) Developing equipment for demounting and subsequent handling of very thin silicon wafers. (4) Developing cell processes using 100-..mu..m-thick silicon wafers that produce encapsulated cells with efficiencies of at least 15.4% at an overall yield exceeding 95%. (5) Expanding existing in-line manufacturing data reporting systems to provide active process control. (6) Establishing a 50-MW (annual nominal capacity) green-field Mega-plant factory model template based on this new thin polycrystalline silicon technology. (7) Facilitating an increase in the silicon feedstock industry's production capacity for lower-cost solar-grade silicon feedstock..

  1. 76 FR 9320 - Foreign-Trade Zone 274-Butte-Silver Bow, MT; Application for Manufacturing Authority REC Silicon...

    Science.gov (United States)

    2011-02-17

    ... Authority REC Silicon (Polysilicon and Silane Gas) Butte, MT An application has been submitted to the..., requesting manufacturing authority on behalf of REC Silicon, located in Butte, Montana. The application was... regulations of the Board (15 CFR part 400). It was formally filed on February 11, 2011. The REC Silicon...

  2. The design and manufacturing development of an active silicon substrate MCM

    Science.gov (United States)

    Roughton, M. G.; Waite, L.

    1994-10-01

    The demand for engine control systems with reduced weight, size and cost, increased integration, improved reliability and higher temperature operation drives the system designer to the use of advanced hybrid assembly technologies. This paper describes the design and manufacturing development of a silicon based 'D' type multichip module, MCM, containing an active substrate of memory. This CPU module is one of the building blocks for a range of generic engine control systems. The active substrate approach potentially gives higher packing density than wafer scale due to its 3D configuration. The active substrate comprises 12 SRAM 128K x 8 bit of diffused memory arranged in groups of three. The design is organized so that a 'memory manager' ASIC selects pages of good memory from the substrate die thus obtaining the best possible yield. A single wafer contains 4 silicon hybrid substrates, each approximately 40mm sq, which will be processed before separating into discrete circuits. The MCM structure is comprised of four aluminium metallization layers with benzocyclobutene, BCB, as the dielectric. Approximately 16 other devices including a processor, the 'memory manager' ASIC, a Processor Support ASIC and EDPROM, plus resistor network chips and decoupling capacitors will be added to the silicon substrate using adhesive and wire bond interconnection. The 'memory manager' ASIC tests the RAM on power-up, reject areas of bad memory and configures the good areas such that a continuous block of functional RAM is available to the processor. The RAM is configured as a 16 bit wide with both 16 bit and 8 bit read/write accesses being supported. The total module is to be assembled in a high temperature co-fired ceramic package with 200 I/O. After test and any rework that may be necessary the package will be sealed with a Kovar lid ready for final test.

  3. Multivariate data analysis of process control data from neutron transmutation doping of silicon

    DEFF Research Database (Denmark)

    Heydorn, K.; Hegaard, N.

    1994-01-01

    Final resistivities obtained by neutron transmutation doping (NTD) of silicon can be measured only after an annealing process has been carried out at the manufacturer's plant. The reactor centre carrying out the neutron doping process by irradiation under selected conditions must control the proc...... the process by indirect measurement of the product quality. The method of partial least squares was used to identify important parameters for improving the quality of the NTD-silicon, as well as for predicting the final quality data observed by the customer.......Final resistivities obtained by neutron transmutation doping (NTD) of silicon can be measured only after an annealing process has been carried out at the manufacturer's plant. The reactor centre carrying out the neutron doping process by irradiation under selected conditions must control...

  4. In-house manufacturing of cylindrical silicone models for hemodynamic research

    Science.gov (United States)

    Denisenko, Nikita S.; Kulik, Viktor M.

    2017-10-01

    Laboratory studies of fluid motion in artificial vessels modeling a distinct part of circulatory system of human are of a great importance for fundamental biomechanics and for medical applications. In the medicine they are used for advancing known and developing new methods for curing cardiovascular diseases. In biomechanics, the phantoms of blood vessels are used for studying the fluid motion. However, they are quite expensive. Therefore, a development of technique for in-house manufacturing of phantoms is quite attractive. In this paper methods of manufacturing cylindrical channels of silicone rubbers (the model of the straight part of an artery) and determination of their elastic properties are described. A specially developed acrylic mold is used for this purpose. The phantoms are cast from a mixture of SKTN-A silicone and PMS-5 oil (Penta-91, Novosibirsk, Russia). The oil is used for changing elasticity properties of the silicone.

  5. Aggregates in monoclonal antibody manufacturing processes.

    Science.gov (United States)

    Vázquez-Rey, María; Lang, Dietmar A

    2011-07-01

    Monoclonal antibodies have proved to be a highly successful class of therapeutic products. Large-scale manufacturing of pharmaceutical antibodies is a complex activity that requires considerable effort in both process and analytical development. If a therapeutic protein cannot be stabilized adequately, it will lose partially or totally its therapeutic properties or even cause immunogenic reactions thus potentially further endangering the patients' health. The phenomenon of protein aggregation is a common issue that compromises the quality, safety, and efficacy of antibodies and can happen at different steps of the manufacturing process, including fermentation, purification, final formulation, and storage. Aggregate levels in drug substance and final drug product are a key factor when assessing quality attributes of the molecule, since aggregation might impact biological activity of the biopharmaceutical. In this review it is analyzed how aggregates are formed during monoclonal antibody industrial production, why they have to be removed and the manufacturing process steps that are designed to either minimize or remove aggregates in the final product. Copyright © 2011 Wiley Periodicals, Inc.

  6. Throughput for steel pipes manufacturing process design

    Directory of Open Access Journals (Sweden)

    N. Fafandjel

    2008-10-01

    Full Text Available Conventional approach to pipe manufacturing process design is using capacity to satisfy maximal load for each process. In the new approach, throughput is suggested as a basic determinant aiming at finding dynamic balance among following and previous process phases. Throughput is defined by the interval of time between product exiting from the preceding process phase and its entry to the next one. Interval of time for the product delivery from the preceding phase must be less or equal as the amount of time necessary for activating the next phase. Knowing the performances of the next phase one can impact to the characteristics of the preceding phase. Throughput can be also used as a more precise way for observed process productivity measurement. Such approach is suggested and for other complex technological processes.

  7. A simulation study on garment manufacturing process

    Science.gov (United States)

    Liong, Choong-Yeun; Rahim, Nur Azreen Abdul

    2015-02-01

    Garment industry is an important industry and continues to evolve in order to meet the consumers' high demands. Therefore, elements of innovation and improvement are important. In this work, research studies were conducted at a local company in order to model the sewing process of clothes manufacturing by using simulation modeling. Clothes manufacturing at the company involves 14 main processes, which are connecting the pattern, center sewing and side neating, pockets sewing, backside-sewing, attaching the front and back, sleeves preparation, attaching the sleeves and over lock, collar preparation, collar sewing, bottomedge sewing, buttonholing sewing, removing excess thread, marking button, and button cross sewing. Those fourteen processes are operated by six tailors only. The last four sets of processes are done by a single tailor. Data collection was conducted by on site observation and the probability distribution of processing time for each of the processes is determined by using @Risk's Bestfit. Then a simulation model is developed using Arena Software based on the data collected. Animated simulation model is developed in order to facilitate understanding and verifying that the model represents the actual system. With such model, what if analysis and different scenarios of operations can be experimented with virtually. The animation and improvement models will be presented in further work.

  8. Manufacturing Process for OLED Integrated Substrate

    Energy Technology Data Exchange (ETDEWEB)

    Hung, Cheng-Hung [Vitro Flat Glass LLC, Cheswick, PA (United States). Glass Technology Center

    2017-03-31

    The main objective of this project was to develop a low-cost integrated substrate for rigid OLED solid-state lighting produced at a manufacturing scale. The integrated substrates could include combinations of soda lime glass substrate, light extraction layer, and an anode layer (i.e., Transparent Conductive Oxide, TCO). Over the 3+ year course of the project, the scope of work was revised to focus on the development of a glass substrates with an internal light extraction (IEL) layer. A manufacturing-scale float glass on-line particle embedding process capable of producing an IEL glass substrate having a thickness of less than 1.7mm and an area larger than 500mm x 400mm was demonstrated. Substrates measuring 470mm x 370mm were used in the OLED manufacturing process for fabricating OLED lighting panels in single pixel devices as large as 120.5mm x 120.5mm. The measured light extraction efficiency (calculated as external quantum efficiency, EQE) for on-line produced IEL samples (>50%) met the project’s initial goal.

  9. 77 FR 16158 - Current Good Manufacturing Practice in Manufacturing, Processing, Packing, or Holding of Drugs...

    Science.gov (United States)

    2012-03-20

    ... Manufacturing Practice in Manufacturing, Processing, Packing, or Holding of Drugs; Revision of Certain Labeling... Administration (FDA) is amending the packaging and labeling control provisions of the current good manufacturing..., 21 CFR part 211 is amended as follows: PART 211--CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED...

  10. Process chain modeling and selection in an additive manufacturing context

    DEFF Research Database (Denmark)

    Thompson, Mary Kathryn; Stolfi, Alessandro; Mischkot, Michael

    2016-01-01

    This paper introduces a new two-dimensional approach to modeling manufacturing process chains. This approach is used to consider the role of additive manufacturing technologies in process chains for a part with micro scale features and no internal geometry. It is shown that additive manufacturing...... evolving fields like additive manufacturing....

  11. Modular Elastomer Photoresins for Digital Light Processing Additive Manufacturing.

    Science.gov (United States)

    Thrasher, Carl J; Schwartz, Johanna J; Boydston, Andrew J

    2017-11-15

    A series of photoresins suitable for the production of elastomeric objects via digital light processing additive manufacturing are reported. Notably, the printing procedure is readily accessible using only entry-level equipment under ambient conditions using visible light projection. The photoresin formulations were found to be modular in nature, and straightforward adjustments to the resin components enabled access to a range of compositions and mechanical properties. Collectively, the series includes silicones, hydrogels, and hybrids thereof. Printed test specimens displayed maximum elongations of up to 472% under tensile load, a tunable swelling behavior in water, and Shore A hardness values from 13.7 to 33.3. A combination of the resins was used to print a functional multimaterial three-armed pneumatic gripper. These photoresins could be transformative to advanced prototyping applications such as simulated human tissues, stimuli-responsive materials, wearable devices, and soft robotics.

  12. Computational Process Modeling for Additive Manufacturing (OSU)

    Science.gov (United States)

    Bagg, Stacey; Zhang, Wei

    2015-01-01

    Powder-Bed Additive Manufacturing (AM) through Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) is being used by NASA and the Aerospace industry to "print" parts that traditionally are very complex, high cost, or long schedule lead items. The process spreads a thin layer of metal powder over a build platform, then melts the powder in a series of welds in a desired shape. The next layer of powder is applied, and the process is repeated until layer-by-layer, a very complex part can be built. This reduces cost and schedule by eliminating very complex tooling and processes traditionally used in aerospace component manufacturing. To use the process to print end-use items, NASA seeks to understand SLM material well enough to develop a method of qualifying parts for space flight operation. Traditionally, a new material process takes many years and high investment to generate statistical databases and experiential knowledge, but computational modeling can truncate the schedule and cost -many experiments can be run quickly in a model, which would take years and a high material cost to run empirically. This project seeks to optimize material build parameters with reduced time and cost through modeling.

  13. Large-Scale PV Module Manufacturing Using Ultra-Thin Polycrystalline Silicon Solar Cells: Annual Subcontract Report, 1 April 2002--30 September 2003 (Revised)

    Energy Technology Data Exchange (ETDEWEB)

    Wohlgemuth, J.; Shea, S. P.

    2004-04-01

    The goal of BP Solar's Crystalline PVMaT program is to improve the present polycrystalline silicon manufacturing facility to reduce cost, improve efficiency, and increase production capacity. Key components of the program are: increasing ingot size; improving ingot material quality; improving material handling; developing wire saws to slice 100 ..mu..m thick silicon wafers on 200 ..mu..m centers; developing equipment for demounting and subsequent handling of very thin silicon wafers; developing cell processes using 100 ..mu..m thick silicon wafers that produce encapsulated cells with efficiencies of at least 15.4% at an overall yield exceeding 95%; expanding existing in-line manufacturing data reporting systems to provide active process control; establishing a 50 MW (annual nominal capacity) green-field Mega plant factory model template based on this new thin polycrystalline silicon technology; and facilitating an increase in the silicon feedstock industry's production capacity for lower-cost solar-grade silicon feedstock.

  14. State-of-the-art in Manufacturing Pyrochemical Processing Crucibles

    Energy Technology Data Exchange (ETDEWEB)

    Parkinson, David Allen [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2016-05-03

    Engineers at Los Alamos National Laboratory have been purifying plutonium through pyrochemical processing for many years. The harsh environments involved with the pyrochemical processes include high temperatures (700-900 °C), molten salts and reactive metals (MgCl2, PuCl3, NaCl-KCl, CaCl2, Pu, Ca), and chlorine gas. Because of these corrosive conditions, designing and developing the pyrochemical processing equipment has always been an intriguing technical challenge. In this article I focus on the design and development of the pyrochemical processing crucible for the electrorefining (ER) process, applying design for manufacturability principles throughout the process. I review the current crucible design and electrorefining process and explore possibilities of making the crucible as one part, building the anode and cathode into the crucible, and various material of construction improvements. Materials of construction that should be reviewed further include alumina, silicon nitride, and a tantalum carbon alloy. I briefly review the application of three-dimensional (3D) printing to the process of producing the ER crucible, including thermoplastic 3D printing and mechanical property concerns. I finish by summarizing current plans and possibilities of improving the ER crucible.

  15. An Improved Manufacturing Approach for Discrete Silicon Microneedle Arrays with Tunable Height-Pitch Ratio

    Directory of Open Access Journals (Sweden)

    Renxin Wang

    2016-10-01

    Full Text Available Silicon microneedle arrays (MNAs have been widely studied due to their potential in various transdermal applications. However, discrete MNAs, as a preferred choice to fabricate flexible penetrating devices that could adapt curved and elastic tissue, are rarely reported. Furthermore, the reported discrete MNAs have disadvantages lying in uniformity and height-pitch ratio. Therefore, an improved technique is developed to manufacture discrete MNA with tunable height-pitch ratio, which involves KOH-dicing-KOH process. The detailed process is sketched and simulated to illustrate the formation of microneedles. Furthermore, the undercutting of convex mask in two KOH etching steps are mathematically analyzed, in order to reveal the relationship between etching depth and mask dimension. Subsequently, fabrication results demonstrate KOH-dicing-KOH process. {321} facet is figured out as the surface of octagonal pyramid microneedle. MNAs with diverse height and pitch are also presented to identify the versatility of this approach. At last, the metallization is realized via successive electroplating.

  16. Silicon Quantum Dots for Quantum Information Processing

    Science.gov (United States)

    2013-11-01

    16 2.2.2 Si/SiGe Heterostructures . . . . . . . . . . . . . . . . . . . 18 2.2.3 Silicon Nanowires ...Recently, silicon MOS, silicon/silicon- germanium (Si/SiGe) heterostructures and silicon nanowire architectures have also achieved spin manipulation and...Churchill, D. J. Reilly, J. Xiang, C. M. Lieber, and C. M. Marcus. A Ge/Si heterostructure nanowire -based double quantum dot with integrated charge

  17. CHO Quasispecies—Implications for Manufacturing Processes

    Directory of Open Access Journals (Sweden)

    Florian M. Wurm

    2013-10-01

    Full Text Available Chinese hamster ovary (CHO cells are a source of multi-ton quantities of protein pharmaceuticals. They are, however, immortalized cells, characterized by a high degree of genetic and phenotypic diversity. As is known for any biological system, this diversity is enhanced by selective forces when laboratories (no sharing of gene pools grow cells under (diverse conditions that are practical and useful. CHO cells have been used in culture for more than 50 years, and various lines of cells are available and have been used in manufacturing. This article tries to represent, in a cursory way, the history of CHO cells, particularly the origin and subsequent fate of key cell lines. It is proposed that the name CHO represents many different cell types, based on their inherent genetic diversity and their dynamic rate of genetic change. The continuing remodeling of genomic structure in clonal or non-clonal cell populations, particularly due to the non-standardized culture conditions in hundreds of different labs renders CHO cells a typical case for “quasispecies”. This term was coined for families of related (genomic sequences exposed to high mutation rate environments where a large fraction of offspring is expected to carry one or more mutations. The implications of the quasispecies concept for CHO cells used in protein manufacturing processes are significant. CHO genomics/transcriptomics may provide only limited insights when done on one or two “old” and poorly characterized CHO strains. In contrast, screening of clonal cell lines, derived from a well-defined starting material, possibly within a given academic or industrial environment, may reveal a more narrow diversity of phenotypes with respect to physiological/metabolic activities and, thus, allow more precise and reliable predictions of the potential of a clone for high-yielding manufacturing processes.

  18. A method for manufacturing a tool part for an injection molding process, a hot embossing process, a nano-imprint process, or an extrusion process

    DEFF Research Database (Denmark)

    2013-01-01

    The present invention relates to a method for manufacturing a tool part for an injection molding process, a hot embossing process, nano-imprint process or an extrusion process. First, there is provided a master structure (10) with a surface area comprising nanometre-sized protrusions (11) with a ......The present invention relates to a method for manufacturing a tool part for an injection molding process, a hot embossing process, nano-imprint process or an extrusion process. First, there is provided a master structure (10) with a surface area comprising nanometre-sized protrusions (11...... of manufacturing the master structure, e.g. a black silicon wafer. It is a further advantage of the present invention that it provides an advantageous way of making tools capable of producing self-cleaning surfaces without the need for chemical coating....

  19. Processing of microstrip detectors on Czochralski grown high resistivity silicon substrates

    CERN Document Server

    Härkönen, J; Tuovinen, E; Mehtälä, P; Lassila-Perini, K M; Ovchinnikov, V; Heikkilä, P; Ylikoski, M; Palmu, L; Kallijärvi, S; Nikkila, H; Anttila, O; Niinikoski, T O; Eremin, V; Ivanov, A; Verbitskaya, E

    2003-01-01

    We have processed large-area strip sensors on silicon wafers grown by the magnetic Czochralski (MCZ) method. The n-type MCZ silicon wafers manufactured by Okmetic Oyj have nominal resistivity of 900 Omega cm and oxygen concentration of less than 10 ppma. The Photoconductive Decay (PCD) measurements, current-voltage measurements and capacitance-voltage measurements were made to characterise the samples. The leakage current of 3 muA at 900 V bias voltage was measured on the 32.5 cm**2 detector. Detector depletion took place at about 420 V. According to PCD measurements, process induced contamination was effectively bound and neutralised by the oxygen present in Czochralski silicon. During the sample processing, the silicon resistivity increased in spite of the lack of specific donor- killing heat treatment.

  20. Composite manufacturing process for wind energy turbines

    Energy Technology Data Exchange (ETDEWEB)

    Rekret, A. [Mastercore System Ltd., Mississauga, ON (Canada)

    2008-07-01

    This paper described a unibody design for vertical axis wind turbines developed by the Mastercore Group of companies (Mastercore). The company's thermoplastic composites are among the strongest, lightest, and highest efficiency wind or water blades available in the market. The unibody design requires neither an external frame, nor an internal strut. This paper described the aerodynamic principle loads; lade shape and turbine design; and the manufacturing system. Mastercore's engineered product addresses the problem of turbulence that is caused by a smooth blade. A smooth blade causes noise, instability and can result in a loss of energy. Mastercore produces a broad range of accurately controllable impregnation levels, saving on the cost of resin and providing uniform mechanical properties. Their processes focus on the efficient impregnation of tows to manufacture in-line fabrics, tapes and other substrates based on carbon, glass, aramid or any other type of reinforcements. The process is environmentally sound, eliminates the emission of volatile organic compounds (VOCs), reduces wastes and meets stringent regulations. 7 figs.

  1. Manufacturing technology program for high burnout silicon Schottky-barrier mixer diodes for Navy air-to-air avionics

    Science.gov (United States)

    Anand, Y.; Ellis, S.

    1982-02-01

    This report describes the establishment of low cost semiconductor processes to manufacture low-barrier-height high-burnout X-band silicon Schottky barrier diodes in production quantities. These devices are thermal-compression-bonded in a rugged low-cost pill (ODS-119) package. They exhibit an overall low noise figure of 7.0 dB (single side band) at 0.5 mW of local oscillator power level and RF burnout of 12 watts (tau = 1 microsec and 1000 Hz rep. rate). Reliability and ruggedness of the design has been demonstrated by tests taken from MIL.S 19500 F.

  2. Silicon-on-ceramic coating process. Silicon sheet growth development for the Large-Area Silicon Sheet and Cell Development Tasks of the Low-Cost Silicon Solar Array Project. Quarterly report No. 8, December 28, 1977--March 28, 1977

    Energy Technology Data Exchange (ETDEWEB)

    Chapman, P.W. Zook, J.D.; Heaps, J D; Maclolek, R B; Koepke, B; Butter, C D; Schult, S B

    1978-04-20

    A research program to investigate the technical and economic feasibility of producing solar-cell-quality sheet silicon by coating inexpensive ceramic substrates with a thin layer of polycrystalline silicon is described. The coating methods to be developed are directed toward a minimum-cost process for producing solar cells with a terrestrial conversion efficiency of 12 percent or greater. By applying a graphite coating to one face of a ceramic substrate, molten silicon can be caused to wet only that graphite-coated face and produce uniform thin layers of large-grain polycrystalline silicon; thus, only a minimal quantity of silicon is consumed. A dip-coating method for putting silicon on ceramic (SOC) has been shown to produce solar-cell-quality sheet silicon. This method and a continuous coating process also being investigated have excellent scale-up potential which offers an outstanding cost-effective way to manufacture large-area solar cells. A variety of ceramic materials have been dip-coated with silicon. The investigation has shown that mullite substrates containing an excess of SiO/sub 2/ best match the thermal expansion coefficient of silicon and hence produce the best SOC layers. With such substrates, smooth and uniform silicon layers 25 cm/sup 2/ in area have been achieved with single-crystal grains as large as 4 mm in width and several cm in length. Solar cells with areas from 1 to 10 cm/sup 2/ have been fabricated from material withas-grown surface. Recently, an antireflection (AR) coating has been applied to SOC cells. Conversion efficiencies greater than 9% have been achieved without optimizing series resistance characteristics. Such cells typically have open-circuit voltages and short-circuit current densities of 0.51 V and 20 mA/cm/sup 2/, respectively.

  3. An Improved Manufacturing Approach for Discrete Silicon Microneedle Arrays with Tunable Height-Pitch Ratio

    OpenAIRE

    Renxin Wang; Wei Wang(College of William and Mary); Zhihong Li

    2016-01-01

    Silicon microneedle arrays (MNAs) have been widely studied due to their potential in various transdermal applications. However, discrete MNAs, as a preferred choice to fabricate flexible penetrating devices that could adapt curved and elastic tissue, are rarely reported. Furthermore, the reported discrete MNAs have disadvantages lying in uniformity and height-pitch ratio. Therefore, an improved technique is developed to manufacture discrete MNA with tunable height-pitch ratio, which involves ...

  4. Low cost silicon solar array project large area silicon sheet task: Silicon web process development

    Science.gov (United States)

    Duncan, C. S.; Seidensticker, R. G.; Mchugh, J. P.; Blais, P. D.; Davis, J. R., Jr.

    1977-01-01

    Growth configurations were developed which produced crystals having low residual stress levels. The properties of a 106 mm diameter round crucible were evaluated and it was found that this design had greatly enhanced temperature fluctuations arising from convection in the melt. Thermal modeling efforts were directed to developing finite element models of the 106 mm round crucible and an elongated susceptor/crucible configuration. Also, the thermal model for the heat loss modes from the dendritic web was examined for guidance in reducing the thermal stress in the web. An economic analysis was prepared to evaluate the silicon web process in relation to price goals.

  5. Metal additive-manufacturing process and residual stress modeling

    National Research Council Canada - National Science Library

    Megahed, Mustafa; Mindt, Hans-Wilfried; N’Dri, Narcisse; Duan, Hongzhi; Desmaison, Olivier

    2016-01-01

    Additive manufacturing (AM), widely known as 3D printing, is a direct digital manufacturing process, where a component can be produced layer by layer from 3D digital data with no or minimal use of machining, molding, or casting...

  6. Process-induced strain in silicon-on-insulator materials

    CERN Document Server

    Tiberj, A; Blanc, C; Contreras, S; Camassel, J

    2002-01-01

    We present a detailed investigation of the influence of oxidation and thinning processes on the in-plane stress in silicon-on-insulator materials. Combining double x-ray diffraction, Fourier transformed infrared and micro-Raman spectroscopy, we show that one can separately evaluate the stress present in the silicon over layer, the buried oxide and the underlying (handle) silicon wafer at any time of a device-forming process.

  7. Development of processes for the production of low cost silicon dendritic web for solar cells

    Science.gov (United States)

    Duncan, C. S.; Seidensticker, R. G.; Mchugh, J. P.; Hopkins, R. H.; Skutch, M. E.; Driggers, J. M.; Hill, F. E.

    1980-01-01

    High area output rates and continuous, automated growth are two key technical requirements for the growth of low-cost silicon ribbons for solar cells. By means of computer-aided furnace design, silicon dendritic web output rates as high as 27 sq cm/min have been achieved, a value in excess of that projected to meet a $0.50 per peak watt solar array manufacturing cost. The feasibility of simultaneous web growth while the melt is replenished with pelletized silicon has also been demonstrated. This step is an important precursor to the development of an automated growth system. Solar cells made on the replenished material were just as efficient as devices fabricated on typical webs grown without replenishment. Moreover, web cells made on a less-refined, pelletized polycrystalline silicon synthesized by the Battelle process yielded efficiencies up to 13% (AM1).

  8. Simulating the Composite Propellant Manufacturing Process

    Science.gov (United States)

    Williamson, Suzanne; Love, Gregory

    2000-01-01

    There is a strategic interest in understanding how the propellant manufacturing process contributes to military capabilities outside the United States. The paper will discuss how system dynamics (SD) has been applied to rapidly assess the capabilities and vulnerabilities of a specific composite propellant production complex. These facilities produce a commonly used solid propellant with military applications. The authors will explain how an SD model can be configured to match a specific production facility followed by a series of scenarios designed to analyze operational vulnerabilities. By using the simulation model to rapidly analyze operational risks, the analyst gains a better understanding of production complexities. There are several benefits of developing SD models to simulate chemical production. SD is an effective tool for characterizing complex problems, especially the production process where the cascading effect of outages quickly taxes common understanding. By programming expert knowledge into an SD application, these tools are transformed into a knowledge management resource that facilitates rapid learning without requiring years of experience in production operations. It also permits the analyst to rapidly respond to crisis situations and other time-sensitive missions. Most importantly, the quantitative understanding gained from applying the SD model lends itself to strategic analysis and planning.

  9. 13th Workshop on Crystalline Silicon Solar Cell Materials and Processes: Extended Abstracts and Papers

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B. L.; Rand, J.; Saitoh, T.; Sinton, R.; Stavola, M.; Swanson, D.; Tan, T.; Weber, E.; Werner, J.; Al-Jassim, M.

    2003-08-01

    The 13th Workshop will provide a forum for an informal exchange of technical and scientific information between international researchers in the photovoltaic and relevant non-photovoltaic fields. It will offer an excellent opportunity for researchers in private industry and at universities to prioritize mutual needs for future collaborative research. The workshop is intended to address the fundamental aspects of impurities and defects in silicon: their properties, the dynamics during device processing, and their application for developing low-cost processes for manufacturing high-efficiency silicon solar cells. A combination of oral, poster, and discussion sessions will review recent advances in crystal growth, new cell structures, new processes and process characterization techniques, and cell fabrication approaches suitable for future manufacturing demands.

  10. A framework for manufacturing execution system deployment in an advanced additive manufacturing process

    OpenAIRE

    D'ANTONIO, Gianluca; SEGONDS, Frédéric; LAVERNE, Floriane; Sauza-Bedolla, Joel; Chiabert, Paolo

    2017-01-01

    The deployment of additive manufacturing (AM) processes had a rapid and broad increase in the last years, and the same trend is expected tohold in the near future. A way to better exploit the advantages of such technology is the use of appropriate information tools. However, today thereis a lack of software applications devoted to this innovative manufacturing process. To overcome this issue, in the present work the application of manufacturing execution systems (MES), a tool commonly used in...

  11. Auxetic polyurethane foam: Manufacturing and processing analysis

    Science.gov (United States)

    Jahan, Md Deloyer

    Materials with negative Poisson's ratio are referred to as auxetic materials. They are different from conventional materials in their deformation behavior when responding to external stresses. The cross-section of the materials widens in the lateral direction when being stretched in the longitudinal direction and becomes narrower when being compressed longitudinally. While a number of natural auxetic materials exist, most auxetic materials are synthetic. They show interesting properties and have potential in several important applications. Auxetic materials exhibit better mechanical properties than conventional materials such as enhanced indentation resistance, shear resistance, toughness, damping and energy absorption capacity, sound absorption, variable permeability and capability of producing complex curvature. These properties are beneficial in a wide range of applications including personal protective equipments, sound absorbers, packaging, smart filtration, drug delivery, tissue scaffolding, seat cushioning, etc. A wide range of auxetic materials has been synthesized. They include different polymers, metals, composites and ceramics. Among these, auxetic polyurethane (PU) foam is one of the most widely studied types of auxetic materials. Auxetic PU foams are usually fabricated by altering the microstructure of conventional foams and the unusual mechanical properties originate from the deformation characteristics of the microstructures. Three most important processing parameters in fabricating auxetic PU foam that dictate auxetic behavior are processing temperature, heating time and volumetric compression ratio. This study addresses several important issues in the manufacturing and characterization of auxetic PU foam. First, an improved automatic measuring technique has been developed to determine Poisson's ratio of auxetic PU foam. The technique involves development of a Matlab based image processing program. The second part of the study includes an

  12. Role of point defects/defect complexes in silicon device processing. Book of abstracts, fourth workshop

    Energy Technology Data Exchange (ETDEWEB)

    1994-06-01

    The 41 abstracts are arranged into 6 sessions: impurities and defects in commercial substrates: their sources, effects on material yield, and material quality; impurity gettering in silicon: limits and manufacturability of impurity gettering and in silicon solar cells; impurity/defect passivation; new concepts in silicon growth: improved initial quality and thin films; and silicon solar cell design opportunities.

  13. IMPROVING MANUFACTURING PROCESSES USING SIMULATION METHODS

    Directory of Open Access Journals (Sweden)

    Sławomir KŁOS

    2016-12-01

    Full Text Available The paper presents the results of simulation research on buffer space allocated in a flow line and operation times influence on the throughput of a manufacturing system. The production line in the study consists of four stages and is based on a real machining manufacturing system of a small production enterprise. Using Tecnomatix Plant Simulation software, a simulation model of the system was created and set of experiments was planned. Simulation experiments were prepared for different capacities of intermediate buffers located between manufacturing resources and operation times as input parameters, and the throughput per hour and average life span of products as the output.

  14. Friction Stir Processing for Efficient Manufacturing

    Energy Technology Data Exchange (ETDEWEB)

    Mr. Christopher B. Smith; Dr. Oyelayo Ajayi

    2012-01-31

    Friction at contacting surfaces in relative motion is a major source of parasitic energy loss in machine systems and manufacturing processes. Consequently, friction reduction usually translates to efficiency gain and reduction in energy consumption. Furthermore, friction at surfaces eventually leads to wear and failure of the components thereby compromising reliability and durability. In order to reduce friction and wear in tribological components, material surfaces are often hardened by a variety of methods, including conventional heat treatment, laser surface hardening, and thin-film coatings. While these surface treatments are effective when used in conjunction with lubrication to prevent failure, they are all energy intensive and could potentially add significant cost. A new concept for surface hardening of metallic materials and components is Friction Stir Processing (FSP). Compared to the current surface hardening technologies, FSP is more energy efficient has no emission or waste by products and may result in better tribological performance. FSP involves plunging a rotating tool to a predetermined depth (case layer thickness) and translating the FSP tool along the area to be processed. This action of the tool produces heating and severe plastic deformation of the processed area. For steel the temperature is high enough to cause phase transformation, ultimately forming hard martensitic phase. Indeed, FSP has been used for surface modification of several metals and alloys so as to homogenize the microstructure and refine the grain size, both of which led to improved fatigue and corrosion resistance. Based on the effect of FSP on near-surface layer material, it was expected to have beneficial effects on friction and wear performance of metallic materials. However, little or no knowledge existed on the impact of FSP concerning friction and wear performance the subject of the this project and final report. Specifically for steel, which is the most dominant

  15. Modular manufacturing processes : Status, challenges, and opportunities

    NARCIS (Netherlands)

    Baldea, Michael; Edgar, Thomas F.; Stanley, Bill L.; Kiss, Anton A.

    2017-01-01

    Chemical companies are constantly seeking new, high-margin growth opportunities, the majority of which lie in high-grade, specialty chemicals, rather than in the bulk sector. To realize these opportunities, manufacturers are increasingly considering decentralized, flexible production facilities:

  16. Developing the Manufacturing Process for Hylene MP Curing Agent

    Energy Technology Data Exchange (ETDEWEB)

    Eastwood, Eric

    2009-02-16

    This report details efforts to scale-up and re-establish the manufacturing process for the curing agent known as Hylene MP. First, small scale reactions were completed with varying conditions to determine key drivers for yielding high quality product. Once the optimum conditions were determined on the small scale, the scaled-up process conditions were determined. New equipment was incorporated into the manufacturing process to create a closed production system and improve chemical exposure controls and improve worker safety. A safe, efficient manufacturing process was developed to manufacture high quality Hylene MP in large quantities.

  17. Printing Processes Used to Manufacture Photovoltaic Solar Cells

    Science.gov (United States)

    Rardin, Tina E.; Xu, Renmei

    2011-01-01

    There is a growing need for renewable energy sources, and solar power is a good option in many instances. Photovoltaic solar panels are now being manufactured via various methods, and different printing processes are being incorporated into the manufacturing process. Screen printing has been used most prevalently in the printing process to make…

  18. Application of silicone based elastomers for manufacturing of Green Fiber Bottle

    DEFF Research Database (Denmark)

    Saxena, Prateek; Bissacco, Giuliano

    Due to ever-increasing demand of sustainable products, eco-friendly packaging solutions are finding their importance in the paper packaging industry. Green Fiber Bottle (GFB) is an alternative to plastic, glass and metal based packaging for beverages. The tool concept for manufacturing of paper b...... bottle uses a silicone based elastomer as the core. The expansion of core in the tool resists shrinkage of paper during drying as well as helps in obtaining good fiber compaction. The feasibility of the tool concept in the production of GFB is discussed in this work....

  19. Process model development for optimization of forged disk manufacturing processes

    Energy Technology Data Exchange (ETDEWEB)

    Fischer, C.E.; Gunasekera, J.S. [Ohio Univ., Athens, OH (United States). Center for Advanced Materials Processing; Malas, J.C. [Wright Labs., Wright Patterson AFB, OH (United States). Materials Directorate

    1997-12-31

    This paper addresses the development of a system which will enable the optimization of an entire processing sequence for a forged part. Typically such a sequence may involve several stages and alternative routes of manufacturing a given part. It is important that such a system be optimized globally, (rather than locally, as is the current practice) in order to achieve improvements in affordability, producibility, and performance. This paper demonstrates the development of a simplified forging model, discussion techniques for searching and reducing a very large design space, and an objective function to evaluate the cost of a design sequence.

  20. Effect of manufacturing and experimental conditions on the mechanical and surface properties of silicone elastomer scaffolds used in endothelial mechanobiological studies.

    Science.gov (United States)

    Campeau, Marc-Antoine; Lortie, Audrey; Tremblay, Pierrick; Béliveau, Marc-Olivier; Dubé, Dominic; Langelier, Ève; Rouleau, Léonie

    2017-07-14

    Mechanobiological studies allow the characterization of cell response to mechanical stresses. Cells need to be supported by a material with properties similar to the physiological environment. Silicone elastomers have been used to produce various in vitro scaffolds of different geometries for endothelial cell studies given its relevant mechanical, optical and surface properties. However, obtaining defined and repeatable properties is a challenge as depending on the different manufacturing and processing steps, mechanical and surface properties may vary significantly between research groups. The impact of different manufacturing and processing methods on the mechanical and surface properties was assessed by measuring the Young's modulus and the contact angle. Silicone samples were produced using different curing temperatures and processed with different sterilization techniques and hydrophilization conditions. Different curing temperatures were used to obtain materials of different stiffness with a chosen silicone elastomer, i.e. Sylgard 184®. Sterilization by boiling had a tendency to stiffen samples cured at lower temperatures whereas UV and ethanol did not alter the material properties. Hydrophilization using sulphuric acid allowed to decrease surface hydrophobicity, however this effect was lost over time as hydrophobic recovery occurred. Extended contact with water maintained decreased hydrophobicity up to 7 days. Mechanobiological studies require complete cell coverage of the scaffolds used prior to mechanical stresses exposure. Different concentrations of fibronectin and collagen were used to coat the scaffolds and cell seeding density was varied to optimize cell coverage. This study highlights the potential bias introduced by manufacturing and processing conditions needed in the preparation of scaffolds used in mechanobiological studies involving endothelial cells. As manufacturing, processing and cell culture conditions are known to influence cell

  1. UOE Pipe Manufacturing Process Simulation: Equipment Designing and Construction

    Science.gov (United States)

    Delistoian, Dmitri; Chirchor, Mihael

    2017-12-01

    UOE pipe manufacturing process influence directly on pipeline resilience and operation capacity. At present most spreaded pipe manufacturing method is UOE. This method is based on cold forming. After each technological step appears a certain stress and strain level. For pipe stress strain study is designed and constructed special equipment that simulate entire technological process.UOE pipe equipment is dedicated for manufacturing of longitudinally submerged arc welded DN 400 (16 inch) steel pipe.

  2. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual technical report, 1 January 1996--30 June 1996

    Energy Technology Data Exchange (ETDEWEB)

    Wohlgemuth, J [Solarex Corp., Frederick, MD (United States)

    1997-01-01

    Two specific objectives of Solarex`s program are to reduce the manufacturing cost for polycrystalline silicon photovoltaic modules to less than $1.20/watt and to increase the manufacturing capacity by a factor of three. This report highlights accomplishments during the period of January 1 through June 30, 1996. Accomplishments include: began the conversion of production casting stations to increase ingot size; operated the wire saw in a production mode with higher yields and lower costs than achieved on the ID saws; developed and qualified a new wire guide coating material that doubles the wire guide lifetime and produces significantly less scatter in wafer thickness; completed a third pilot run of the cost-effective Al paste back-surface-field (BSF) process, verifying a 5% increase in cell efficiency and demonstrating the ability to process and handle the BSF paste cells; completed environmental qualification of modules using cells produced by an all-print metallization process; optimized the design of the 15.2-cm by 15.2-cm polycrystalline silicon solar cells; demonstrated the application of a high-efficiency process in making 15.2-cm by 15.2-cm solar cells; demonstrated that cell efficiency increases with decreasing wafer thickness for the Al paste BSF cells; qualified a vendor-supplied Tedlar/ethylene vinyl acetate (EVA) laminate to replace the combination of separate sheets of EVA and Tedlar backsheet; demonstrated the operation of a prototype unit to trim/lead attach/test modules; and demonstrated the operation of a wafer pull-down system for cassetting wet wafers.

  3. Platform for 3D inline process control in additive manufacturing

    Science.gov (United States)

    Preissler, Marc; Zhang, Chen; Rosenberger, Maik; Notni, Gunther

    2017-06-01

    3D - Inline - Process - Control is getting more attention in any fields of manufacturing processes to increase productivity and quality. Sensor systems are necessary to capture the currently process status and are basement for Inline-Process- Control. The presented work is a possibility to get inline information's about the additive manufacturing process Fused Filament Fabrication. The requirement is the ability to manipulate the machine code to get free field of view to the topside of the object after every manufactured layer. The adaptable platform layout makes possible to create different approaches for inline process control. One approach is the single camera layout from bird view to get 2,5D information's about the manufactured object and the other one is the active stereoscopic camera layout with pattern projection. Both approaches are showing a possibility to get information's of the manufactured object in process. Additional this cases allow a view inside the manufactured object and defects can be located. Deviations in the manufacturing process can be corrected and relevant parameters can be adapted during slicing process to increase the manufacturing quality.

  4. Process for the Manufacture of Ajoene Derivatives

    DEFF Research Database (Denmark)

    2012-01-01

    to a method for manufacturing (E,Z) ajoene of formula (1) wherein the conformation of the internal C=C- bond can be either E or Z or a mixture thereof, said method comprising reacting allicin of formula (3) with an acid in the presence of a solvent to provide (E,Z ajoene) of formula (1) as defined above. Yet...

  5. Process for the manufacture of ajoene derivatives

    DEFF Research Database (Denmark)

    2012-01-01

    to a method for manufacturing (E,Z) ajoene of formula (1) wherein the conformation of the internal C=C- bond can be either E or Z or a mixture thereof, said method comprising reacting allicin of formula (3) with an acid in the presence of a solvent to provide (E,Z ajoene) of formula (1) as defined above. Yet...

  6. Sustainable Manufacturing via Multi-Scale, Physics-Based Process Modeling and Manufacturing-Informed Design

    Energy Technology Data Exchange (ETDEWEB)

    None

    2017-04-01

    This factsheet describes a project that developed and demonstrated a new manufacturing-informed design framework that utilizes advanced multi-scale, physics-based process modeling to dramatically improve manufacturing productivity and quality in machining operations while reducing the cost of machined components.

  7. 31 CFR 500.412 - Process vs. manufacture.

    Science.gov (United States)

    2010-07-01

    ... 31 Money and Finance: Treasury 3 2010-07-01 2010-07-01 false Process vs. manufacture. 500.412 Section 500.412 Money and Finance: Treasury Regulations Relating to Money and Finance (Continued) OFFICE... Interpretations § 500.412 Process vs. manufacture. A commodity subject to § 500.204 remains subject howsoever it...

  8. External designers in product design processes of small manufacturing firms

    NARCIS (Netherlands)

    Berends, Hans; Reymen, Isabelle; Stultiëns, Rutger G L; Peutz, Murk

    Small manufacturing firms often fail to reap the benefits of good design practices. This study investigates how the involvement of external designers influences the evolution of product design processes in small manufacturing firms. Qualitative and quantitative process research methods were used to

  9. Nonlinear Silicon Photonic Signal Processing Devices for Future Optical Networks

    Directory of Open Access Journals (Sweden)

    Cosimo Lacava

    2017-01-01

    Full Text Available In this paper, we present a review on silicon-based nonlinear devices for all optical nonlinear processing of complex telecommunication signals. We discuss some recent developments achieved by our research group, through extensive collaborations with academic partners across Europe, on optical signal processing using silicon-germanium and amorphous silicon based waveguides as well as novel materials such as silicon rich silicon nitride and tantalum pentoxide. We review the performance of four wave mixing wavelength conversion applied on complex signals such as Differential Phase Shift Keying (DPSK, Quadrature Phase Shift Keying (QPSK, 16-Quadrature Amplitude Modulation (QAM and 64-QAM that dramatically enhance the telecom signal spectral efficiency, paving the way to next generation terabit all-optical networks.

  10. Development of manufacturing capability for high-concentration, high-efficiency silicon solar cells

    Energy Technology Data Exchange (ETDEWEB)

    Sinton, R.A.; Verlinden, P.J.; Crane, R.A.; Swanson, R.N. [SunPower Corp., Sunnyvale, CA (United States)

    1996-10-01

    This report presents a summary of the major results from a program to develop a manufacturable, high-efficiency silicon concentrator solar cell and a cost-effective manufacturing facility. The program was jointly funded by the Electric Power Research Institute, Sandia National Laboratories through the Concentrator Initiative, and SunPower Corporation. The key achievements of the program include the demonstration of 26%-efficient silicon concentrator solar cells with design-point (20 W/cm{sup 2}) efficiencies over 25%. High-performance front-surface passivations; that were developed to achieve this result were verified to be absolutely stable against degradation by 475 days of field exposure at twice the design concentration. SunPower demonstrated pilot production of more than 1500 of these cells. This cell technology was also applied to pilot production to supply 7000 17.7-cm{sup 2} one-sun cells (3500 yielded wafers) that demonstrated exceptional quality control. The average efficiency of 21.3% for these cells approaches the peak efficiency ever demonstrated for a single small laboratory cell within 2% (absolute). Extensive cost models were developed through this program and calibrated by the pilot-production project. The production levels achieved indicate that SunPower could produce 7-10 MW of concentrator cells per year in the current facility based upon the cell performance demonstrated during the program.

  11. Optimization of steel bar manufacturing process using six sigma

    Science.gov (United States)

    Naeem, Khawar; Ullah, Misbah; Tariq, Adnan; Maqsood, Shahid; Akhtar, Rehman; Nawaz, Rashid; Hussain, Iftikhar

    2016-03-01

    Optimization of a manufacturing process results in higher productivity and reduced wastes. Production parameters of a local steel bar manufacturing industry of Pakistan is optimized by using six Sigma-Define, measure, analyze, improve, and controlmethodology. Production data is collected and analyzed. After analysis, experimental design result is used to identify significant factors affecting process performance. The significant factors are controlled to optimized level using two-level factorial design method. A regression model is developed that helps in the estimation of response under multi variable input values. Model is tested, verified, and validated by using industrial data collected at a local steel bar manufacturing industry of Peshawar(Khyber Pakhtunkhwa, Pakistan). The sigma level of the manufacturing process is improved to 4.01 from 3.58. The novelty of the research is the identification of the significant factors along with the optimum levels that affects the process yield, and the methodology to optimize the steel bar manufacturing process.

  12. Wellbore manufacturing processes for in situ heat treatment processes

    Science.gov (United States)

    Davidson, Ian Alexander; Geddes, Cameron James; Rudolf, Randall Lynn; Selby, Bruce Allen; MacDonald, Duncan Charles

    2012-12-11

    A method includes making coiled tubing at a coiled tubing manufacturing unit coupled to a coiled tubing transportation system. One or more coiled tubing reels are transported from the coiled tubing manufacturing unit to one or more moveable well drilling systems using the coiled tubing transportation system. The coiled tubing transportation system runs from the tubing manufacturing unit to one or more movable well drilling systems, and then back to the coiled tubing manufacturing unit.

  13. Process Optimization Guide for Military Manufacturing and Maintenance Facilities

    National Research Council Canada - National Science Library

    Lin, Mike

    1999-01-01

    ... and their potential for improvements. Through process optimization (PO), energy and environmental performance can be improved by analyzing and changing the manufacturing and maintenance processes themselves to increase productivity...

  14. Formation of Silicon Carbide in the Silicomanganese Process

    OpenAIRE

    Davidsen, Jens Erik

    2011-01-01

    As the silicon content in a silicomanganese alloy increase, silicon carbide becomes the stable carbon phase. Little work is published on the formation of silicon carbide in the SiMn process. This thesis examines the formation of SiC through the reaction between slag, metal and coke. The goal of the thesis has been to determine where and how SiC is formed in the silicomanganese process. Focus has been given to formation through liquid-solid reactions.The investigation was carried out by heatin...

  15. Material Quality and Process Monitoring in Metal Additive Manufacturing

    OpenAIRE

    Clemon, Lee

    2017-01-01

    Additive manufacturing is rapidly becoming available to designers, hobbyists, and industrial manufacturers. Unfortunately, process control and predictability remain beyond the grasp of most users and even machine tool builders. This manuscript employs design and material quality monitoring to explore solutions to these challenges. Metallurgical study and design limitations were explored through intentional design. Design for additive manufacturing was shown to provide insight into both proces...

  16. Current manufacturing processes of drug-eluting sutures.

    Science.gov (United States)

    Champeau, Mathilde; Thomassin, Jean-Michel; Tassaing, Thierry; Jérôme, Christine

    2017-11-01

    Drug-eluting sutures represent the next generation of surgical sutures since they fulfill their mechanical functions but also deliver the drug in their vicinity after implantation. These implants are produced by a variety of manufacturing processes. Drug-eluting sutures represent the next generation of surgical sutures since they fulfill their mechanical functions but also deliver the drug in their vicinity after implantation. These implants are produced by a variety of manufacturing processes. Two general approaches can be followed: (i) the ones that add the API into the material during the manufacturing process of the suture and (ii) the ones that load the API to an already manufactured suture. Areas covered: This review provides an overview of the current manufacturing processes for drug-eluting suture production and discusses their benefits and drawbacks depending on the type of drugs. The mechanical properties and the drug delivery profile of drug-eluting sutures are highlighted since these implants must fulfill both criteria. Expert opinion: For limited drug contents, melt extrusion and electrospinning are the emerging processes since the drug is added during the suture manufacture process. Advantageously, the drug release profile can be tuned by controlling the processing parameters specific to each process and the composition of the drug-containing polymer. If high drug content is targeted, the coating or grafting of a drug layer on a pre-manufactured suture allows for preservation of the tensile strength requirements of the suture.

  17. Linear signal processing using silicon micro-ring resonators

    DEFF Research Database (Denmark)

    Peucheret, Christophe; Ding, Yunhong; Ou, Haiyan

    2012-01-01

    We review our recent achievements on the use of silicon micro-ring resonators for linear optical signal processing applications, including modulation format conversion, phase-to-intensity modulation conversion and waveform shaping.......We review our recent achievements on the use of silicon micro-ring resonators for linear optical signal processing applications, including modulation format conversion, phase-to-intensity modulation conversion and waveform shaping....

  18. Optical signal processing by silicon photonics

    CERN Document Server

    Ahmed, Jameel; Adeel, Freeha; Hussain, Ashiq

    2014-01-01

    The main objective of this book is to make respective graduate students understand the nonlinear effects inside SOI waveguide and possible applications of SOI waveguides in this emerging research area of optical fibre communication. This book focuses on achieving successful optical frequency shifting by Four Wave Mixing (FWM) in silicon-on-insulator (SOI) waveguide by exploiting a nonlinear phenomenon.

  19. Risk calculations in the manufacturing technology selection process

    DEFF Research Database (Denmark)

    Farooq, S.; O'Brien, C.

    2010-01-01

    in the shape of opportunities and threats in different decision-making environments. Practical implications - The research quantifies the risk associated with different available manufacturing technology alternatives. This quantification of risk crystallises the process of technology selection decision making...... and supports an industrial manager in achieving objective and comprehensive decisions regarding selection of a manufacturing technology. Originality/value - The paper explains the process of risk calculation in manufacturing technology selection by dividing the decision-making environment into manufacturing......Purpose - The purpose of this paper is to present result obtained from a developed technology selection framework and provide a detailed insight into the risk calculations and their implications in manufacturing technology selection process. Design/methodology/approach - The results illustrated...

  20. Key Features of the Manufacturing Vision Development Process

    DEFF Research Database (Denmark)

    Dukovska-Popovska, Iskra; Riis, Jens Ove; Boer, Harry

    2005-01-01

    This paper discusses the key features of the process of Manufacturing Vision Development, a process that enables companies to develop their future manufacturing concept. The basis for the process is a generic five-phase methodology (Riis and Johansen 2003) developed as a result of ten years...... of action research. The methodology recommends wide participation of people from different hierarchical and functional positions, who engage in a relatively short, playful and creative process and come up with a vision (concept) for the future manufacturing system in the company. Based on three case studies...... of companies going through the initial phases of the methodology, this research identified the key features of the Manufacturing Vision Development process. The paper elaborates the key features by defining them, discussing how and when they can appear, and how they influence the process....

  1. Environmental Strategies for Sustainable Manufacturing Process of Composites

    Science.gov (United States)

    Kireitseu, Maxim

    2017-09-01

    This research is focused on the strategic road mapping of composite manufacturing process and aims to understand the sustainability and related costs of composite part manufacturing. A manufacturing route of a serial automotive component is mapped and modelled using the following steps: (1) a holistic, cradle to grave product model for both manuflacturing and assembly operations, (2) development of life-cycle model and analytical tools, and (3) direct data collection and measure of environmental impacts of manufacturing. Besides the theoretical outcomes recommendations are given considering further recycling and recovery of materials so as to provide further direction for sustainability research in carbon and glass fibre composites.

  2. Evaluation of surface analysis methods for characterization of trace metal surface contaminants found in silicon IC manufacturing

    Energy Technology Data Exchange (ETDEWEB)

    Diebold, A.C.; Maillot, P.; Gordon, M.; Baylis, J.; Chacon, J.; Witowski, R. (SEMATECH, Austin, TX (United States)); Arlinghaus, H. (Atom Sciences, Inc., Oak Ridge, TN (United States)); Knapp, J.A.; Doyle, B.L. (Sandia National Labs., Albuquerque, NM (United States))

    1991-01-01

    A major topic at recent silicon-based integrated circuit (IC) manufacturing symposia is the pursuit of decreased contamination levels. The aim is to remove contamination from both processes and materials. In conjunction with this effort, characterization methods are being pushed to lower and lower detection limits. In this paper, we evaluate surface analysis methods used to determine the concentration of inorganic contamination on unpatterned Si wafers. We compare sampling depths, detection limits, and applicability of each method for use in support of Si IC manufacturing. This comparison is further limited to Fe and Cu which are transition metal contaminants associated with manufacturing yield loss. The surface analysis methods included in this evaluation are: Total Reflection X-Ray Fluorescence (TXRF or TRXRF); Secondary Ion Mass Spectrometry (SIMS); two post-ionization'' methods Surface Analysis by Laser Ionization (SALI) and Sputter Initiated Resonant Ionization Spectroscopy (SIRIS); Heavy Ion Backscattering Spectroscopy (HIBS); and Vapor Phase Phase Decomposition (VPD) based methods Atomic Absorption (VPD-AA) along with VPD-TXRF. Sets of 6 in. Si wafers with concentration levels between 10{sup 9} atoms/cm{sup 2} and 10{sup 12} atoms/cm{sup 2} Fe and Cu were characterized by TXRF, SIMS, SIRIS, and HIBS. This data allows estimation of detection limits (DLs) and relative method accuracy. In Section 1 we describe each surface analysis method and the circumstance under which it would be used to support Si IC manufacturing. The equipment used for this comparison and the 150 mm Si wafer set are described in Section 2. Results from each method are contrasted in Section 3. Finally, a conclusion is presented in Section 4.

  3. Recent Developments in Abrasive Hybrid Manufacturing Processes

    National Research Council Canada - National Science Library

    Adam Ruszaj; Sebastian Skoczypiec; Dominik Wyszyński

    2017-01-01

    ... processes already applied in practice. This tendency also occurs in abrasive machining processes which are often supported by ultrasonic vibrations, electrochemical dissolution or by electrical discharges...

  4. Process-tolerant manufacturing: An optimization strategy for improving manufacturing yields

    Energy Technology Data Exchange (ETDEWEB)

    Readey, M.J.; Lovejoy, C.D. II (Carnegie Mellon Univ., Pittsburgh, PA (United States))

    1993-09-01

    Low manufacturing yields result in high product costs, long lead times, and considerable nonrecyclable material waste. Improving these yields requires minimizing the variability introduced during processing. Processing conditions that lead to process tolerant behavior, where process variability has little effect on the final product of interest, are identified. Dramatic improvements in manufacturing yield are required if ceramics are to be cost competitive with other engineering materials. One effective approach to improving yields is to identify the processing conditions that lead to process-tolerant manufacturing. This approach derives from basic concepts of optimization theory, and is facilitated by the use of a simple graphical technique. The strategy is widely applicable to the ceramics industry, and could quickly result in lower production costs and shorter deliver times.

  5. Chemical processing of materials on silicon: more functionality, smaller features, and larger wafers.

    Science.gov (United States)

    Marchack, Nathan; Chang, Jane P

    2012-01-01

    The invention of the transistor followed by more than 60 years of aggressive device scaling and process integration has enabled the global information web and subsequently transformed how people communicate and interact. The principles and practices built upon chemical processing of materials on silicon have been widely adapted and applied to other equally important areas, such as microfluidic systems for chemical and biological analysis and microscale energy storage solutions. The challenge of continuing these technological advances hinges on further improving the performance of individual devices and their interconnectivity while making the manufacturing processes economical, which is dictated by the materials' innate functionality and how they are chemically processed. In this review, we highlight challenges in scaling up the silicon wafers and scaling down the individual devices as well as focus on needs and challenges in the synthesis and integration of multifunctional materials.

  6. Process and quality verification controls for solid propellant manufacturing

    Science.gov (United States)

    Rogers, C. J.

    1983-01-01

    It is pointed out that in-process tests to verify quality and detect discrepant propellant which could compromise motor performance are essential elements of the solid composite propellant manufacturing process. The successful performance of the 260SL-1 and 260SL-2 motors aptly verified the controls used for manufacturing the propellant. The present investigation is concerned with the selected control parameters, and their relationships to composition and final propellant properties. Control performance is evaluated by comparison with processing data experienced in the manufacture of the propellant for the 260SL-1 motor. It is found that the in-process quality verification controls utilized in the propellant manufacturing process for the 260-in. diameter motor contributed significantly to the confidence of successful and predictable motor performance.

  7. Silicon-on-ceramic process: silicon sheet growth and device development for the Large-Area Silicon Sheet and Cell Development Tasks of the Low-Cost Solar Array Project. Quarterly report No. 11, January 1-March 30, 1979

    Energy Technology Data Exchange (ETDEWEB)

    Chapman, P.W.; Zook, J.D.; Heaps, J.D.; Grung, B.L.; Koepke, B.; Schuldt, S.B.

    1979-04-30

    The purpose of the research program is to investigate the technical and economic feasibility of producing solar-cell-quality sheet silicon by coating inexpensive ceramic substrates with a thin layer of polycrystalline silicon. The coating methods to be developed are directed toward a minimum-cost process for producing solar cells with a terrestrial conversion efficiency of 12 percent or greater. By applying a graphite coating to one face of a ceramic substrate, molten silicon can be caused to wet only that graphite-coated face and produce uniform thin layers of large-grain polycrystalline silicon; thus, only a minimal quantity of silicon is consumed. A dip-coating method for putting silicon on ceramic (SOC) has been shown to produce solar-cell-quality sheet silicon. This method and a continuous coating process also being investigated have excellent scale-up potential which offers an outstanding, cost-effective way to manufacture large-area solar cells. Results and accomplishments are described.

  8. Additive Manufacturing: Multi Material Processing and Part Quality Control

    DEFF Research Database (Denmark)

    Pedersen, David Bue

    This Ph.D dissertation,ffAdditive Manufacturing: Multi Material Processing and Part Quality Controlff, deal with Additive Manufacturing technologies which is a common name for a series of processes that are recognized by being computer controlled, highly automated, and manufacture objects...... age. Now, with the geometrical freedom given back to the designer and engineer, a technology stale-mate keep us from benefitting from this freedom. Parts can easily be designed and manufactured beyond the capabilities of all common industrial measurement and verification methods, the designer...... was realized within the scope of this project. To empathize why, and how versatile the prospect of multi-material platforms is, a set of subsystems that can be realized by multi-material manufacturing using FDM extrusion has been conceived. A functional battery is built using multi material extrusion...

  9. Ultra-high-speed Optical Signal Processing using Silicon Photonics

    DEFF Research Database (Denmark)

    Oxenløwe, Leif Katsuo; Ji, Hua; Jensen, Asger Sellerup

    on silicon photonics. In particular we use nano-engineered silicon waveguides (nanowires) [1] enabling efficient phasematched four-wave mixing (FWM), cross-phase modulation (XPM) or self-phase modulation (SPM) for ultra-high-speed optical signal processing of ultra-high bit rate serial data signals. We show......— In supercomputers, the optical inter-connects are getting closer and closer to the processing cores. Today, a single supercomputer system has as many optical links as the whole worldwide web together, and it is envisaged that future computing chips will contain multiple electronic processor cores...... that silicon can indeed be used to control Tbit/s serial data signals [2], perform 640 Gbit/s wavelength conversion [3] 640 Gbit/s serial-to-parallel conversion [4], 160 Gbit/s packet switching as well as all-optical regeneration [5]. We will also discuss the performance limitations of crystalline silicon...

  10. In-Process Monitoring of Additive Manufacturing Project

    Data.gov (United States)

    National Aeronautics and Space Administration — The key innovation in this project is the implementation of an Imaging Fourier Transform Spectrometer (IFTS) for in situ metal additive manufacturing process...

  11. Process standardization for the manufacture of Thabdi Peda

    National Research Council Canada - National Science Library

    Modha, H M; Patel, N M; Patel, H G; Patel, K N

    .... For industrial production of such products a standardized process is needed. Present study was designed to arrive at a method of manufacture for Thabdi Peda, a very popular sweet in Saurashtra region of Gujarat...

  12. Novel processes for advanced manufacturing: summary of a workshop

    National Research Council Canada - National Science Library

    Mellody, Maureen

    2013-01-01

    ...) of the National Materials and Manufacturing Board of the National Research Council (NRC) held a workshop on December 5 and 6, 2012, to discuss new and novel processes in industrial modernization...

  13. Systems engineering management process maturity of South African manufacturing organisations

    CSIR Research Space (South Africa)

    Lemberger, ID

    2014-07-01

    Full Text Available to integrate people, processes and technologies to deliver innovative complex systems. The investigation set out to improve the understanding of systems engineering (SE) with focus on organisations in manufacturing of coke, petroleum, chemical products, rubber...

  14. Manufacturing of anode supported SOFCs: Processing parameters and their influence

    DEFF Research Database (Denmark)

    Ramousse, Severine; Menon, Mohan; Brodersen, Karen

    2007-01-01

    contains a complex microstructure. In order to improve the cell performance as well as reducing the processing costs, it has been found necessary to consider the process chain holistically, because successful manufacture of such a cell and the achievement of optimal final properties depend on each......The establishment of low cost, highly reliable and reproducible manufacturing processes has been focused for commercialization of SOFC technology. A major challenge in the production chain is the manufacture of anode-supported planar SOFC's single cells in which each layer in a layered structure...... of the processing steps and their interdependence. A large database for several thousand anode-supported SOFCs manufactured annually at the Risoe National Laboratory in collaboration with Topsoe Fuel Cell A/S has been constructed. This enables a statistical analysis of the various controlling parameters. Some...

  15. Enhancing Manufacturing Process Education via Computer Simulation and Visualization

    Science.gov (United States)

    Manohar, Priyadarshan A.; Acharya, Sushil; Wu, Peter

    2014-01-01

    Industrially significant metal manufacturing processes such as melting, casting, rolling, forging, machining, and forming are multi-stage, complex processes that are labor, time, and capital intensive. Academic research develops mathematical modeling of these processes that provide a theoretical framework for understanding the process variables…

  16. Defective Reduction in Frozen Pie Manufacturing Process

    Science.gov (United States)

    Nooted, Oranuch; Tangjitsitcharoen, Somkiat

    2017-06-01

    The frozen pie production has a lot of defects resulting in high production cost. Failure mode and effect analysis (FMEA) technique has been applied to improve the frozen pie process. Pareto chart is also used to determine the major defects of frozen pie. There are 3 main processes that cause the defects which are the 1st freezing to glazing process, the forming process, and the folding process. The Risk Priority Number (RPN) obtained from FMEA is analyzed to reduce the defects. If RPN of each cause exceeds 45, the process will be considered to be improved and selected for the corrective and preventive actions. The results showed that RPN values decreased after the correction. Therefore, the implementation of FMEA technique can help to improve the performance of frozen pie process and reduce the defects approximately 51.9%.

  17. Machining parameter optimization in turning process for sustainable manufacturing

    OpenAIRE

    S. G. Dambhare; S. J. Deshmukh; A. B. Borade

    2015-01-01

    There is an increase in awareness about sustainable manufacturing process. Manufacturing industries are backbone of a country’s economy. Although it is important but there is a great concern about consumption of resources and waste creation. The primary aim of this study was to explore sustainability concern in turning process in an Indian machining industry. The effect of cutting parameters, Speed/Feed/Depth of Cut, the machining environment, Dry/MQL/Wet, and the type of cutting tool on sust...

  18. Optimization of the process chain for mirrors made of silicon carbide

    Science.gov (United States)

    Waechter, Daniel; Kroedel, Matthias; Huenten, Martin; Klocke, Fritz

    2012-09-01

    Different grades of silicon carbide (SiC) became an established material for structures as well as optical mirrors in space-borne applications. But the manufacturing still causes high efforts and restrains an extension of application in further fields. The research project MirrorFab aims for a qualification of an optimized process chain for manufacturing mirrors made of Cesic®. Cesic® consists of a matrix of SiC reinforced with chopped carbon fibers. There is a space qualified Cesic® manufacturing process and an established network for the supply chain. The project addresses the required gain in efficiency and flexibility in the manufacturing capabilities. The consortium covers the major parts of the process chain. It aims for increasing the performance of each manufacturing technology. Additionally, the consideration of the complete process chain enables a holistic optimization approach. This paper deals particularly with the process optimization of the grinding step after infiltration. The benefit of the use of an ultra precision grinding machine for mirrors in the range of 200 mm is evaluated. This paper presents the results of a systematical study on the influence of the grit size, the type of bond as well the major machining parameters on the surface roughness and the grinding forces, when machining the material Cesic®. A major finding is, that the use of ultra fine grinding wheels does not result in a superior surface quality compared to the use of a D46 grinding wheel with resinoid bond.

  19. Eighth Workshop on Crystalline Silicon Solar Cell Materials and Processes; Summary Discussion Sessions

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B.; Swanson, D.; Sinton, R.; Stavola, M.; Tan, T.

    1998-12-08

    This report is a summary of the panel discussions included with the Eighth Workshop on Crystalline Silicon Solar Cell Materials and Processes. The theme of the workshop was ''Supporting the Transition to World Class Manufacturing.'' This workshop provided a forum for an informal exchange of information between researchers in the photovoltaic and nonphotovoltaic fields on various aspects of impurities and defects in silicon, their dynamics during device processing, and their application in defect engineering. This interaction helped establish a knowledge base that can be used for improving device-fabrication processes to enhance solar-cell performance and reduce cell costs. It also provided an excellent opportunity for researchers from industry and universities to recognize mutual needs for future joint research.

  20. Efficiency of manufacturing processes energy and ecological perspectives

    CERN Document Server

    Li, Wen

    2015-01-01

     This monograph presents a reliable methodology for characterising the energy and eco-efficiency of unit manufacturing processes. The Specific Energy Consumption, SEC, will be identified as the key indicator for the energy efficiency of unit processes.  An empirical approach will be validated on different machine tools and manufacturing processes to depict the relationship between process parameters and energy consumptions. Statistical results and additional validation runs will corroborate the high level of accuracy in predicting the energy consumption. In relation to the eco-efficiency, the value and the associated environmental impacts of  manufacturing processes will also be discussed. The interrelationship between process parameters, process value and the associated environmental impact will be integrated in the evaluation of eco-efficiency. The book concludes with a further investigation of the results in order to develop strategies for further efficiency improvement. The target audience primarily co...

  1. Manufacture of functional surfaces through combined application of tool manufacturing processes and Robot Assisted Polishing

    DEFF Research Database (Denmark)

    Eriksen, Rasmus Solmer; Arentoft, Mogens; Grønbæk, J.

    2012-01-01

    The tool surface topography is often a key parameter in the tribological performance of modern metal forming tools. A new generation of multifunctional surfaces is achieved by combination of conventional tool manufacturing processes with a novel Robot Assisted Polishing process. This novel surface...

  2. The processing and potential applications of porous silicon

    Energy Technology Data Exchange (ETDEWEB)

    Shieh, Syyuan [Univ. of California, Berkeley, CA (United States)

    1992-07-01

    Stability of a cylindrical pore under the influence of surface energy is important for porous silicon (PS) processing in the integrated circuit industry. Once the zig-zag cylindrical pores of porous silicon or oxidized porous silicon (OPS) are unstable and breakup into rows of isolated spherical pores, oxidation of PS and densification/nitridation of OPS become difficult. Swing to difficulty transport of reactant gas (O2, NH3) or the trapped gas (for densification of OPS). A first order analysis of the stability of a cylindrical pore or cylinder is considered first. Growth of small sinusoidal perturbations by viscous flow or evaporation/condensation result in dependence of perturbation growth rate on perturbation wavelength. Rapid thermal oxidation (RTO) of porous silicon is proposed as an alternative for the tedious two-step 300 and 800C oxidation process. Transmission electron microscopy, energy dispersive spectroscopy ESCA are used for quality control. Also, rapid thermal nitridation of oxidized porous silicon in ammonia is proposed to enhance OPS resistance to HF solution. Pores breakup of OPS results in a trapped gas problem during densification. Wet helium is proposed as OPS densification ambient gas to shorten densification time. Finally, PS is proposed to be an extrinsic gettering center in silicon wafers. The suppression of oxidation-induced stacking faults is used to demonstrate the gettering ability. Possible mechanism is discussed.

  3. The processing and potential applications of porous silicon

    Energy Technology Data Exchange (ETDEWEB)

    Syyuan Shieh.

    1992-07-01

    Stability of a cylindrical pore under the influence of surface energy is important for porous silicon (PS) processing in the integrated circuit industry. Once the zig-zag cylindrical pores of porous silicon or oxidized porous silicon (OPS) are unstable and breakup into rows of isolated spherical pores, oxidation of PS and densification/nitridation of OPS become difficult. Swing to difficulty transport of reactant gas (O{sub 2}, NH{sub 3}) or the trapped gas (for densification of OPS). A first order analysis of the stability of a cylindrical pore or cylinder is considered first. Growth of small sinusoidal perturbations by viscous flow or evaporation/condensation result in dependence of perturbation growth rate on perturbation wavelength. Rapid thermal oxidation (RTO) of porous silicon is proposed as an alternative for the tedious two-step 300 and 800C oxidation process. Transmission electron microscopy, energy dispersive spectroscopy ESCA are used for quality control. Also, rapid thermal nitridation of oxidized porous silicon in ammonia is proposed to enhance OPS resistance to HF solution. Pores breakup of OPS results in a trapped gas problem during densification. Wet helium is proposed as OPS densification ambient gas to shorten densification time. Finally, PS is proposed to be an extrinsic gettering center in silicon wafers. The suppression of oxidation-induced stacking faults is used to demonstrate the gettering ability. Possible mechanism is discussed.

  4. Application Of Artificial Neural Networks In Modeling Of Manufactured Front Metallization Contact Resistance For Silicon Solar Cells

    Directory of Open Access Journals (Sweden)

    Musztyfaga-Staszuk M.

    2015-09-01

    Full Text Available This paper presents the application of artificial neural networks for prediction contact resistance of front metallization for silicon solar cells. The influence of the obtained front electrode features on electrical properties of solar cells was estimated. The front electrode of photovoltaic cells was deposited using screen printing (SP method and next to manufactured by two methods: convectional (1. co-fired in an infrared belt furnace and unconventional (2. Selective Laser Sintering. Resistance of front electrodes solar cells was investigated using Transmission Line Model (TLM. Artificial neural networks were obtained with the use of Statistica Neural Network by Statsoft. Created artificial neural networks makes possible the easy modelling of contact resistance of manufactured front metallization and allows the better selection of production parameters. The following technological recommendations for the screen printing connected with co-firing and selective laser sintering technology such as optimal paste composition, morphology of the silicon substrate, co-firing temperature and the power and scanning speed of the laser beam to manufacture the front electrode of silicon solar cells were experimentally selected in order to obtain uniformly melted structure well adhered to substrate, of a small front electrode substrate joint resistance value. The prediction possibility of contact resistance of manufactured front metallization is valuable for manufacturers and constructors. It allows preserving the customers’ quality requirements and bringing also measurable financial advantages.

  5. Investigations on the processing of solid silicon rubber in blow moulding

    Science.gov (United States)

    Hopmann, Ch.; Funk, A.; Windeck, C.

    2015-05-01

    Complex hollow parts made of thermoplastics are often produced in the extrusion blow moulding process. This cost-efficient production technique with a high reproducibility, a high degree of automation and short cycle times has not been adapted for rubber processing until now. Current research activities at IKV focus on the processing of silicone rubber in extrusion blow moulding with an adapted processing and rapid cross-linking systems. The blow moulding process allows an automated and effective production of complex hollow parts made of solid silicone rubber in one step. The use of expensive core techniques, which lead to comparatively high reject rates in injection moulding, is not necessary. Expensive and time-consuming assembly steps can be reduced. This substantially increases the efficiency of the process. A systematic material selection of different solid silicone rubber compounds and cross-linking systems for the extrusion blow moulding process is a major focus of investigation. In this context, the term blow mouldability of polymers is defined and the suitability of solid silicone rubbers in combination with cross-linking systems for the blow moulding process is analysed. Characteristic mechanical and physical properties allow the identification of suitable material systems and give advice for the implementation of the new process. Extrusion blow moulding of solid silicone rubber is a new and innovative manufacturing concept to produce elastomeric hollow parts. Influences on the forming process are not known for silicone rubber yet. Therefore, to obtain a detailed process description is another focus of the research project. This includes the forming process, the processing and the influences of the material and the curing reaction on the processing. In the first instance, the investigation and description of the forming process as well as the detailed analysis of the processing parameters, such as curing time, mould temperature, wall thickness of the

  6. All-Optical Signal Processing using Silicon Devices

    DEFF Research Database (Denmark)

    Oxenløwe, Leif Katsuo; Pu, Minhao; Ding, Yunhong

    2014-01-01

    This paper presents an overview of recent wo rk on the use of silicon waveguides for processing optical data signals. We will describe ultra-fast, ultra-broadband, polarisation-insensitive and phase-sensitive applications including processing of spectrally-efficient data formats and optical phase...

  7. Producing Silicon Carbide/Silicon Nitride Fibers

    Science.gov (United States)

    1986-01-01

    Manufacturing process makes CxSiyNz fibers. Precursor fibers spun from extruding machine charged with polycarbosilazane resin. When pyrolyzed, resin converted to cross-linked mixture of silicon carbide and silicon nitride, still in fiber form. CxSiyNz fibers promising substitutes for carbon fibers in high-strength, low-weight composites where high electrical conductivity unwanted.

  8. The Lean Design of Manufacturing Process

    Directory of Open Access Journals (Sweden)

    Dana Strachotová

    2008-12-01

    Full Text Available This article is intended to using of Six Sigma methodology. A break trough strategy to significantly improve customer satisfaction and shareholder value by reducing variability in every aspects of business. It enhances the ability to delivery customer satisfaction and cost improvement results faster – within months from the start, and sustains the rate of improvement on-going. One of the most powerful ways to improve business performance is combining business process management (BPM strategies with Six Sigma strategies. BPM strategies emphasize process improvements and automation to drive performance, while Six Sigma uses statistical analysis to drive quality improvements. The two strategies are not mutually exclusive, however, and some savvy companies have discovered that combining BPM and Six Sigma can create dramatic results. Six Sigma methodology teaches and deploys hard skills and business practices emphasizing.

  9. Lean Manufacturing Principles Improving the Targeting Process

    Science.gov (United States)

    2012-06-08

    Parent headquarters (HQ) often do not know how to integrate new units into their targeting process, resulting in a waste of asset allocation and...called the CARVER Method, which stands for criticality, accessibility, recuperability , vulnerability, effect and recognizability. It’s in the special...is to eliminate waste . The Lean view of waste is “anything that adds to the time and cost of making a product, but does not add values from the

  10. Ninth workshop on crystalline silicon solar cell materials and processes: Summary discussion sessions

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B.; Tan, T.; Swanson, D.; Rosenblum, M.; Sinton, R.

    1999-11-23

    This report is a summary of the panel discussions included with the Ninth Workshop on Crystalline Silicon Solar Cell Materials and Processes. The theme for the workshop was ``R and D Challenges and Opportunities in Si Photovoltaics.'' This theme was chosen because it appropriately reflects a host of challenges that the growing production of Si photovoltaics will be facing in the new millennium. The anticipated challenges will arise in developing strategies for cost reduction, increased production, higher throughput per manufacturing line, new sources of low-cost Si, and the introduction of new manufacturing processes for cell production. At the same time, technologies based on CdTe and CIS will come on line posing new competition. With these challenges come new opportunities for Si PV to wean itself from the microelectronics industry, to embark on a more aggressive program in thin-film Si solar cells, and to try new approaches to process monitoring.

  11. Processing and Quality Evaluation of Additive Manufacturing Monolayer Specimens

    Directory of Open Access Journals (Sweden)

    Christiane Wendt

    2016-01-01

    Full Text Available Although its importance has increased significantly, Additive Manufacturing is not yet a fully accepted industrial manufacturing process for load-carrying parts. The future success of the process group depends on its standardization. This work proposes a methodology for the design, manufacturing, and quality evaluation of specimens manufactured by Fused Layer Modeling that are composed of only one layer (so-called monolayers. The processing methodology and properties of monolayers have not been studied systematically yet. A first systematic design of monolayers for mechanical testing is presented. Rectangular and circular monolayers adapted to the loads of tensile and compression testing are manufactured using different trajectory strategies. Frequently occurring macro- and microgeometrical defects are evaluated and categorized in order to optimize the part quality. This work also studies the effect of some manufacturing parameters such as the gap between print head and machine bed, trajectory strategy, bed leveling, and temperatures on part quality. The most suitable specimens are tested mechanically in tensile or compression tests. In the case of study, tensile strength values are only 8.6% lower than the values for reference tests on the unextruded filament. However, the properties deviate more strongly for compression tests which may be due to the selected specimen geometry.

  12. Framework for Sustainability Performance Assessment for Manufacturing Processes- A Review

    Science.gov (United States)

    Singh, K.; Sultan, I.

    2017-07-01

    Manufacturing industries are facing tough competition due to increasing raw material cost and depleting natural resources. There is great pressure on the industry to produce environmental friendly products using environmental friendly processes. To address these issues modern manufacturing industries are focusing on sustainable manufacturing. To develop more sustainable societies, industries need to better understand how to respond to environmental, economic and social challenges. This paper proposed some framework and tools that accelerate the transition towards a sustainable system. The developed framework will be beneficial for sustainability assessment comparing different plans alongside material properties, ultimately helping the manufacturing industries to reduce the carbon emissions and material waste, besides improving energy efficiency. It is expected that this would be highly beneficial for determination of environmental impact of a process at early design stages. Therefore, it would greatly help the manufacturing industries for selection of process plan based on sustainable indices. Overall objective of this paper would have good impact on reducing air emissions and protecting environment. We expect this work to contribute to the development of a standard reference methodology to help further sustainability in the manufacturing sector.

  13. Ultra-Fast Optical Signal Processing in Nonlinear Silicon Waveguides

    DEFF Research Database (Denmark)

    Oxenløwe, Leif Katsuo; Galili, Michael; Pu, Minhao

    2011-01-01

    We describe recent demonstrations of exploiting highly nonlinear silicon nanowires for processing Tbit/s optical data signals. We perform demultiplexing and optical waveform sampling of 1.28 Tbit/s and wavelength conversion of 640 Gbit/s data signals.......We describe recent demonstrations of exploiting highly nonlinear silicon nanowires for processing Tbit/s optical data signals. We perform demultiplexing and optical waveform sampling of 1.28 Tbit/s and wavelength conversion of 640 Gbit/s data signals....

  14. Laser and electron beam processing of silicon and gallium arsenide

    Energy Technology Data Exchange (ETDEWEB)

    Narayan, J.

    1979-10-01

    Laser (photon) and electron beams provide a controlled source of heat by which surface layers of silicon and gallium arsenide can be rapidly melted and cooled with rates exceeding 10/sup 80/C/sec. The melting process has been used to remove displacement damage in ion implanted Si and GaAs, to remove dislocations, loops and precipitates in silicon and to study impurity segregation and solubility limits. The mechanisms associated with various phenomena will be examined. The possible impact of laser and electron beam processing on device technology, particularly with respect to solar cells is discussed.

  15. Phase-sensitive optical processing in silicon waveguides

    DEFF Research Database (Denmark)

    Petermann, Klaus; Gajda, A.; Dziallas, Claudia

    2015-01-01

    Parametric optical signal processing is reviewed for silicon nano-rib-waveguides with a reverse-biased pin-junction. Phase-sensitive parametric amplification with a phase-sensitive extinction of more than 20 dB has been utilized for the regeneration of DPSK signals......Parametric optical signal processing is reviewed for silicon nano-rib-waveguides with a reverse-biased pin-junction. Phase-sensitive parametric amplification with a phase-sensitive extinction of more than 20 dB has been utilized for the regeneration of DPSK signals...

  16. NASA's In-Space Manufacturing Project: Materials and Manufacturing Process Development Update

    Science.gov (United States)

    Prater, Tracie; Bean, Quincy; Werkheiser, Niki; Ledbetter, Frank

    2017-01-01

    The mission of NASA's In-Space Manufacturing (ISM) project is to identify, design, and implement on-demand, sustainable manufacturing solutions for fabrication, maintenance and repair during exploration missions. ISM has undertaken a phased strategy of incrementally increasing manufacturing capabilities to achieve this goal. The ISM project began with the development of the first 3D printer for the International Space Station. To date, the printer has completed two phases of flight operations. Results from phase I specimens indicated some differences in material properties between ground-processed and ISS-processed specimens, but results of follow-on analyses of these parts and a ground-based study with an equivalent printer strongly indicate that this variability is likely attributable to differences in manufacturing process settings between the ground and flight prints rather than microgravity effects on the fused deposition modeling (FDM) process. Analysis of phase II specimens from the 3D Printing in Zero G tech demo, which shed further light on the sources of material variability, will be presented. The ISM project has also developed a materials characterization plan for the Additive Manufacturing Facility, the follow-on commercial multimaterial 3D printing facility developed for ISS by Made in Space. This work will yield a suite of characteristic property values that can inform use of AMF by space system designers. Other project activities include development of an integrated 3D printer and recycler, known as the Refabricator, by Tethers Unlimited, which will be operational on ISS in 2018. The project also recently issued a broad area announcement for a multimaterial fabrication laboratory, which may include in-space manufacturing capabilities for metals, electronics, and polymeric materials, to be deployed on ISS in the 2022 timeframe.

  17. A Review on the Mechanical Modeling of Composite Manufacturing Processes

    DEFF Research Database (Denmark)

    Baran, Ismet; Cinar, Kenan; Ersoy, Nuri

    2016-01-01

    between the involved physical phenomena mainly related to material flow, heat transfer and polymerization or crystallization. Development of numerical process models is required for virtual design and optimization of the composite manufacturing process which avoids the expensive trial-and-error based......The increased usage of fiber reinforced polymer composites in load bearing applications requires a detailed understanding of the process induced residual stresses and their effect on the shape distortions. This is utmost necessary in order to have more reliable composite manufacturing since...... the residual stresses alter the internal stress level of the composite part during the service life and the residual shape distortions may lead to not meeting the desired geometrical tolerances. The occurrence of residual stresses during the manufacturing process inherently contains diverse interactions...

  18. Mining manufacturing data for discovery of high productivity process characteristics.

    Science.gov (United States)

    Charaniya, Salim; Le, Huong; Rangwala, Huzefa; Mills, Keri; Johnson, Kevin; Karypis, George; Hu, Wei-Shou

    2010-06-01

    Modern manufacturing facilities for bioproducts are highly automated with advanced process monitoring and data archiving systems. The time dynamics of hundreds of process parameters and outcome variables over a large number of production runs are archived in the data warehouse. This vast amount of data is a vital resource to comprehend the complex characteristics of bioprocesses and enhance production robustness. Cell culture process data from 108 'trains' comprising production as well as inoculum bioreactors from Genentech's manufacturing facility were investigated. Each run constitutes over one-hundred on-line and off-line temporal parameters. A kernel-based approach combined with a maximum margin-based support vector regression algorithm was used to integrate all the process parameters and develop predictive models for a key cell culture performance parameter. The model was also used to identify and rank process parameters according to their relevance in predicting process outcome. Evaluation of cell culture stage-specific models indicates that production performance can be reliably predicted days prior to harvest. Strong associations between several temporal parameters at various manufacturing stages and final process outcome were uncovered. This model-based data mining represents an important step forward in establishing a process data-driven knowledge discovery in bioprocesses. Implementation of this methodology on the manufacturing floor can facilitate a real-time decision making process and thereby improve the robustness of large scale bioprocesses. 2010 Elsevier B.V. All rights reserved.

  19. Developing the Manufacturing Process for VCE: Binder for Filled Elastomers

    Energy Technology Data Exchange (ETDEWEB)

    E.A. Eastwood

    2009-11-01

    This topical report presents work completed to re-establish the manufacturing process for poly(ethylene-co-vinyl acetate-co-vinyl alcohol) terpolymer called VCE. The new VCE formulations meet the material requirements and have lower melt viscosity, which results in improved production for the next assembly. In addition, the reaction conditions were optimized in order to achieve a satisfactory conversion rate to enable production in a single work shift. Several equipment and process changes were made to yield a manufacturing process with improved product quality, yield, efficiency, and worker safety.

  20. Design of Test Parts to Characterize Micro Additive Manufacturing Processes

    DEFF Research Database (Denmark)

    Thompson, Mary Kathryn; Mischkot, Michael

    2015-01-01

    The minimum feature size and obtainable tolerances of additive manufacturing processes are linked to the smallest volumetric elements (voxels) that can be created. This work presents the iterative design of a test part to investigate the resolution of AM processes with voxel sizes at the micro...... scale. Each design iteration reduces the test part size, increases the number of test features, improves functionality, and decreases coupling in the part. The final design is a set of three test parts that are easy to orient and measure, and that provide useful information about micro additive...... manufacturing processes....

  1. Toward Meaningful Manufacturing Variation Data in Design - Feature Based Description of Variation in Manufacturing Processes

    DEFF Research Database (Denmark)

    Eifler, Tobias; Boorla, Srinivasa Murthy; Howard, Thomas J.

    2016-01-01

    by the availability of sophisticated methods and tools alone, but does evidently also depend on the accuracy of the input information used. As existing approaches for the description of manufacturing variation focus however, almost exclusively, on monitoring and controlling production processes, there is frequently...

  2. Manufacturing Squares: An Integrative Statistical Process Control Exercise

    Science.gov (United States)

    Coy, Steven P.

    2016-01-01

    In the exercise, students in a junior-level operations management class are asked to manufacture a simple product. Given product specifications, they must design a production process, create roles and design jobs for each team member, and develop a statistical process control plan that efficiently and effectively controls quality during…

  3. Additive Manufacturing of High-Entropy Alloys by Laser Processing

    NARCIS (Netherlands)

    Ocelik, V.; Janssen, Niels; Smith, Stefan; De Hosson, J. Th M.

    This contribution concentrates on the possibilities of additive manufacturing of high-entropy clad layers by laser processing. In particular, the effects of the laser surface processing parameters on the microstructure and hardness of high-entropy alloys (HEAs) were examined. AlCoCrFeNi alloys with

  4. Parallel direct solver for finite element modeling of manufacturing processes

    DEFF Research Database (Denmark)

    Nielsen, Chris Valentin; Martins, P.A.F.

    2017-01-01

    The central processing unit (CPU) time is of paramount importance in finite element modeling of manufacturing processes. Because the most significant part of the CPU time is consumed in solving the main system of equations resulting from finite element assemblies, different approaches have been...... developed to optimize solutions and reduce the overall computational costs of large finite element models....

  5. The Role of Anode Manufacturing Processes in Net Carbon Consumption

    Directory of Open Access Journals (Sweden)

    Khalil Khaji

    2016-05-01

    Full Text Available Carbon anodes are consumed in electrolysis cells during aluminum production. Carbon consumption in pre-bake anode cells is 400–450 kg C/t Al, considerably higher than the theoretical consumption of 334 kg C/t Al. This excess carbon consumption is partly due to the anode manufacturing processes. Net carbon consumption over the last three years at Emirates Aluminium (EMAL, also known as Emirates Global Aluminium (EGA Al Taweelah was analyzed with respect to anode manufacturing processes/parameters. The analysis indicates a relationship between net carbon consumption and many manufacturing processes, including anode desulfurization during anode baking. Anode desulfurization appears to increase the reaction surface area, thereby helping the Boudouard reaction between carbon and carbon dioxide in the electrolysis zone, as well as reducing the presence of sulfur which could inhibit this reaction. This paper presents correlations noted between anode manufacturing parameters and baked anode properties, and their impact on the net carbon consumption in electrolytic pots. Anode reactivities affect the carbon consumption in the pots during the electrolysis of alumina. Pitch content in anodes, impurities in anodes, and anode desulfurization during baking were studied to find their influence on anode reactivities. The understanding gained through this analysis helped reduce net carbon consumption by adjusting manufacturing processes. For an aluminum smelter producing one million tonnes of aluminum per year, the annual savings could be as much as US $0.45 million for every kg reduction in net carbon consumption.

  6. Seventh Workshop on The Role of Impurities and Defects in Silicon Device Processing

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, Bhushan; Swanson, Richard; Tan, Teh

    1997-10-01

    The Seventh Workshop on the Role of Impurities and Defects in Silicon Device Processing, held August 11-13, 1997, in Vail, Colorado, was a great success. The workshop theme, `R{ampersand}D Issues for Crystalline Silicon to Support GW/yr Goal by the Year 2010,` provided a focus that proved both timely and stimulating. The workshop attracted 76 attendees from six countries, who participated in lively discussions of the issues. This is an upbeat time for the photovoltaic industry as sales passed 100 megawatts per year. The workshop revealed that worldwide R{ampersand}D in silicon PV is stronger than ever. The new thin-Si technologies are developing remarkably fast since the resurgence in their interest about 10 years ago. A number of groups around the world are reporting cell results with efficiencies above 9% from polycrystalline cells deposited on low-cost substrates. Conventional wafer and ribbon Si manufacturing costs continue to come down as new capacity is added. Detailed studies on manufacturing costs convincingly show, for the first time, that module manufacturing costs in the range of $0.70 to $1.90 per watt are achievable with manufacturing volumes per facility in the range of 100 to 500 megawatts per year. Such cost reduction will improve profitability and allow expansion into ever-larger markets. This encouraging prognosis for future technology, when coupled with the current climate of 20% market growth despite stable, or even increasing, module prices, signals the eminent emergence of PV as a vital, global industry. Exciting times indeed; one gigawatt per year is not so far away!

  7. Continuous Flow in Labour-Intensive Manufacturing Process

    Science.gov (United States)

    Pacheco Eng., Jhonny; Carbajal MSc., Eduardo; Stoll-Ing., Cesar, Dr.

    2017-06-01

    A continuous-flow manufacturing represents the peak of standard production, and usually it means high production in a strict line production. Furthermore, low-tech industry demands high labour-intensive, in this context the efficient of the line production is tied at the job shop organization. Labour-intensive manufacturing processes are a common characteristic for developing countries. This research aims to propose a methodology for production planning in order to fulfilment a variable monthly production quota. The main idea is to use a clock as orchestra director in order to synchronize the rate time (takt time) of customer demand with the manufacturing time. In this way, the study is able to propose a stark reduction of stock in process, over-processing, and unnecessary variability.

  8. Final Air Toxics Standards for Clay Ceramics Manufacturing, Glass Manufacturing, and Secondary Nonferrous Metals Processing Area Sources Fact Sheet

    Science.gov (United States)

    This page contains a December 2007 fact sheet with information regarding the National Emissions Standards for Hazardous Air Pollutants (NESHAP) for Clay Ceramics Manufacturing, Glass Manufacturing, and Secondary Nonferrous Metals Processing Area Sources

  9. The Development of Manufacturing Process Analysis: Lesson Learned from Process Mining

    Directory of Open Access Journals (Sweden)

    Bernardo Nugroho Yahya

    2014-01-01

    Full Text Available Process analysis is recognized as a major stage in business process reengineering that has developed over the last two decades. In the field of manufacturing, manufacturing process analysis (MPA is defined as performance analysis of the production process. The performance analysis is an outline from data and knowledge into useful forms that can be broadly applied in manufacturing sectors. Process mining, an emerge tool focusing on process perspective and resource perspective, is a way to analyze system based on the event log. The objective of this study is to extend the existing process analysis framework by considering attribute perspective. This study also aims to learn the lessons from some experiences on process mining in manufacture industries. The result of this study will help manufacturing organizations to utilize the process mining approach for analyzing their respective processes.

  10. Process development status report for advanced manufacturing projects

    Energy Technology Data Exchange (ETDEWEB)

    Brinkman, J.R.; Homan, D.A.

    1990-03-30

    This is the final status report for the approved Advanced Manufacturing Projects for FY 1989. Five of the projects were begun in FY 1987, one in FY 1988, and one in FY 1989. The approved projects cover technology areas in welding, explosive material processing and evaluation, ion implantation, and automated manufacturing. It is expected that the successful completion of these projects well result in improved quality and/or reduced cost for components produced by Mound. Those projects not brought to completion will be continued under Process development in FY 1990.

  11. Ultrasonic-assisted manufacturing processes: Variational model and numerical simulations

    KAUST Repository

    Siddiq, Amir

    2012-04-01

    We present a computational study of ultrasonic assisted manufacturing processes including sheet metal forming, upsetting, and wire drawing. A fully variational porous plasticity model is modified to include ultrasonic softening effects and then utilized to account for instantaneous softening when ultrasonic energy is applied during deformation. Material model parameters are identified via inverse modeling, i.e. by using experimental data. The versatility and predictive ability of the model are demonstrated and the effect of ultrasonic intensity on the manufacturing process at hand is investigated and compared qualitatively with experimental results reported in the literature. © 2011 Elsevier B.V. All rights reserved.

  12. Ultrasonic-assisted manufacturing processes: variational model and numerical simulations.

    Science.gov (United States)

    Siddiq, Amir; El Sayed, Tamer

    2012-04-01

    We present a computational study of ultrasonic assisted manufacturing processes including sheet metal forming, upsetting, and wire drawing. A fully variational porous plasticity model is modified to include ultrasonic softening effects and then utilized to account for instantaneous softening when ultrasonic energy is applied during deformation. Material model parameters are identified via inverse modeling, i.e. by using experimental data. The versatility and predictive ability of the model are demonstrated and the effect of ultrasonic intensity on the manufacturing process at hand is investigated and compared qualitatively with experimental results reported in the literature. Copyright © 2011 Elsevier B.V. All rights reserved.

  13. Silicon web process development. [for low cost solar cells

    Science.gov (United States)

    Duncan, C. S.; Hopkins, R. H.; Seidensticker, R. G.; Mchugh, J. P.; Hill, F. E.; Heimlich, M. E.; Driggers, J. M.

    1979-01-01

    Silicon dendritic web, a single crystal ribbon shaped during growth by crystallographic forces and surface tension (rather than dies), is a highly promising base material for efficient low cost solar cells. The form of the product smooth, flexible strips 100 to 200 microns thick, conserves expensive silicon and facilitates automation of crystal growth and the subsequent manufacturing of solar cells. These characteristics, coupled with the highest demonstrated ribbon solar cell efficiency-15.5%-make silicon web a leading candidate to achieve, or better, the 1986 Low Cost Solar Array (LSA) Project cost objective of 50 cents per peak watt of photovoltaic output power. The main objective of the Web Program, technology development to significantly increase web output rate, and to show the feasibility for simultaneous melt replenishment and growth, have largely been accomplished. Recently, web output rates of 23.6 sq cm/min, nearly three times the 8 sq cm/min maximum rate of a year ago, were achieved. Webs 4 cm wide or greater were grown on a number of occassions.

  14. Increasing component functionality via multi-process additive manufacturing

    Science.gov (United States)

    Coronel, Jose L.; Fehr, Katherine H.; Kelly, Dominic D.; Espalin, David; Wicker, Ryan B.

    2017-05-01

    Additively manufactured components, although extensively customizable, are often limited in functionality. Multi-process additive manufacturing (AM) grants the ability to increase the functionality of components via subtractive manufacturing, wire embedding, foil embedding and pick and place. These processes are scalable to include several platforms ranging from desktop to large area printers. The Multi3D System is highlighted, possessing the capability to perform the above mentioned processes, all while transferring a fabricated component with a robotic arm. Work was conducted to fabricate a patent inspired, printed missile seeker. The seeker demonstrated the advantage of multi-process AM via introduction of the pick and place process. Wire embedding was also explored, with the successful interconnect of two layers of embedded wires in different planes. A final demonstration of a printed contour bracket, served to show the reduction of surface roughness on a printed part is 87.5% when subtractive manufacturing is implemented in tandem with AM. Functionality of the components on all the cases was improved. Results included optical components embedded within the printed housing, wires embedded with interconnection, and reduced surface roughness. These results highlight the improved functionality of components through multi-process AM, specifically through work conducted with the Multi3D System.

  15. Optimization of process parameter for synthesis of silicon quantum ...

    Indian Academy of Sciences (India)

    Home; Journals; Bulletin of Materials Science; Volume 36; Issue 3. Optimization of process parameter for synthesis of silicon quantum dots using low pressure chemical vapour deposition. Dipika Barbadikar Rashmi Gautam Sanjay Sahare Rajendra Patrikar Jatin Bhatt. Volume 36 Issue 3 June 2013 pp 483-490 ...

  16. Processing of Radiation Hard Particle Detectors on Czochralski Silicon

    CERN Document Server

    Tuovinen, Esa

    2012-01-01

    The purpose of this work was to study the radiation hardness of particle detectors. Silicon detectors are cost-effective andhave an excellent spatial resolution. Therefore, they are widely used in many high-energy physics experiments. It is knownthat oxygen improves the radiation hardness of silicon detectors. The natural way to have a high concentration of oxygen insilicon is to use magnetic Czochralski silicon (MCz-Si). MCz-Si has intrinsically a relatively uniform and high level ofoxygen (5x10^17 cm^3) compared to regular float-zone silicon (FZ-Si). Such a level is hard to attain with other methods,namely the diffusion oxygenation of float-zone silicon.In the Large Hadron Collider (LHC) and its potential upgrade, the luminosity and the fluencies of fast hadrons can be sohigh that detectors made of standard detector-grade FZ-Si might not survive the planned operating period. MCz-Si offers animprovement to the lifetime of particle detectors through improved radiation hardness.This thesis takes a process-orie...

  17. Monitoring Chlorfenapyr in Green Tea during the Manufacturing Process

    Science.gov (United States)

    Takahashi, Atsushi; Kishi, Yasuhiro; Ogawa, Hideyuki; Nakajima, Kenta

    In order to clarify the change in the leaves of agricultural chemicals during the green tea manufacturing process, we analyzed chlorfenapyr in tea leaves obtained at each processing stage by using an immunoassay. Chlorfenapyr is a novel broad-spectrum insecticide-miticide registered in many countries for the control of various insects and mite pests. Chlorfenapyr is stable and persistent in the environment. Furthermore, it is widely applied for tea cultivation in Japan. Therefore, we selected chlorfenapyr for analysis in this study. In the unrefined tea (Aracha) manufacturing process, the highest level of chlorfenapyr was 16.5 ppm, which was obtained in tea powder separated from leaves at the secondary drying stage. However, the level at the other processing stages in tea leaves was approximately 9 ppm, and no significant difference in the chlorfenapyr level was detected between the processing stages. After Aracha processing, tea leaves are classified on the basis of their size, shape and color; this is the refined tea (Shiagecha) manufacturing process. After this process, although a high level of chlorfenapyr was detected in bud tea (8.1 ppm) and honcha (on-grade tea; 6.2 ppm), the level in the other classified teas was approximately 4.0 ppm. Thus, this paper shows the difference in the chlorfenapyr level in tea leaves obtained at each processing stage. This indicated that there are significant differences in the agricultural chemical levels between the green tea processing stages.

  18. Integration of Advanced Simulation and Visualization for Manufacturing Process Optimization

    Science.gov (United States)

    Zhou, Chenn; Wang, Jichao; Tang, Guangwu; Moreland, John; Fu, Dong; Wu, Bin

    2016-05-01

    The integration of simulation and visualization can provide a cost-effective tool for process optimization, design, scale-up and troubleshooting. The Center for Innovation through Visualization and Simulation (CIVS) at Purdue University Northwest has developed methodologies for such integration with applications in various manufacturing processes. The methodologies have proven to be useful for virtual design and virtual training to provide solutions addressing issues on energy, environment, productivity, safety, and quality in steel and other industries. In collaboration with its industrial partnerships, CIVS has provided solutions to companies, saving over US38 million. CIVS is currently working with the steel industry to establish an industry-led Steel Manufacturing Simulation and Visualization Consortium through the support of National Institute of Standards and Technology AMTech Planning Grant. The consortium focuses on supporting development and implementation of simulation and visualization technologies to advance steel manufacturing across the value chain.

  19. Thermodynamic analysis of resources used in manufacturing processes.

    Science.gov (United States)

    Gutowski, Timothy G; Branham, Matthew S; Dahmus, Jeffrey B; Jones, Alissa J; Thiriez, Alexandre

    2009-03-01

    In this study we use a thermodynamic framework to characterize the material and energy resources used in manufacturing processes. The analysis and data span a wide range of processes from "conventional" processes such as machining, casting, and injection molding, to the so-called "advanced machining" processes such as electrical discharge machining and abrasive waterjet machining, and to the vapor-phase processes used in semiconductor and nanomaterials fabrication. In all, 20 processes are analyzed. The results show that the intensity of materials and energy used per unit of mass of material processed (measured either as specific energy or exergy) has increased by at least 6 orders of magnitude over the past several decades. The increase of material/energy intensity use has been primarily a consequence of the introduction of new manufacturing processes, rather than changes in traditional technologies. This phenomenon has been driven by the desire for precise small-scale devices and product features and enabled by stable and declining material and energy prices over this period. We illustrate the relevance of thermodynamics (including exergy analysis) for all processes in spite of the fact that long-lasting focus in manufacturing has been on product quality--not necessarily energy/material conversion efficiency. We promote the use of thermodynamics tools for analysis of manufacturing processes within the context of rapidly increasing relevance of sustainable human enterprises. We confirm that exergy analysis can be used to identify where resources are lost in these processes, which is the first step in proposing and/or redesigning new more efficient processes.

  20. Process Modeling and Validation for Metal Big Area Additive Manufacturing

    Energy Technology Data Exchange (ETDEWEB)

    Simunovic, Srdjan [ORNL; Nycz, Andrzej [ORNL; Noakes, Mark W. [ORNL; Chin, Charlie [Dassault Systemes; Oancea, Victor [Dassault Systemes

    2017-05-01

    Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to accelerate the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

  1. Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

    Science.gov (United States)

    MacDonald, D.; Fernández, R.; Delloro, F.; Jodoin, B.

    2017-04-01

    Titanium parts are ideally suited for aerospace applications due to their unique combination of high specific strength and excellent corrosion resistance. However, titanium as bulk material is expensive and challenging/costly to machine. Production of complex titanium parts through additive manufacturing looks promising, but there are still many barriers to overcome before reaching mainstream commercialization. The cold gas dynamic spraying process offers the potential for additive manufacturing of large titanium parts due to its reduced reactive environment, its simplicity to operate, and the high deposition rates it offers. A few challenges are to be addressed before the additive manufacturing potential of titanium by cold gas dynamic spraying can be reached. In particular, it is known that titanium is easy to deposit by cold gas dynamic spraying, but the deposits produced are usually porous when nitrogen is used as the carrier gas. In this work, a method to manufacture low-porosity titanium components at high deposition efficiencies is revealed. The components are produced by combining low-pressure cold spray using nitrogen as the carrier gas with low-cost titanium powder produced using the Armstrong process. The microstructure and mechanical properties of additive manufactured titanium components are investigated.

  2. Porosity of additive manufacturing parts for process monitoring

    Science.gov (United States)

    Slotwinski, J. A.; Garboczi, E. J.

    2014-02-01

    Some metal additive manufacturing processes can produce parts with internal porosity, either intentionally (with careful selection of the process parameters) or unintentionally (if the process is not well-controlled.) Material porosity is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants, since surface-breaking pores allow for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the process. We are developing an ultrasonic sensor for detecting changes in porosity in metal parts during fabrication on a metal powder bed fusion system, for use as a process monitor. This paper will describe our work to develop an ultrasonic-based sensor for monitoring part porosity during an additive build, including background theory, the development and detailed characterization of reference additive porosity samples, and a potential design for in-situ implementation.

  3. Incorporating VIBE into the precision optics manufacturing process

    Science.gov (United States)

    DeGroote Nelson, Jessica; Gould, Alan; Klinger, Charles; Mandina, Michael

    2011-09-01

    The VIBE™ process is a full-aperture, conformal polishing process incorporating high frequency and random motion designed to rapidly remove sub-surface damage in a VIBE pre-polish step and eliminate mid-spatial frequency (MSF) errors in a VIBE finishing step. The VIBE process has potential to be introduced in two areas of today's modern optics manufacturing process. The first instance is replacing the conventional pre-polishing step with the rapid VIBE pre-polish step. Results will be discussed in this paper that show 10 - 50x higher removal rates compared to conventional polishing for a variety of optical materials. High removal rates combined with the compliant lap results in damage-free surfaces that have the same form that was generated by the CNC generation process for spherical and non-spherical surfaces. The second potential area to incorporate VIBE into today's modern optics manufacturing process is as a finishing step after deterministic sub-aperture polishing to remove mid-spatial frequency errors. By selectively altering the compliant properties of the VIBE pad, and adjusting the frequency of the VIBE motion, VIBE finishing can reduce the mid-spatial frequencies caused from sub-aperture polishing processes while maintaining the desired corrected surface form. This paper will serve as an in-depth review of the VIBE process and how it complements other modern CNC optics manufacturing technologies, as well as highlighting recent VIBE advances specifically in the area of conformal optic fabrication.

  4. Manufacturing Demonstration Facility: Roll-to-Roll Processing

    Energy Technology Data Exchange (ETDEWEB)

    Datskos, Panos G [ORNL; Joshi, Pooran C [ORNL; List III, Frederick Alyious [ORNL; Duty, Chad E [ORNL; Armstrong, Beth L [ORNL; Ivanov, Ilia N [ORNL; Jacobs, Christopher B [ORNL; Graham, David E [ORNL; Moon, Ji Won [ORNL

    2015-08-01

    This Manufacturing Demonstration Facility (MDF)e roll-to-roll processing effort described in this report provided an excellent opportunity to investigate a number of advanced manufacturing approaches to achieve a path for low cost devices and sensors. Critical to this effort is the ability to deposit thin films at low temperatures using nanomaterials derived from nanofermentation. The overarching goal of this project was to develop roll-to-roll manufacturing processes of thin film deposition on low-cost flexible substrates for electronics and sensor applications. This project utilized ORNL s unique Pulse Thermal Processing (PTP) technologies coupled with non-vacuum low temperature deposition techniques, ORNL s clean room facility, slot dye coating, drop casting, spin coating, screen printing and several other equipment including a Dimatix ink jet printer and a large-scale Kyocera ink jet printer. The roll-to-roll processing project had three main tasks: 1) develop and demonstrate zinc-Zn based opto-electronic sensors using low cost nanoparticulate structures manufactured in a related MDF Project using nanofermentation techniques, 2) evaluate the use of silver based conductive inks developed by project partner NovaCentrix for electronic device fabrication, and 3) demonstrate a suite of low cost printed sensors developed using non-vacuum deposition techniques which involved the integration of metal and semiconductor layers to establish a diverse sensor platform technology.

  5. Customer-driven manufacturing in the food processing industry

    NARCIS (Netherlands)

    Donk, D.P. van

    2000-01-01

    Food processing industry copes with high logistical demands from its customers. This paper studies a company changing to more customer (order) driven manufacturing. In order to help decide which products should be made to order and which made to stock, a frame is developed and applied to find and

  6. Bridging nanometer design-to-manufacturing gap: automated design rules correction and silicon verification

    Science.gov (United States)

    Karklin, Linard N.; Oren, Micha; Dudau, Dragos; Jordan, James D.

    2003-08-01

    Following Moore's Law semiconductor industry is going through a challenging transition from 180 nm to 130 nm manufacturing process geometries and rapidly approaching 90 nm geometries. The major challenges associated with the transition to nanometer design include: (1) Increasing design sizes and complexity (e.g. 300-400M transistors for FPGAs); (2) Increasing number of design rules (approaching 2000 for advanced 90 nm processes); (3) Increasing design cycle (4-9 months for ASICs); (4) Increasing design cost (advanced design flow cost $15M+). With the size and complexity of today's advanced ASICs and SoCs, the ability of designers to efficiently fix DRC errors is becoming a critical challenge impacting productivity and time-to-market. Designers need new EDA tools to process designs of very high complexity in shorter time. New tools should bridge design and process worlds by transparently providing designers with more detailed process (lithography) information. In this paper the authors will describe a method for manufacturing verification of automated design rule fixes. Many types of design rule violation are detected, automatically fixed, and verified by lithography simulation.

  7. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, 8 December 1993--30 June 1994

    Energy Technology Data Exchange (ETDEWEB)

    Wohlgemuth, J. [Solarex Corp., Frederick, MD (United States)

    1995-03-01

    This report describes work done under a 3-year program to advance Solarex`s cast polycrystalline silicon manufacturing technology, reduce module production cost, increase module performance, and expand Solarex`s commercial production capacities. The accomplishments described in this report are as follows: (1) the authors designed modifications to casting stations, ceramic molds, and sizing saws to allow for casting and sizing of larger ingots; (2) they demonstrated the casting of ingots with 17% larger volume; (3) the selected and purchased a new wire saw from HCT Shaping Systems; (4) they demonstrated wafering of eight bricks (2,400 wafers or {approximately}4.4 kilowatts at the cell level) in a 6.5-h run; (5) they demonstrated 14% average cell efficiency in the laboratory using an aluminum paste back surface field; (6) the Automation and Robotics Research Institute (ARRI) completed a modeling study of the Solarex module assembly process; (7) they identified and qualified three new lower-cost back sheet materials through accelerated environmental tests; and (8) they designed and built a test structure for mounting frameless modules, and selected two adhesives and began testing their ability to hold modules to the structure.

  8. Offshoring trends in the manufacturing process within the automotive industry

    DEFF Research Database (Denmark)

    Simplay, S.; Hansen, Zaza Nadja Lee

    2014-01-01

    consisting of original equipment manufacturers and engineering service providers. The findings indicated some offshoring trends in the automotive industry. Offshoring in this industry is moving from a manufacturing focus to incorporate large parts of the process, including high-level product development......This paper investigates offshoring trends in the automotive industry. The research approach consisted of combining empirical findings from case companies with latest research from the field. Empirical data was collected through case studies from 15 automotive organisations based in Europe...... with a focus on offshoring in the automotive industry and provides practitioners with information on a cutting-edge trend to the industry...

  9. Low cost solar array project. Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

    Science.gov (United States)

    1980-01-01

    Technical activities are reported in the design of process, facilities, and equipment for producing silicon at a rate and price comensurate with production goals for low cost solar cell modules. The silane-silicone process has potential for providing high purity poly-silicon on a commercial scale at a price of fourteen dollars per kilogram by 1986, (1980 dollars). Commercial process, economic analysis, process support research and development, and quality control are discussed.

  10. Process monitoring for intelligent manufacturing processes - Methodology and application to Robot Assisted Polishing

    DEFF Research Database (Denmark)

    Pilny, Lukas

    Process monitoring provides important information on the product, process and manufacturing system during part manufacturing. Such information can be used for process optimization and detection of undesired processing conditions to initiate timely actions for avoidance of defects, thereby improving...... quality assurance. This thesis is aimed at a systematic development of process monitoring solutions, constituting a key element of intelligent manufacturing systems towards zero defect manufacturing. A methodological approach of general applicability is presented in this concern.The approach consists...... of six consecutive steps for identification of product Vital Quality Characteristics (VQCs) and Key Process Variables (KPVs), selection and characterization of sensors, optimization of sensors placement, validation of the monitoring solutions, definition of the reference manufacturing performance...

  11. Quality and Safety Assurance of Iron Casts and Manufacturing Processes

    Directory of Open Access Journals (Sweden)

    Kukla S.

    2016-06-01

    Full Text Available The scope of this work focuses on the aspects of quality and safety assurance of the iron cast manufacturing processes. Special attention was given to the processes of quality control and after-machining of iron casts manufactured on automatic foundry lines. Due to low level of automation and huge work intensity at this stage of the process, a model area was established which underwent reorganization in accordance with the assumptions of the World Class Manufacturing (WCM. An analysis of work intensity was carried out and the costs were divided in order to identify operations with no value added, particularly at individual manufacturing departments. Also an analysis of ergonomics at work stations was carried out to eliminate activities that are uncomfortable and dangerous to the workers' health. Several solutions were proposed in terms of rationalization of work organization at iron cast after-machining work stations. The proposed solutions were assessed with the use of multi-criteria assessment tools and then the best variant was selected based on the assumed optimization criteria. The summary of the obtained results reflects benefits from implementation of the proposed solutions.

  12. Observational Data-Driven Modeling and Optimization of Manufacturing Processes

    OpenAIRE

    Sadati, Najibesadat; Chinnam, Ratna Babu; Nezhad, Milad Zafar

    2017-01-01

    The dramatic increase of observational data across industries provides unparalleled opportunities for data-driven decision making and management, including the manufacturing industry. In the context of production, data-driven approaches can exploit observational data to model, control and improve the process performance. When supplied by observational data with adequate coverage to inform the true process performance dynamics, they can overcome the cost associated with intrusive controlled de...

  13. Infrared Signature Analysis: Real Time Monitoring Of Manufacturing Processes

    Science.gov (United States)

    Bangs, Edmund R.

    1988-01-01

    The ability to monitor manufacturing processes in an adaptive control mode and perform an inspection in real time is of interest to fabricators in the pressure vessel, aerospace, automotive, nuclear and shipbuilding industries. Results of a series of experiments using infrared thermography as the principal sensing mode are presented to show how artificial intelligence contained in infrared isotherm, contains vast critical process variables. Image processing computer software development has demonstrated in a spot welding application how the process can be monitored and controlled in real time. The IR vision sensor program is now under way. Research thus far has focused on fusion welding, resistance spot welding and metal removal.

  14. Process to manufacture effervescent tablets: air forced oven melt granulation.

    Science.gov (United States)

    Yanze, F M; Duru, C; Jacob, M

    2000-12-01

    In the present study we apply melt granulation in an air forced oven, called "are forced oven melt granulation" to the single-stage manufacture of effervescent granules consisting of anhydrous citric acid (43.2%) and sodium bicarbonate (56.8%) in order to make tablets. This study established that process parameters such as concentration of PEG 6000, residence time in the air forced oven, fineness of PEG 6000, fineness of the initial effervescent mix and efficiency of two lubricants markedly influenced several granule and tablet characteristics. The granules ready to be compressed into tablets were stable for 7 days at 60% RH/18 degrees C. It is a dry, simple, rapid, effective, economical, reproducible process particularly well suited to the manufacture of effervescent granules which are easily compressed into effervescent tablets. Of all the formulations tested, only formulations B2 and E2 melt granulated for 30 minutes gave tablets which had optimum compression characteristics without processing problems during compression.

  15. Conformal window manufacturing process development and demonstration for polycrystalline materials

    Science.gov (United States)

    Smith, Nathan E.; Gould, Alan R.; Hordin, Tom; Medicus, Kate; Walters, Mark; Brophy, Matthew; DeGroote Nelson, Jessica

    2013-09-01

    Conformal windows pose new and unique challenges to manufacturing due to the shape, measurement of, and requested hard polycrystalline materials. Their non-rotationally symmetric shape and high departure surfaces do not lend themselves to traditional optical fabrication processes. The hard crystalline materials are another challenge due to increased processing time and possibility of grain decoration. We have developed and demonstrated a process for manufacturing various conformal windows out of fused silica, glass, zinc-sulfide multispectral, and spinel. The current process involves CNC generation/grinding, VIBE polishing, and sub-aperture figure correction. The CNC generation step incorporates an ultrasonic assisted grinding machine; the machine settings and tool are being continuously optimized for minimal sub-surface damage and surface form error. In VIBE, polishing to less than 5 nm rms surface roughness while maintaining overall form error is accomplished with a full aperture conformal polishing tool and with rapid removal rates. The final sub-aperture polishing step corrects the overall form error. Currently we utilize our CMM for surface form measurement and have shown that we can produce spinel conformal windows with form error within +/-10 micrometers of the nominal shape, without grain decoration. This conformal window manufacturing process is continuously optimized for cost reduction and precision of the final optic.

  16. Silicon web process development. Annual report

    Energy Technology Data Exchange (ETDEWEB)

    Duncan, C.S.; Seidensticker, R.G.; McHugh, J.P.; Hill, F.E.; Skutch, M.E.; Driggers, J.M.; Hopkins, R.H.

    1980-06-30

    During this reporting period significant milestones have been met. A new barrier crucible design which consistently maintains melt stability over long periods of time has been successfully tested and used in long growth runs. The pellet feeder for melt replenishment was operated continuously for growth runs of up to 17 hours (a one day growth cycle). The liquid level sensor comprising a laser/sensor system was operated, performed well, and meets the requirements for maintaining liquid level height during growth and melt replenishment. An automated feedback loop connecting the feed mechanism and the liquid level sensing system was designed and constructed and, during the preparation of this report, operated successfully for 3 1/2 hours demonstrating the feasibility of semi-automated dendritic web growth. The web throughput task has resulted in a demonstration of wider good quality web as well as a demonstration of higher throughput rates. The accomplishments during the report period are described in detail. The economic analysis of the dendritic web process was updated. The sensitivity of the cost of sheet to variations in capital equipment cost and recycling dendrites was calculated; and it was shown that these factors have relatively little impact on sheet cost. An important finding was that dendrites from web which had gone all the way through the solar cell fabrication process, when melted and grown into web, produce crystals which show no degradation in cell efficiency. Material quality remains high and cells made from web grown at the start, during, and the end of a run from a replenished melt show comparable efficiencies.

  17. Thin film silicon solar cells: advanced processing and characterization - Final report

    Energy Technology Data Exchange (ETDEWEB)

    Ballif, Ch.

    2008-04-15

    This final report elaborated for the Swiss Federal Office of Energy (SFOE) takes a look at the results of a project carried out at the photovoltaics laboratory at the University of Neuchatel in Switzerland. The project aimed to demonstrate the production of high-efficiency thin-film silicon devices on flexible substrates using low cost processes. New ways of improving processing and characterisation are examined. The process and manufacturing know-how necessary to provide support for industrial partners within the framework of further projects is discussed. The authors state that the efficiency of most devices was significantly improved, both on glass substrates and on flexible plastic foils. The process reproducibility was also improved and the interactions between the different layers in the device are now said to be better understood. The report presents the results obtained and discusses substrate materials, transparent conductors, defect analyses and new characterisation tools. Finally, the laboratory infrastructure is described.

  18. Implementation of Statistical Process Control: Evaluating the Mechanical Performance of a Candidate Silicone Elastomer Docking Seal

    Science.gov (United States)

    Oravec, Heather Ann; Daniels, Christopher C.

    2014-01-01

    The National Aeronautics and Space Administration has been developing a novel docking system to meet the requirements of future exploration missions to low-Earth orbit and beyond. A dynamic gas pressure seal is located at the main interface between the active and passive mating components of the new docking system. This seal is designed to operate in the harsh space environment, but is also to perform within strict loading requirements while maintaining an acceptable level of leak rate. In this study, a candidate silicone elastomer seal was designed, and multiple subscale test articles were manufactured for evaluation purposes. The force required to fully compress each test article at room temperature was quantified and found to be below the maximum allowable load for the docking system. However, a significant amount of scatter was observed in the test results. Due to the stochastic nature of the mechanical performance of this candidate docking seal, a statistical process control technique was implemented to isolate unusual compression behavior from typical mechanical performance. The results of this statistical analysis indicated a lack of process control, suggesting a variation in the manufacturing phase of the process. Further investigation revealed that changes in the manufacturing molding process had occurred which may have influenced the mechanical performance of the seal. This knowledge improves the chance of this and future space seals to satisfy or exceed design specifications.

  19. Application of low intensity ultrasonics to cheese manufacturing processes.

    Science.gov (United States)

    Benedito, J; Carcel, J A; Gonzalez, R; Mulet, A

    2002-05-01

    Ultrasound has been used to non-destructively assess the quality of many foods such as meat, fish, vegetables and dairy products. This paper addresses the applications of low intensity ultrasonics in the cheese manufacturing processes and highlights the areas where ultrasonics could be successfully implemented in the future. The decrease of ultrasonic attenuation during the renneting process can be used to determine the optimum cut time for cheese making. The ultrasonic velocity increases during maturation for those types of cheese that become harder during this manufacturing stage, thus being an indicator of the maturity degree. Moreover, ultrasonic measurements could be linked to sensory parameters. From the ultrasonic velocity measurements at two different temperatures, it is possible to assess cheese composition, thus allowing an improvement in the quality and uniformity of cheese commercialization. In addition, in pulse-echo mode it is possible to detect cracked pieces due to abnormal fermentations and also to assess the distance of the crack from the surface.

  20. Small Scale Turbopump Manufacturing Technology and Material Processes

    Science.gov (United States)

    Alvarez, Erika; Morgan, Kristin; Wells, Doug; Zimmerman, Frank

    2011-01-01

    As part of an internal research and development project, NASA Marshall Space Flight Center (MSFC) has been developing a high specific impulse 9,000-lbf LOX/LH2 pump-fed engine testbed with the capability to throttle 10:1. A Fuel Turbopump (FTP) with the ability to operate across a speed range of 30,000-rpm to 100,000-rpm was developed and analyzed. This small size and flight-like Fuel Turbopump has completed the design and analysis phase and is currently in the manufacturing phase. This paper highlights the manufacturing and processes efforts to fabricate an approximately 20-lb turbopump with small flow passages, intricately bladed components and approximately 3-in diameter impellers. As a result of the small scale and tight tolerances of the hardware on this turbopump, several unique manufacturing and material challenges were encountered. Some of the technologies highlighted in this paper include the use of powder metallurgy technology to manufacture small impellers, electron beam welding of a turbine blisk shroud, and casting challenges. The use of risk reduction efforts such as non-destructive testing (NDT) and evaluation (NDE), fractography, material testing, and component spin testing are also discussed in this paper.

  1. Development of Four Unit Processes for Biobased PLA Manufacturing

    OpenAIRE

    Hong, Chae Hwan; Kim, Si Hwan; Seo, Ji-Yeon; Han, Do Suck

    2012-01-01

    Polylactide (PLA), which is one of the most important biocompatible polyesters that are derived from annually renewable biomass such as corn and sugar beets, has attracted much attention for automotive parts application. The manufacturing method of PLA is the ring-opening polymerization of the dimeric cyclic ester of lactic acid, lactide. For the stereocomplex PLA, we developed the four unit processes, fermentation, separation, lactide conversion, and polymerization. Fermentation of sugars to...

  2. Perspectives on the design of safer nanomaterials and manufacturing processes

    Energy Technology Data Exchange (ETDEWEB)

    Geraci, Charles [National Institute for Occupational Safety and Health (United States); Heidel, Donna [Bureau Veritas North America, Inc. (United States); Sayes, Christie [Baylor University (United States); Hodson, Laura, E-mail: lhodson@cdc.gov; Schulte, Paul; Eastlake, Adrienne [National Institute for Occupational Safety and Health (United States); Brenner, Sara [Colleges of Nanoscale Science and Engineering at State University of New York Polytechnic Institute, (SUNY Poly) (United States)

    2015-09-15

    A concerted effort is being made to insert Prevention through Design principles into discussions of sustainability, occupational safety and health, and green chemistry related to nanotechnology. Prevention through Design is a set of principles, which includes solutions to design out potential hazards in nanomanufacturing including the design of nanomaterials, and strategies to eliminate exposures and minimize risks that may be related to the manufacturing processes and equipment at various stages of the lifecycle of an engineered nanomaterial.

  3. Metal Big Area Additive Manufacturing: Process Modeling and Validation

    Energy Technology Data Exchange (ETDEWEB)

    Simunovic, Srdjan [ORNL; Nycz, Andrzej [ORNL; Noakes, Mark W [ORNL; Chin, Charlie [Dassault Systemes; Oancea, Victor [Dassault Systemes

    2017-01-01

    Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology for printing large-scale 3D objects. mBAAM is based on the gas metal arc welding process and uses a continuous feed of welding wire to manufacture an object. An electric arc forms between the wire and the substrate, which melts the wire and deposits a bead of molten metal along the predetermined path. In general, the welding process parameters and local conditions determine the shape of the deposited bead. The sequence of the bead deposition and the corresponding thermal history of the manufactured object determine the long range effects, such as thermal-induced distortions and residual stresses. Therefore, the resulting performance or final properties of the manufactured object are dependent on its geometry and the deposition path, in addition to depending on the basic welding process parameters. Physical testing is critical for gaining the necessary knowledge for quality prints, but traversing the process parameter space in order to develop an optimized build strategy for each new design is impractical by pure experimental means. Computational modeling and optimization may accelerate development of a build process strategy and saves time and resources. Because computational modeling provides these opportunities, we have developed a physics-based Finite Element Method (FEM) simulation framework and numerical models to support the mBAAM process s development and design. In this paper, we performed a sequentially coupled heat transfer and stress analysis for predicting the final deformation of a small rectangular structure printed using the mild steel welding wire. Using the new simulation technologies, material was progressively added into the FEM simulation as the arc weld traversed the build path. In the sequentially coupled heat transfer and stress analysis, the heat transfer was performed to calculate the temperature evolution, which was used in a stress analysis to

  4. Manufacturing process design for multi commodities in agriculture

    Science.gov (United States)

    Prasetyawan, Yudha; Santosa, Andrian Henry

    2017-06-01

    High-potential commodities within particular agricultural sectors should be accompanied by maximum benefit value that can be attained by both local farmers and business players. In several cases, the business players are small-medium enterprises (SMEs) which have limited resources to perform added value process of the local commodities into the potential products. The weaknesses of SMEs such as the manual production process with low productivity, limited capacity to maintain prices, and unattractive packaging due to conventional production. Agricultural commodity is commonly created into several products such as flour, chips, crackers, oil, juice, and other products. This research was initiated by collecting data by interview method particularly to obtain the perspectives of SMEs as the business players. Subsequently, the information was processed based on the Quality Function Deployment (QFD) to determine House of Quality from the first to fourth level. A proposed design as the result of QFD was produced and evaluated with Technology Assessment Model (TAM) and continued with a revised design. Finally, the revised design was analyzed with financial perspective to obtain the cost structure of investment, operational, maintenance, and workers. The machine that performs manufacturing process, as the result of revised design, was prototyped and tested to determined initial production process. The designed manufacturing process offers IDR 337,897, 651 of Net Present Value (NPV) in comparison with the existing process value of IDR 9,491,522 based on similar production input.

  5. Post-Lamination Manufacturing Process Automation for Photovoltaic Modules

    Energy Technology Data Exchange (ETDEWEB)

    Nowlan, M. J.; Murach, J. M.; McCormick, T. W.; Lewis, E. R.; Hogan, S. J. (Spire Corporation)

    1999-08-31

    This report describes work performed by Spire Corporation during Phase 1 of this three-phase PVMaT subcontract to develop new automated post-lamination processes for PV module manufacturing. These processes are applicable to a very broad range of module types, including those made with wafer-based and thin-film solar cells. No off-the-shelf automation was available for these processes prior to this program. Spire conducted a survey of PV module manufacturers to identify current industry practices and to determine the requirements for the automated systems being developed in this program. Spire also completed detailed mechanical and electrical designs and developed software for two prototype automation systems: a module buffer storage system, designated the SPI-BUFFER 350, and an integrated module testing system, designated the SPI-MODULE QA 350. Researchers fabricated, tested, and evaluated both systems with module components from several module manufacturers. A new size simulator , th e SPI-SUN SIMULATOR 350i, was designed with a test area that can handle most production modules without consuming excessive floor space. Spire's subcontractor, the Automation and Robotics Research Institute (ARRI) at the University of Texas, developed and demonstrated module edge trimming, edge sealing, and framing processes that are suitable for automation. The automated processes under development throughout this program are being designed to be combined together to create automated production lines. ARRI completed a cost study to determine the level of investment that can be justified by implementing automation for post-lamination assembly and testing processes. The study concluded that a module production line operating two shifts per day and producing 10 MW of modules per year can justify $2.37 million in capital equipment, assuming a 5-year payback period.

  6. Manufacturing of tailored tubes with a process integrated heat treatment

    Science.gov (United States)

    Hordych, Illia; Boiarkin, Viacheslav; Rodman, Dmytro; Nürnberger, Florian

    2017-10-01

    The usage of work-pieces with tailored properties allows for reducing costs and materials. One example are tailored tubes that can be used as end parts e.g. in the automotive industry or in domestic applications as well as semi-finished products for subsequent controlled deformation processes. An innovative technology to manufacture tubes is roll forming with a subsequent inductive heating and adapted quenching to obtain tailored properties in the longitudinal direction. This processing offers a great potential for the production of tubes with a wide range of properties, although this novel approach still requires a suited process design. Based on experimental data, a process simulation is being developed. The simulation shall be suitable for a virtual design of the tubes and allows for gaining a deeper understanding of the required processing. The model proposed shall predict microstructural and mechanical tube properties by considering process parameters, different geometries, batch-related influences etc. A validation is carried out using experimental data of tubes manufactured from various steel grades.

  7. Fundamental Aspects of Selective Melting Additive Manufacturing Processes

    Energy Technology Data Exchange (ETDEWEB)

    van Swol, Frank B. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Miller, James E. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

    2014-12-01

    Certain details of the additive manufacturing process known as selective laser melting (SLM) affect the performance of the final metal part. To unleash the full potential of SLM it is crucial that the process engineer in the field receives guidance about how to select values for a multitude of process variables employed in the building process. These include, for example, the type of powder (e.g., size distribution, shape, type of alloy), orientation of the build axis, the beam scan rate, the beam power density, the scan pattern and scan rate. The science-based selection of these settings con- stitutes an intrinsically challenging multi-physics problem involving heating and melting a metal alloy, reactive, dynamic wetting followed by re-solidification. In addition, inherent to the process is its considerable variability that stems from the powder packing. Each time a limited number of powder particles are placed, the stacking is intrinsically different from the previous, possessing a different geometry, and having a different set of contact areas with the surrounding particles. As a result, even if all other process parameters (scan rate, etc) are exactly the same, the shape and contact geometry and area of the final melt pool will be unique to that particular configuration. This report identifies the most important issues facing SLM, discusses the fundamental physics associated with it and points out how modeling can support the additive manufacturing efforts.

  8. Machining parameter optimization in turning process for sustainable manufacturing

    Directory of Open Access Journals (Sweden)

    S. G. Dambhare

    2015-09-01

    Full Text Available There is an increase in awareness about sustainable manufacturing process. Manufacturing industries are backbone of a country’s economy. Although it is important but there is a great concern about consumption of resources and waste creation. The primary aim of this study was to explore sustainability concern in turning process in an Indian machining industry. The effect of cutting parameters, Speed/Feed/Depth of Cut, the machining environment, Dry/MQL/Wet, and the type of cutting tool on sustainability factors under study were observed. Analysis of Variance (ANOVA was used to analyse the data obtained from experimentation in a small scale machining industry. The process is modelled mathematically using response surface methodology (RSM.The economic and environmental aspect like surface roughness, material removal rate and energy consumption were considered as sustainability factors. The model helps to understand the effect of the cutting parameters and conditions on surface finish, energy consumption, and material removal rate. The process was optimized for minimum power consumption considering environmental concern as prime importance. Studies suggest that the cutting environment and tool type influenced on the power consumption during turning process. Extended form of the proposed model could be useful to predict the environmental impact due to machining process, which would bring environmental concern into conventional machining.

  9. High-throughput DNA sequencing: a genomic data manufacturing process.

    Science.gov (United States)

    Huang, G M

    1999-01-01

    The progress trends in automated DNA sequencing operation are reviewed. Technological development in sequencing instruments, enzymatic chemistry and robotic stations has resulted in ever-increasing capacity of sequence data production. This progress leads to a higher demand on laboratory information management and data quality assessment. High-throughput laboratories face the challenge of organizational management, as well as technology management. Engineering principles of process control should be adopted in this biological data manufacturing procedure. While various systems attempt to provide solutions to automate different parts of, or even the entire process, new technical advances will continue to change the paradigm and provide new challenges.

  10. Modelling of just-in-sequence supply of manufacturing processes

    Directory of Open Access Journals (Sweden)

    Bányai Tamás

    2017-01-01

    Full Text Available The customer oriented production led to the growth of complexity of manufacturing and connected logistics processes. In many production companies one of the largest asset on balance sheet is inventory. To avoid inventory problems and to be the winners of today’s market situation manufacturing companies try to decrease heavy inventory levels through just-in-time based supply strategies. The aim of this research work is to analyse these supply strategies. The first part of the paper describes the just-in-time based supply and summarises the most important characteristics of them. The second part focuses on the modelling of just-in-sequence based in-plant supply. The models makes it possible to determine different in-plant supply strategies.

  11. A senior manufacturing laboratory for determining injection molding process capability

    Science.gov (United States)

    Wickman, Jerry L.; Plocinski, David

    1992-01-01

    The following is a laboratory experiment designed to further understanding of materials science. This subject material is directed at an upper level undergraduate/graduate student in an Engineering or Engineering Technology program. It is assumed that the student has a thorough understanding of the process and quality control. The format of this laboratory does not follow that which is normally recommended because of the nature of process capability and that of the injection molding equipment and tooling. This laboratory is instead developed to be used as a point of departure for determining process capability for any process in either a quality control laboratory or a manufacturing environment where control charts, process capability, and experimental or product design are considered important topics.

  12. Recent advance in high manufacturing readiness level and high temperature CMOS mixed-signal integrated circuits on silicon carbide

    Science.gov (United States)

    Weng, M. H.; Clark, D. T.; Wright, S. N.; Gordon, D. L.; Duncan, M. A.; Kirkham, S. J.; Idris, M. I.; Chan, H. K.; Young, R. A. R.; Ramsay, E. P.; Wright, N. G.; Horsfall, A. B.

    2017-05-01

    A high manufacturing readiness level silicon carbide (SiC) CMOS technology is presented. The unique process flow enables the monolithic integration of pMOS and nMOS transistors with passive circuit elements capable of operation at temperatures of 300 °C and beyond. Critical to this functionality is the behaviour of the gate dielectric and data for high temperature capacitance-voltage measurements are reported for SiO2/4H-SiC (n and p type) MOS structures. In addition, a summary of the long term reliability for a range of structures including contact chains to both n-type and p-type SiC, as well as simple logic circuits is presented, showing function after 2000 h at 300 °C. Circuit data is also presented for the performance of digital logic devices, a 4 to 1 analogue multiplexer and a configurable timer operating over a wide temperature range. A high temperature micro-oven system has been utilised to enable the high temperature testing and stressing of units assembled in ceramic dual in line packages, including a high temperature small form-factor SiC based bridge leg power module prototype, operated for over 1000 h at 300 °C. The data presented show that SiC CMOS is a key enabling technology in high temperature integrated circuit design. In particular it provides the ability to realise sensor interface circuits capable of operating above 300 °C, accommodate shifts in key parameters enabling deployment in applications including automotive, aerospace and deep well drilling.

  13. Numerical modeling of manufacturing process of corrugated plate

    Directory of Open Access Journals (Sweden)

    Khodos Ol'ga Aleksandrovna

    2014-09-01

    Full Text Available The rigidity increase of structures consisting of plates and shells is a relevant task. One way to obtain plates with enhanced stiffness performance is the corrugation, i.e. change of its topography elevation. Depending on the method, corrugation provides a plate with additional rigidity in one or several directions without weight gain. The most common way to get corrugated plates is pressure forming. The problem of finding the most energy saving method is very relevant. In this regard, a possible approach is to use buckling of thin cylinder. The idea of this technique comes from the fact that as a result of stability loss of cylindrical shell in compression along its elements, the cylinder walls are deformed periodically. The article considers the problem of corrugated plates manufacturing using smooth sheet metal. The method of manufacture is based on irreversible process of cylindrical buckling of a shell previously obtained from a worksheet. Such a deformation process may be useful if the energy spent on its implementation is smaller than the energy in standard process of forming. The task of defining the stiffness of a corrugated plate is quite difficult because it is difficult to experimentally measure the tension, bending and coupled stiffness. The numerical simulation of three ways to manufacture corrugated cylindrical shell made of smooth sheet by elastic-plastic deformation process are offered: the first way is to deform the cylindrical shell under the action of axial load on the butt end, and the second way is the influence of strutting internal pressure. In the third way the cylindrical shell is made of the leaf using the special techniques. In order to compare the effectiveness of the options presented for each case the internal energy is calculated. It is shown that the energy expenditure in buckling method is the smallest.

  14. Additive Manufacturing of Tooling for Refrigeration Cabinet Foaming Processes

    Energy Technology Data Exchange (ETDEWEB)

    Post, Brian K [ORNL; Nuttall, David [ORNL; Cukier, Michael Z [ORNL; Hile, Michael B [ORNL

    2016-07-29

    The primary objective of this project was to leverage the Big Area Additive Manufacturing (BAAM) process and materials into a long term, quick change tooling concept to drastically reduce product lead and development timelines and costs. Current refrigeration foam molds are complicated to manufacture involving casting several aluminum parts in an approximate shape, machining components of the molds and post fitting and shimming of the parts in an articulated fixture. The total process timeline can take over 6 months. The foaming process is slower than required for production, therefore multiple fixtures, 10 to 27, are required per refrigerator model. Molds are particular to a specific product configuration making mixed model assembly challenging for sequencing, mold changes or auto changeover features. The initial goal was to create a tool leveraging the ORNL materials and additive process to build a tool in 4 to 6 weeks or less. A secondary goal was to create common fixture cores and provide lightweight fixture sections that could be revised in a very short time to increase equipment flexibility reduce lead times, lower the barriers to first production trials, and reduce tooling costs.

  15. Eighth workshop on crystalline silicon solar cell materials and processes: Extended abstracts and papers

    Energy Technology Data Exchange (ETDEWEB)

    NONE

    1998-08-01

    The theme of this workshop is Supporting the Transition to World Class Manufacturing. This workshop provides a forum for an informal exchange of information between researchers in the photovoltaic and non-photovoltaic fields on various aspects of impurities and defects in silicon, their dynamics during device processing, and their application in defect engineering. This interaction helps establish a knowledge base that can be used for improving device fabrication processes to enhance solar-cell performance and reduce cell costs. It also provides an excellent opportunity for researchers from industry and universities to recognize mutual needs for future joint research. The workshop format features invited review presentations, panel discussions, and two poster sessions. The poster sessions create an opportunity for both university and industrial researchers to present their latest results and provide a natural forum for extended discussions and technical exchanges.

  16. Analysis of production flow process with lean manufacturing approach

    Science.gov (United States)

    Siregar, Ikhsan; Arif Nasution, Abdillah; Prasetio, Aji; Fadillah, Kharis

    2017-09-01

    This research was conducted on the company engaged in the production of Fast Moving Consumer Goods (FMCG). The production process in the company are still exists several activities that cause waste. Non value added activity (NVA) in the implementation is still widely found, so the cycle time generated to make the product will be longer. A form of improvement on the production line is by applying lean manufacturing method to identify waste along the value stream to find non value added activities. Non value added activity can be eliminated and reduced by utilizing value stream mapping and identifying it with activity mapping process. According to the results obtained that there are 26% of value-added activities and 74% non value added activity. The results obtained through the current state map of the production process of process lead time value of 678.11 minutes and processing time of 173.94 minutes. While the results obtained from the research proposal is the percentage of value added time of 41% of production process activities while non value added time of the production process of 59%. While the results obtained through the future state map of the production process of process lead time value of 426.69 minutes and processing time of 173.89 minutes.

  17. CIMOSA process classification for business process mapping in non-manufacturing firms: A case study

    Science.gov (United States)

    Latiffianti, Effi; Siswanto, Nurhadi; Wiratno, Stefanus Eko; Saputra, Yudha Andrian

    2017-11-01

    A business process mapping is one important means to enable an enterprise to effectively manage the value chain. One of widely used approaches to classify business process for mapping purpose is Computer Integrated Manufacturing System Open Architecture (CIMOSA). CIMOSA was initially designed for Computer Integrated Manufacturing (CIM) system based enterprises. This paper aims to analyze the use of CIMOSA process classification for business process mapping in the firms that do not fall within the area of CIM. Three firms of different business area that have used CIMOSA process classification were observed: an airline firm, a marketing and trading firm for oil and gas products, and an industrial estate management firm. The result of the research has shown that CIMOSA can be used in non-manufacturing firms with some adjustment. The adjustment includes addition, reduction, or modification of some processes suggested by CIMOSA process classification as evidenced by the case studies.

  18. Make-to-order manufacturing - new approach to management of manufacturing processes

    Science.gov (United States)

    Saniuk, A.; Waszkowski, R.

    2016-08-01

    Strategic management must now be closely linked to the management at the operational level, because only in such a situation the company can be flexible and can quickly respond to emerging opportunities and pursue ever-changing strategic objectives. In these conditions industrial enterprises seek constantly new methods, tools and solutions which help to achieve competitive advantage. They are beginning to pay more attention to cost management, economic effectiveness and performance of business processes. In the article characteristics of make-to-order systems (MTO) and needs associated with managing such systems is identified based on the literature analysis. The main aim of this article is to present the results of research related to the development of a new solution dedicated to small and medium enterprises manufacture products solely on the basis of production orders (make-to- order systems). A set of indicators to enable continuous monitoring and control of key strategic areas this type of company is proposed. A presented solution includes the main assumptions of the following concepts: the Performance Management (PM), the Balanced Scorecard (BSC) and a combination of strategic management with the implementation of operational management. The main benefits of proposed solution are to increase effectiveness of MTO manufacturing company management.

  19. Towards in process control of polymer micro manufactured components

    DEFF Research Database (Denmark)

    Calaon, Matteo; Tosello, Guido; Hansen, Hans Nørgaard

    2016-01-01

    In the last decade the number of applications of micro components has increased steadily. In order for Europe to maintain its leading role in the polymer micro-fabrication industry there is a need of expansion for processes capabilities for mass manufacture. The present study focuses on the design...... of a fast-integrated inspection method aimed at part quality monitoring and tolerance conformance verification. The proposed approach investigates as product case study the optimization of polymer (VECTRA® E820i) passive micro microwave components. A focus variation 3D optical high-speed metrology system...

  20. Moulded Pulp Manufacturing: Overview and Prospects for the Process Technology

    DEFF Research Database (Denmark)

    Didone, Mattia; Saxena, Prateek; Meijer, Ellen Brilhuis

    2017-01-01

    . The goal of this paper is to give an overview of the main aspects involved in the manufacture of moulded pulp products. This includes a classification of moulded pulp products, historical and current applications, production processes, materials, mechanical properties and environmental sustainability......Eco-friendly packaging such as moulded pulp products have gained commercial importance in the recent years. However, it remains a greatly under-researched area, and there is an arising need to consolidate the best practices from research and industry in order to increase its implementation...

  1. Study of manufacturing resource perception and process control of a radio-frequency-identification-enabled decentralized flexible manufacturing system

    Directory of Open Access Journals (Sweden)

    Zengqiang Jiang

    2017-01-01

    Full Text Available The fusion of mechatronics, communication, control, and information technologies has introduced new automation paradigms into the production environment. Plug-and-play flexible manufacturing systems will become suitable approaches in the future for the development of modular, flexible, and reconfigurable manufacturing systems, addressing the requirements of global markets. This article introduces a Petri Net model-driven methodology for the development, validation, and operation of a radio-frequency identification-enabled decentralized flexible manufacturing system. After analyzing the manufacturing processes and resources of a flexible manufacturing system, the manufacturing resources are classified into active and passive resources. Each active resource is equipped with a radio-frequency identification reader and each passive resource is banded with a radio-frequency identification tag. Real-time state and behavior logic models are built for manufacturing resources based on extended Petri Nets; the models are translated into XML and integrated with the manufacturing resources. In this fashion, each manufacturing resource becomes an autonomous agent, and it can make self-decisions and update its status through the twinned models. In this manner, automatic perception and process control are realized. Finally, the effectiveness and feasibility of the method are verified in an experimental system.

  2. Advanced Manufacturing Processes Laboratory Building 878 hazards assessment document

    Energy Technology Data Exchange (ETDEWEB)

    Wood, C.; Thornton, W.; Swihart, A.; Gilman, T.

    1994-07-01

    The introduction of the hazards assessment process is to document the impact of the release of hazards at the Advanced Manufacturing Processes Laboratory (AMPL) that are significant enough to warrant consideration in Sandia National Laboratories` operational emergency management program. This hazards assessment is prepared in accordance with the Department of Energy Order 5500.3A requirement that facility-specific hazards assessments be prepared, maintained, and used for emergency planning purposes. This hazards assessment provides an analysis of the potential airborne release of chemicals associated with the operations and processes at the AMPL. This research and development laboratory develops advanced manufacturing technologies, practices, and unique equipment and provides the fabrication of prototype hardware to meet the needs of Sandia National Laboratories, Albuquerque, New Mexico (SNL/NM). The focus of the hazards assessment is the airborne release of materials because this requires the most rapid, coordinated emergency response on the part of the AMPL, SNL/NM, collocated facilities, and surrounding jurisdiction to protect workers, the public, and the environment.

  3. Deterministic processes for manufacturing conformal (freeform) optical surfaces

    Science.gov (United States)

    Ruckman, Jeffrey L.; Fess, Edward M.; Pollicove, Harvey M.

    2001-09-01

    This paper describes the computer-controlled machines and deterministic processes developed by the Center for Optics Manufacturing (COM) at the University of Rochester to produce conformal windows and domes that have non-traditional optical surface geometry and unusual shapes. COM's DMG (deterministic microgrinding) technology produces aspheric and conformal (freeform) surfaces in minutes, versus the weeks that are required to produce the surfaces conventionally. The demonstrated techniques and equipment provide a predictable and repeatable optical production process for just about any IR, visible, or UV material. The DMG process, in concert with newly developed CNC machining equipment, typically yields 1.0 wave peak-to-valley form accuracy, 150 Angstroms rms surface finish, and subsurface damage levels low enough that some of the infrared materials do not require additional polishing.

  4. High Input Voltage, Silicon Carbide Power Processing Unit Performance Demonstration

    Science.gov (United States)

    Bozak, Karin E.; Pinero, Luis R.; Scheidegger, Robert J.; Aulisio, Michael V.; Gonzalez, Marcelo C.; Birchenough, Arthur G.

    2015-01-01

    A silicon carbide brassboard power processing unit has been developed by the NASA Glenn Research Center in Cleveland, Ohio. The power processing unit operates from two sources: a nominal 300 Volt high voltage input bus and a nominal 28 Volt low voltage input bus. The design of the power processing unit includes four low voltage, low power auxiliary supplies, and two parallel 7.5 kilowatt (kW) discharge power supplies that are capable of providing up to 15 kilowatts of total power at 300 to 500 Volts (V) to the thruster. Additionally, the unit contains a housekeeping supply, high voltage input filter, low voltage input filter, and master control board, such that the complete brassboard unit is capable of operating a 12.5 kilowatt Hall effect thruster. The performance of the unit was characterized under both ambient and thermal vacuum test conditions, and the results demonstrate exceptional performance with full power efficiencies exceeding 97%. The unit was also tested with a 12.5kW Hall effect thruster to verify compatibility and output filter specifications. With space-qualified silicon carbide or similar high voltage, high efficiency power devices, this would provide a design solution to address the need for high power electric propulsion systems.

  5. High Input Voltage, Silicon Carbide Power Processing Unit Performance Demonstration

    Science.gov (United States)

    Bozak, Karin E.; Pinero, Luis R.; Scheidegger, Robert J.; Aulisio, Michael V.; Gonzalez, Marcelo C.; Birchenough, Arthur G.

    2015-01-01

    A silicon carbide brassboard power processing unit has been developed by the NASA Glenn Research Center in Cleveland, Ohio. The power processing unit operates from two sources - a nominal 300-Volt high voltage input bus and a nominal 28-Volt low voltage input bus. The design of the power processing unit includes four low voltage, low power supplies that provide power to the thruster auxiliary supplies, and two parallel 7.5 kilowatt power supplies that are capable of providing up to 15 kilowatts of total power at 300-Volts to 500-Volts to the thruster discharge supply. Additionally, the unit contains a housekeeping supply, high voltage input filter, low voltage input filter, and master control board, such that the complete brassboard unit is capable of operating a 12.5 kilowatt Hall Effect Thruster. The performance of unit was characterized under both ambient and thermal vacuum test conditions, and the results demonstrate the exceptional performance with full power efficiencies exceeding 97. With a space-qualified silicon carbide or similar high voltage, high efficiency power device, this design could evolve into a flight design for future missions that require high power electric propulsion systems.

  6. Manufacturing and characterization of bent silicon crystals for studies of coherent interactions with negatively charged particles beams

    Science.gov (United States)

    Germogli, G.; Mazzolari, A.; Bandiera, L.; Bagli, E.; Guidi, V.

    2015-07-01

    Efficient steering of GeV-energy negatively charged particle beams was demonstrated to be possible with a new generation of thin bent silicon crystals. Suitable crystals were produced at the Sensor Semiconductor Laboratory of Ferrara starting from Silicon On Insulator wafers, adopting proper revisitation of silicon micromachining techniques such as Low Pressure Chemical Vapor Deposition, photolithography and anisotropic chemical etching. Mechanical holders, which allow to properly bend the crystal and to reduce unwanted torsions, were employed. Crystallographic directions and crystal holder design were optimized in order to excite quasi-mosaic effect along (1 1 1) planes. Prior to exposing the crystal to particle beams, a full set of characterizations were performed. Infrared interferometry was used to measure crystal thickness with high accuracy. White-light interferometry was employed to characterize surface deformational state and its torsion. High-resolution X-rays diffraction was used to precisely measure crystal bending angle along the beam. Manufactured crystals were installed and tested at the MAMI MAinz MIcrotron to steer sub-GeV electrons, and at SLAC to deflect an electron beam in the 1 to 10 GeV energy range.

  7. Manufacturing and characterization of bent silicon crystals for studies of coherent interactions with negatively charged particles beams

    Energy Technology Data Exchange (ETDEWEB)

    Germogli, G.; Mazzolari, A.; Bandiera, L.; Bagli, E.; Guidi, V.

    2015-07-15

    Efficient steering of GeV-energy negatively charged particle beams was demonstrated to be possible with a new generation of thin bent silicon crystals. Suitable crystals were produced at the Sensor Semiconductor Laboratory of Ferrara starting from Silicon On Insulator wafers, adopting proper revisitation of silicon micromachining techniques such as Low Pressure Chemical Vapor Deposition, photolithography and anisotropic chemical etching. Mechanical holders, which allow to properly bend the crystal and to reduce unwanted torsions, were employed. Crystallographic directions and crystal holder design were optimized in order to excite quasi-mosaic effect along (1 1 1) planes. Prior to exposing the crystal to particle beams, a full set of characterizations were performed. Infrared interferometry was used to measure crystal thickness with high accuracy. White-light interferometry was employed to characterize surface deformational state and its torsion. High-resolution X-rays diffraction was used to precisely measure crystal bending angle along the beam. Manufactured crystals were installed and tested at the MAMI MAinz MIcrotron to steer sub-GeV electrons, and at SLAC to deflect an electron beam in the 1 to 10 GeV energy range.

  8. Evaluation of polymer micro parts produced by additive manufacturing processes using vat photopolymerization method

    DEFF Research Database (Denmark)

    Davoudinejad, Ali; Pedersen, David Bue; Tosello, Guido

    2017-01-01

    Micro manufacturing scale feature production by Additive Manufacturing (AM) processes for the direct production of miniaturized polymer components is analysed in this work. The study characterizes the AM processes for polymer micro parts productions using the vat photopolymerization method...

  9. Characterization of additive manufacturing processes for polymer micro parts productions using direct light processing (DLP) method

    DEFF Research Database (Denmark)

    Davoudinejad, Ali; Pedersen, David Bue; Tosello, Guido

    The process capability of additive manufacturing (AM) for direct production of miniaturized polymer components with micro features is analyzed in this work. The consideration of the minimum printable feature size and obtainable tolerances of AM process is a critical step to establish a process...

  10. Manufacture of Φ1.2m reaction bonded silicon carbide mirror blank CFID

    Science.gov (United States)

    Zhang, Ge; Zhao, Rucheng; Zhao, Wenxing; Bao, Jianxun

    2010-05-01

    Silicon carbide (SiC) is a new type candidate material for large-scale lightweight space mirror. Its low thermal distortion, high stiffness, fine optical quality and dimensional stability, make SiC an ideal material for large space born telescope. Since ten years Changchun institute optics, fine mechanics and physics (CIOMP) has developed reaction bonded SiC (RB-SiC) technology for space application, and can fabricate RB-SiC mirror with scale less than 1.0 meter for telescope. The green body is prepared with gel-casting method which is an attractive new ceramic forming process for making high-quality, complex-shaped ceramic parts. And then unmolding, drying, binder burning out, reacting bonded, the RB-SiC can be obtained. But with the development of space-born or ground telescope, the scale of primary mirror has exceeded 1.0 meter. So CIOMP has developed an assembly technique which called novel reaction-formed joint technology for larger RB-SiC mirror blank. The steps include joining of green bodies with mixture comprised of SiC particles and phenolic resin etc, firing, machining and sintering. Joining the Φ1.2 meter RB-SiC mirror blank by the novel reaction-formed joint technology. And testing the welding layer's performance, the results show that the thickness of 54-77μm, the microstructure and thermal property can be comparable to the substrate and the mechanical property are excellent in bending strength of 307MPa.

  11. Cost estimation of a specifically designed direct light processing (DLP) additive manufacturing machine for precision printing

    DEFF Research Database (Denmark)

    Charalambis, Alessandro; Davoudinejad, Ali; Tosello, Guido

    2017-01-01

    Additive Manufacturing (AM) refers to a portfolio of novel manufacturing technologies based on a layer-by-layer fabrication method.The market and industrial application of additive manufacturing technologies as an established manufacturing process have increasedexponentially in the last years...

  12. Manufacture of Third-Generation Lentivirus for Preclinical Use, with Process Development Considerations for Translation to Good Manufacturing Practice.

    Science.gov (United States)

    Gándara, Carolina; Affleck, Valerie; Stoll, Elizabeth Ann

    2018-02-01

    Lentiviral vectors are used in laboratories around the world for in vivo and ex vivo delivery of gene therapies, and increasingly clinical investigation as well as preclinical applications. The third-generation lentiviral vector system has many advantages, including high packaging capacity, stable gene expression in both dividing and post-mitotic cells, and low immunogenicity in the recipient organism. Yet, the manufacture of these vectors is challenging, especially at high titers required for direct use in vivo, and further challenges are presented by the process of translating preclinical gene therapies toward manufacture of products for clinical investigation. The goals of this paper are to report the protocol for manufacturing high-titer third-generation lentivirus for preclinical testing and to provide detailed information on considerations for translating preclinical viral vector manufacture toward scaled-up platforms and processes in order to make gene therapies under Good Manufacturing Practice that are suitable for clinical trials.

  13. Simulation of the proton implantation process in silicon

    Energy Technology Data Exchange (ETDEWEB)

    Faccinelli, Martin; Hadley, Peter [Graz University of Technology, Institute of Solid State Physics (Austria); Jelinek, Moriz; Wuebben, Thomas [Infineon Technologies Austria AG, Villach (Austria); Laven, Johannes G.; Schulze, Hans-Joachim [Infineon Technologies AG, Neubiberg (Germany)

    2016-12-15

    Proton implantation is one of many processes used to ad-just the electronic and mechanical properties of silicon. Though the process has been extensively studied, it is still not clear which exact defects are formed and what their concentration profiles are. In this article, a simulation method is presented, which provides a better understanding of the implantation process. The simulation takes into account the diffusion of mobile point defects and their reactions to defect complexes, as well as the dissociation of defect complexes. Concentration profiles for a set of defect complexes after an implantation at 400 keV and a dose of 5 x 10{sup 14} H{sup +}cm{sup -2} are presented. (copyright 2016 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  14. Optimization of a thermal manufacturing process: drawing of optical fibers

    Energy Technology Data Exchange (ETDEWEB)

    Xu Cheng; Jaluria, Y. [State University of New Jersey, Piscataway, NJ (United States). Dept. of Mechanical and Aerospace Engineering

    2005-08-01

    The optimization of thermal systems and processes has received much less attention than their simulation and often lags behind optimization in other engineering areas. This paper considers the optimization of the important thermal manufacturing process involved in the drawing of optical fibers. Despite the importance of optical fibers and the need to enhance product quality and reduce costs, very little work has been done on the optimization of the process. The main aspects that arise in the optimization of such thermal processes are considered in detail in order to formulate an appropriate objective function and to determine the existence of optimal conditions. Using validated numerical models to simulate the thermal transport processes that govern the characteristics of the fiber and the production rate, the study investigates the relevant parametric space and obtains the domain in which the process is physically feasible. This is followed by an attempt to narrow the feasible region and focus on the domain that could lead to optimization. Employing standard optimization techniques, optimal conditions are determined for typical operating parameters. The study thus provides a basis for choosing optimal design conditions and for more detailed investigations on the feasibility and optimization of this complicated and important process. (author)

  15. Process model for carbothermic production of silicon metal

    Energy Technology Data Exchange (ETDEWEB)

    Andresen, B.

    1995-09-12

    This thesis discusses an advanced dynamical two-dimensional cylinder symmetric model for the high temperature part of the carbothermic silicon metal process, and its computer encoding. The situation close to that which is believed to exist around one of three electrodes in full-scale industrial furnaces is modelled. This area comprises a gas filled cavity surrounding the lower tip of the electrode, the metal pool underneath and the lower parts of the materials above. The most important phenomena included are: Heterogeneous chemical reactions taking place in the high-temperature zone (above 1860 {sup o}C), Evaporation and condensation of silicon, Transport of materials by dripping, Turbulent or laminar fluid flow, DC electric arcs, Heat transport by convection, conduction and radiation. The results from the calculations, such as production rates, gas- and temperature distributions, furnace- and particle geometries, fluid flow fields etc, are presented graphically. In its present state the model is a prototype. The process is very complex, and the calculations are time consuming. The governing equations are coded into a Fortran 77 computer code applying the commercial 3D code FLUENT as a basis. 64 refs., 110 figs., 11 tabs.

  16. 77 FR 31875 - Certain Rubber Resins and Processes for Manufacturing Same; Notice of Receipt of Complaint...

    Science.gov (United States)

    2012-05-30

    ... COMMISSION Certain Rubber Resins and Processes for Manufacturing Same; Notice of Receipt of Complaint... complaint entitled Certain Rubber Resins and Processes for Manufacturing Same, DN 2897; the Commission is... importation of certain rubber resins and processes for manufacturing same. The complaint names as respondents...

  17. 21 CFR 201.122 - Drugs for processing, repacking, or manufacturing.

    Science.gov (United States)

    2010-04-01

    ... 21 Food and Drugs 4 2010-04-01 2010-04-01 false Drugs for processing, repacking, or manufacturing... for processing, repacking, or manufacturing. A drug in a bulk package, except tablets, capsules, or... manufacturing, processing, or repacking”; and if in substantially all dosage forms in which it may be dispensed...

  18. 21 CFR 801.122 - Medical devices for processing, repacking, or manufacturing.

    Science.gov (United States)

    2010-04-01

    ... manufacturing. 801.122 Section 801.122 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND....122 Medical devices for processing, repacking, or manufacturing. A device intended for processing... act if its label bears the statement “Caution: For manufacturing, processing, or repacking”. ...

  19. 13 kA Superconducting Busbars Manufacturing Process

    CERN Document Server

    Principe, R; Fornasiere, E

    2012-01-01

    In the LHC, the superconducting Main Bending magnets and Quadrupole magnets are series-connected electrically in different excitation circuits by means of superconducting busbars, carrying a maximum current of 13 kA. These superconducting busbars consist of a superconducting Rutherford cable thermally and electrically coupled to a copper section all along the length. The function of the copper section is essentially to provide an alternative path for the magnet current in case of resistive transition. The production of these components was originally outsourced. The decision to import the technology at CERN led to a global re-engineering of the standard process. Although based on the procedures adopted during the LHC construction, a few modifications and improvements have been implemented, profiting of the experience gained in the last few years. This document details the manufacturing process of the 13 kA busbars as it is actually performed at CERN, emphasizing the new solutions adopted during the first mon...

  20. Carbon dioxide capture from a cement manufacturing process

    Science.gov (United States)

    Blount, Gerald C [North Augusta, SC; Falta, Ronald W [Seneca, SC; Siddall, Alvin A [Aiken, SC

    2011-07-12

    A process of manufacturing cement clinker is provided in which a clean supply of CO.sub.2 gas may be captured. The process also involves using an open loop conversion of CaO/MgO from a calciner to capture CO.sub.2 from combustion flue gases thereby forming CaCO.sub.3/CaMg(CO.sub.3).sub.2. The CaCO.sub.3/CaMg(CO.sub.3).sub.2 is then returned to the calciner where CO.sub.2 gas is evolved. The evolved CO.sub.2 gas, along with other evolved CO.sub.2 gases from the calciner are removed from the calciner. The reactants (CaO/MgO) are feed to a high temperature calciner for control of the clinker production composition.

  1. A Digital Methodology for the Design Process of Aerospace Assemblies with Sustainable Composite Processes & Manufacture

    Science.gov (United States)

    McEwan, W.; Butterfield, J.

    2011-05-01

    The well established benefits of composite materials are driving a significant shift in design and manufacture strategies for original equipment manufacturers (OEMs). Thermoplastic composites have advantages over the traditional thermosetting materials with regards to sustainability and environmental impact, features which are becoming increasingly pertinent in the aerospace arena. However, when sustainability and environmental impact are considered as design drivers, integrated methods for part design and product development must be developed so that any benefits of sustainable composite material systems can be assessed during the design process. These methods must include mechanisms to account for process induced part variation and techniques related to re-forming, recycling and decommissioning, which are in their infancy. It is proposed in this paper that predictive techniques related to material specification, part processing and product cost of thermoplastic composite components, be integrated within a Through Life Management (TLM) product development methodology as part of a larger strategy of product system modeling to improve disciplinary concurrency, realistic part performance, and to place sustainability at the heart of the design process. This paper reports the enhancement of digital manufacturing tools as a means of drawing simulated part manufacturing scenarios, real time costing mechanisms, and broader lifecycle performance data capture into the design cycle. The work demonstrates predictive processes for sustainable composite product manufacture and how a Product-Process-Resource (PPR) structure can be customised and enhanced to include design intent driven by `Real' part geometry and consequent assembly. your paper.

  2. The Intelligent Control Technology of Manufacturing Execution Process Based on RFID

    Directory of Open Access Journals (Sweden)

    Fan Ruicheng

    2015-01-01

    Full Text Available Intelligent manufacturing is an important trend in the development of the future manufacturing industry, and how to use the current technology to realize the existing traditional manufacturing mode change to the intelligent manufacturing mode need to be studied. Aimed at the implementation of the intelligent manufacturing mode, this paper proposed the intelligent manufacturing execution process control technology based on RFID. The framework of intelligent manufacturing execution process control technology proposed an effective way to realize the manufacturing process intelligent control based on existing MES; the technology of logistics identification and control based on RFID realized the effectiveness control of logistics; the intelligent monitoring technology of mobile terminal solve the mobile terminal positioning problem, MES pushing information to mobile terminal problem and other problems. Finally, the author developed a set of intelligent manufacturing execution process control system which includes RFID reader, MES server, mobile terminal, and verified the effectiveness of the above mentioned technologies.

  3. Development of pulsed processes for the manufacture of solar cells. Final report

    Energy Technology Data Exchange (ETDEWEB)

    Minnucci, J.A.

    1979-04-01

    The results of a one and half year program to develop the processes required for low-energy ion implantation for the automated production of silicon solar cells are described. The program included (1) demonstrating state-of-the-art ion implantation equipment and designing an automated ion implanter, (2) making efforts to improve the performance of ion-implanted solar cells to 16.5 percent AM1, (3) developing a model of the pulse annealing process used in solar cell production, and (4) preparing an economic analysis of the process costs of ion implantation and furnace annealing. During the program, phosphorus ions at an energy of 10 keV and dose of 2 x 10/sup 15/ cm/sup -2/ were implanted in silicon solar cells to produce junctions, while boron ions at 25 keV and 5 x 10/sup 15/ cm/sup -2/ were implanted in the cells to produce effective back surface fields. An ion implantation facility with a beam current up to 4 mA and a production throughput of 300 wafers per hour was designed and installed. A design was prepared for a 100-mA, automated implanter with a production capacity of 100 MW/sub e/ per year. Two process sequences were developed which employ ion implantation and furnace or pulse annealing. The JPL-Solar Array Manufacturing Industry Simulation (SAMIS) computer program was used to determine costs for junction formation by ion implantation and various furnace annealing cycles to demonstrate cost effectiveness of these methods.

  4. Advances in the Dow Corning process for solar-grade silicon

    Science.gov (United States)

    Hunt, L. P.; Dosaj, V. D.; Mccormick, J. R.; Rauchholz, A. W.

    1978-01-01

    The Dow Corning process consists of the carbothermic reduction of silica to produce silicon that is then purified by unidirectional solidification. The process has produced silicon of semiconductor quality with respect to all elements except boron and phosphorus at about 10 ppma and aluminum at 0.1 ppma. Solar cells produced from this silicon gave AM0 conversion efficiencies of 11%. A process cost analysis is presented.

  5. Cost estimation of a specifically designed direct light processing (DLP) additive manufacturing machine for precision printing

    DEFF Research Database (Denmark)

    Charalambis, Alessandro; Davoudinejad, Ali; Tosello, Guido

    2017-01-01

    Additive Manufacturing (AM) refers to a portfolio of novel manufacturing technologies based on a layer-by-layer fabrication method.The market and industrial application of additive manufacturing technologies as an established manufacturing process have increasedexponentially in the last years cre...... of confidence thecost of any part manufactured with the mentioned 3D printing technology....... creating new opportunities for manufacturers in a variety of industrial sectors. AM is an essentialprototyping technique for product design and development that is used in many different fields. However, the suitability of AMapplications in actual production in an industrial context needs to be determined......Additive Manufacturing (AM) refers to a portfolio of novel manufacturing technologies based on a layer-by-layer fabrication method.The market and industrial application of additive manufacturing technologies as an established manufacturing process have increasedexponentially in the last years...

  6. TiCl4 Barrier Process Engineering in Semiconductor Manufacturing

    Directory of Open Access Journals (Sweden)

    Tuung Luoh

    2016-01-01

    Full Text Available Titanium nitride (TiN not only was utilized in the wear-resistant coatings industry but it was also adopted in barrier processes for semiconductor manufacturing. Barrier processes include the titanium (Ti and TiN processes, which are commonly used as diffusion barriers in via/contact applications. However, engineers frequently struggle at the via/contact module in the beginning of every technology node. As devices shrink, barrier processes become more challenging to overcome the both the physical fill-in and electrical performance requirements of advanced small via/contact plugs. The aim of this paper is to investigate various chemical vapor deposition (CVD TiCl4-based barrier processes to serve the application of advanced small via/contact plugs and the metal gate processes. The results demonstrate that the plasma-enhanced chemical vapor deposition (PECVD TiCl4-based Ti process needs to select a feasible process temperature to avoid Si surface corrosion by high-temperature chloride flow. Conventional high step coverage (HSC CVD TiCl4-based TiN processes give much better impurity performance than metal organic chemical vapor deposition (MOCVD TiN. However, the higher chloride content in HSC film may degrade the long-term reliability of the device. Furthermore, it is evidenced that a sequential flow deposition (SFD CVD TiCl4-based process with multiple cycles can give much less chloride content, resulting in faster erase speeds and lower erase levels than that of conventional HSC TiN.

  7. An Overview of Cloud Implementation in the Manufacturing Process Life Cycle

    Science.gov (United States)

    Kassim, Noordiana; Yusof, Yusri; Hakim Mohamad, Mahmod Abd; Omar, Abdul Halim; Roslan, Rosfuzah; Aryanie Bahrudin, Ida; Ali, Mohd Hatta Mohamed

    2017-08-01

    The advancement of information and communication technology (ICT) has changed the structure and functions of various sectors and it has also started to play a significant role in modern manufacturing in terms of computerized machining and cloud manufacturing. It is important for industries to keep up with the current trend of ICT for them to be able survive and be competitive. Cloud manufacturing is an approach that wanted to realize a real-world manufacturing processes that will apply the basic concept from the field of Cloud computing to the manufacturing domain called Cloud-based manufacturing (CBM) or cloud manufacturing (CM). Cloud manufacturing has been recognized as a new paradigm for manufacturing businesses. In cloud manufacturing, manufacturing companies need to support flexible and scalable business processes in the shop floor as well as the software itself. This paper provides an insight or overview on the implementation of cloud manufacturing in the modern manufacturing processes and at the same times analyses the requirements needed regarding process enactment for Cloud manufacturing and at the same time proposing a STEP-NC concept that can function as a tool to support the cloud manufacturing concept.

  8. 10th Workshop on Crystalline Silicon Solar Cell Materials and Processes: Extended Abstracts and Papers from the Workshop, Copper Mountain Resort; August 14-16, 2000

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B.L.; Gee, J.; Kalejs, J.; Saitoh, R.; Stavola, M.; Swanson, D.; Tan, T.; Weber, E.; Werner, J.

    2000-08-11

    The 10th Workshop provided a forum for an informal exchange of technical and scientific information between international researchers in the photovoltaic and non-photovoltaic fields. Discussions included the various aspects of impurities and defects in silicon-their properties, the dynamics during device processing, and their application for developing low-cost processes for manufacturing high-efficiency silicon solar cells. Sessions and panel discussions also reviewed thin-film crystalline-silicon PV, advanced cell structures, new processes and process characterization techniques, and future manufacturing requirements to meet the ambitious expansion goals described in the recently released US PV Industry Roadmap. The Workshop also provided an excellent opportunity for researchers in private industry and at universities to recognize a mutual need for future collaborative research. The three-day workshop consisted of presentations by invited speakers, followed by discussion sessions. In addition, there was two poster sessions presenting the latest research and development results. The subjects discussed included: solar cell processing, light-induced degradation, gettering and passivation, crystalline silicon growth, thin-film silicon solar cells, and impurities and defects. Two special sessions featured at this workshop: advanced metallization and interconnections, and characterization methods.

  9. Solution-Processable Silicon Phthalocyanines in Electroluminescent and Photovoltaic Devices.

    Science.gov (United States)

    Zysman-Colman, Eli; Ghosh, Sanjay S; Xie, Guohua; Varghese, Shinto; Chowdhury, Mithun; Sharma, Nidhi; Cordes, David B; Slawin, Alexandra M Z; Samuel, Ifor D W

    2016-04-13

    Phthalocyanines and their main group and metal complexes are important classes of organic semiconductor materials but are usually highly insoluble and so frequently need to be processed by vacuum deposition in devices. We report two highly soluble silicon phthalocyanine (SiPc) diester compounds and demonstrate their potential as organic semiconductor materials. Near-infrared (λ(EL) = 698-709 nm) solution-processed organic light-emitting diodes (OLEDs) were fabricated and exhibited external quantum efficiencies (EQEs) of up to 1.4%. Binary bulk heterojunction solar cells employing P3HT or PTB7 as the donor and the SiPc as the acceptor provided power conversion efficiencies (PCE) of up to 2.7% under simulated solar illumination. Our results show that soluble SiPcs are promising materials for organic electronics.

  10. Laser Process for Selective Emitter Silicon Solar Cells

    Directory of Open Access Journals (Sweden)

    G. Poulain

    2012-01-01

    Full Text Available Selective emitter solar cells can provide a significant increase in conversion efficiency. However current approaches need many technological steps and alignment procedures. This paper reports on a preliminary attempt to reduce the number of processing steps and therefore the cost of selective emitter cells. In the developed procedure, a phosphorous glass covered with silicon nitride acts as the doping source. A laser is used to open locally the antireflection coating and at the same time achieve local phosphorus diffusion. In this process the standard chemical etching of the phosphorous glass is avoided. Sheet resistance variation from 100 Ω/sq to 40 Ω/sq is demonstrated with a nanosecond UV laser. Numerical simulation of the laser-matter interaction is discussed to understand the dopant diffusion efficiency. Preliminary solar cells results show a 0.5% improvement compared with a homogeneous emitter structure.

  11. Optimization of the manufacturing process of a titanium aluminide metal matrix composite using a viscoplastic constitutive theory

    Energy Technology Data Exchange (ETDEWEB)

    Sherwood, J.A.; Quimby, H.M. [Univ. of Massachusetts, Lowell, MA (United States). Dept. of Mechanical Engineering

    1996-04-01

    The thermomechanical behavior of a titanium aluminide metal matrix composite reinforced with silicon carbide fibers is computationally investigated to determine an optimum manufacturing process. The investigations are completed using the Ramaswamy-Stouffer constitutive model and the finite element method. Hold times at a given temperature were used in an effort to allow the residual stresses to relax. However, the subsequent temperature changes erased the benefit of such holds. Thermomechanical cycling was determined to be the optimum method for reducing the residual stress field after cooldown from consolidation.

  12. The Forming Process Researched in Sandblasting Separation of Masked Silicon Wafers

    Directory of Open Access Journals (Sweden)

    V. V. Zhukov

    2016-01-01

    Full Text Available The object of study is a semiconductor silicon disc-crystal currently used in the design of semiconductor diodes. The disc-crystal is manufactured by the sandblasting separation of a premasked silicon wafer into individual elements. The crystal has frustum-of-a-cone shape with its top diameter determined by a protective masking disc diameter and the bottom one defined by the features of the forming process. The apex angle of the cone 2α or a half-angle α between the lateral surface of the cone and the normal drawn to its base is used as a reference value.The work has studied the influence a thickness of the separated wafer and a width of the gap between the masked discs on the crystal shape. The masking cover is a set of square protective elements (3x3 mm, spaced at 0.6; 0.7; 0.8 and 0.9 mm. The mask material is a self-adhesive PVC-film with thickness of 200 microns. Pilot-plant semi-automatic sandblasting equipment was used to for separation.After processing of results (the angle 2α at the top of the cone the following conclusions have been made:- with increasing thickness of the silicon wafers the gap between the protective discs of mask must be increased;- in case a range of the minimum gaps between the protective discs is within 0.35 - 1.20 mm the half-angle α, which defines the shape of the cut surface, can be considered to be constant and equal to 12º ... 14º.

  13. Intelligent technologies in process of highly-precise products manufacturing

    Science.gov (United States)

    Vakhidova, K. L.; Khakimov, Z. L.; Isaeva, M. R.; Shukhin, V. V.; Labazanov, M. A.; Ignatiev, S. A.

    2017-10-01

    One of the main control methods of the surface layer of bearing parts is the eddy current testing method. Surface layer defects of bearing parts, like burns, cracks and some others, are reflected in the results of the rolling surfaces scan. The previously developed method for detecting defects from the image of the raceway was quite effective, but the processing algorithm is complicated and lasts for about 12 ... 16 s. The real non-stationary signals from an eddy current transducer (ECT) consist of short-time high-frequency and long-time low-frequency components, therefore a transformation is used for their analysis, which provides different windows for different frequencies. The wavelet transform meets these conditions. Based on aforesaid, a methodology for automatically detecting and recognizing local defects in bearing parts surface layer has been developed on the basis of wavelet analysis using integral estimates. Some of the defects are recognized by the amplitude component, otherwise an automatic transition to recognition by the phase component of information signals (IS) is carried out. The use of intelligent technologies in the manufacture of bearing parts will, firstly, significantly improve the quality of bearings, and secondly, significantly improve production efficiency by reducing (eliminating) rejections in the manufacture of products, increasing the period of normal operation of the technological equipment (inter-adjustment period), the implementation of the system of Flexible facilities maintenance, as well as reducing production costs.

  14. Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control.

    Science.gov (United States)

    Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

    2014-01-01

    Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented.

  15. Process standardization for the manufacture of Thabdi Peda.

    Science.gov (United States)

    Modha, H M; Patel, N M; Patel, H G; Patel, K N

    2015-06-01

    Traditional dairy products in India are manufactured using age old methods. Such methods varies from place to place. For industrial production of such products a standardized process is needed. Present study was designed to arrive at a method of manufacture for Thabdi Peda, a very popular sweet in Saurashtra region of Gujarat. Range of process parameters like fat percent of milk (4 to 8 %), rate of sugar addition (6 to 10 %) and duration of final heat desiccation (20 to 60 min) were studied and optimum values determined using Response Surface Methodology (RSM) with central composite rotatable design (CCRD). The samples obtained from trials were analyzed for sensory, physicochemical, compositional and textural attributes. The optimized process developed with 10 kg batch of milk having 6 % fat, 8.33 % rate of sugar addition and 34 min duration of heating produced most acceptable product. Standardized Thabdi Peda was found to contain on an average 16.80 % fat, 17.48 % moisture, 11.25 % protein, 20.95 % lactose, 29.99 % sucrose, 3.53 % ash and it gave 28.75 % yield. The pH, water activity and HMF (μ Mole/100 g) content were 6.42, 0.807 and 121.91 respectively. Standard plate count, Yeast and Mold counts were observed to be 3.68 log cfu/g, and 2.51 log cfu/g respectively. No coliforms were observed in Thabdi Peda.

  16. DUPIC nuclear fuel manufacturing and process technology development

    Energy Technology Data Exchange (ETDEWEB)

    Yang, Myung Seung; Park, J. J.; Lee, J. W. [and others

    2000-05-01

    In this study, DUPIC fuel fabrication technology and the active fuel laboratory were developed for the study of spent nuclear fuel. A new nuclear fuel using highly radioactive nuclear materials can be studied at the active fuel laboratory. Detailed DUPIC fuel fabrication process flow was developed considering the manufacturing flow, quality control process and material accountability. The equipment layout of about twenty DUPIC equipment at IMEF M6 hot cell was established for the minimization of the contamination during DUPIC processes. The characteristics of the SIMFUEL powder and pellets was studied in terms of milling conditions. The characteristics of DUPIC powder and pellet was studied by using 1 kg of spent PWR fuel at PIEF nr.9405 hot cell. The results were used as reference process conditions for following DUPIC fuel fabrication at IMEF M6. Based on the reference fabrication process conditions, the main DUPIC pellet fabrication campaign has been started at IMEF M6 using 2 kg of spent PWR fuel since 2000 January. As of March 2000, about thirty DUPIC pellets were successfully fabricated.

  17. Silicon nanowires for ultra-fast and ultrabroadband optical signal processing

    DEFF Research Database (Denmark)

    Ji, Hua; Hu, Hao; Pu, Minhao

    2015-01-01

    In this paper, we present recent research on silicon nanowires for ultra-fast and ultra-broadband optical signal processing at DTU Fotonik. The advantages and limitations of using silicon nanowires for optical signal processing are revealed through experimental demonstrations of various optical...... signal processing....

  18. Chemical vapour etching-based porous silicon and grooving: Application in silicon solar cells processing

    Energy Technology Data Exchange (ETDEWEB)

    Ben Rabha, M.; Boujmil, M.F.; Saadoun, M.; Bessais, B. [Institut National de Recherche Scientifique et Technique, Laboratoire de Photovoltaique et des Semiconducteurs, BP 95, 2050 Hammam-Lif (Tunisia)

    2005-06-01

    Sponge like porous silicon (PS) was formed by a simple and low cost chemical vapour etching (CVE) method and applied in polycrystalline silicon (mc-Si) solar cells processing. The CVE method consists of exposing Si wafers to HNO{sub 3}/HF vapours. It was shown that 8 min of HNO{sub 3}/HF CVE (volume ratio = 1/7) is sufficient to form optimized PS layers on the emitter of mc-Si cells. The CVE-based PS can simultaneously passivate the Si surface and serves as an effective antireflection coating (ARC). As a result, the reflectivity decreases by about 60% of its initial value and the internal quantum efficiency is improved, particularly in the short wavelength region. For acid vapours rich in HNO{sub 3} (HNO{sub 3}/HF >1/4), the CVE method favours the formation of a (NH{sub 4}){sub 2}SiF{sub 6} powder, which is highly soluble in water. These findings let us achieve anisotropic grooving that enables to groove mc-Si wafers locally and in depth using an adequate anti-acid mask. The CVE - based grooving technique was used to form buried metallic contacts on the rear and frontal surface of the Si wafer in order to improve the current collection in mc-Si solar cells. No alteration of the spectral response in the long wavelength range was observed in mc-Si cells with rear-buried contacts. Adjustments of theoretical spectral responses to experimental ones show an increase in the effective electron diffusion length (Ln), which was attributed to Al gettering (passivation) at grain boundaries and to the reduction of the effective thickness of the base of the cells. (copyright 2005 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim) (orig.)

  19. Solid electrolyte material manufacturable by polymer processing methods

    Science.gov (United States)

    Singh, Mohit; Gur, Ilan; Eitouni, Hany Basam; Balsara, Nitash Pervez

    2012-09-18

    The present invention relates generally to electrolyte materials. According to an embodiment, the present invention provides for a solid polymer electrolyte material that is ionically conductive, mechanically robust, and can be formed into desirable shapes using conventional polymer processing methods. An exemplary polymer electrolyte material has an elastic modulus in excess of 1.times.10.sup.6 Pa at 90 degrees C. and is characterized by an ionic conductivity of at least 1.times.10.sup.-5 Scm-1 at 90 degrees C. An exemplary material can be characterized by a two domain or three domain material system. An exemplary material can include material components made of diblock polymers or triblock polymers. Many uses are contemplated for the solid polymer electrolyte materials. For example, the present invention can be applied to improve Li-based batteries by means of enabling higher energy density, better thermal and environmental stability, lower rates of self-discharge, enhanced safety, lower manufacturing costs, and novel form factors.

  20. Electroacoustics modeling of piezoelectric welders for ultrasonic additive manufacturing processes

    Science.gov (United States)

    Hehr, Adam; Dapino, Marcelo J.

    2016-04-01

    Ultrasonic additive manufacturing (UAM) is a recent 3D metal printing technology which utilizes ultrasonic vibrations from high power piezoelectric transducers to additively weld similar and dissimilar metal foils. CNC machining is used intermittent of welding to create internal channels, embed temperature sensitive components, sensors, and materials, and for net shaping parts. Structural dynamics of the welder and work piece influence the performance of the welder and part quality. To understand the impact of structural dynamics on UAM, a linear time-invariant model is used to relate system shear force and electric current inputs to the system outputs of welder velocity and voltage. Frequency response measurements are combined with in-situ operating measurements of the welder to identify model parameters and to verify model assumptions. The proposed LTI model can enhance process consistency, performance, and guide the development of improved quality monitoring and control strategies.

  1. Process monitoring of additive manufacturing by using optical tomography

    Science.gov (United States)

    Zenzinger, Guenter; Bamberg, Joachim; Ladewig, Alexander; Hess, Thomas; Henkel, Benjamin; Satzger, Wilhelm

    2015-03-01

    Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure. A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim structure. Results of our optical tomography (OT) method as obtained on real defects are presented.

  2. Application of silicone based elastomers for manufacturing of Green Fiber Bottle

    DEFF Research Database (Denmark)

    Saxena, Prateek; Bissacco, Giuliano

    2017-01-01

    -stageprocess, where the wood fibers are first thermoformed in the desired shape followed by drying of theformed geometry [2]. To ensure the robustness of the bottle and to avoid shrinkage of cellulose fibers,the wet-formed bottle is pressurized using a silicone core. The core is inserted inside the drying tooland...... inflated. This keeps the wet bottle under pressure thereby enhancing formation of good hydrogenbonds, and hence providing good strength. The feasibility of the tool design concept is supported withFinite Element Model. The hyperelastic behaviour of silicone is defined by the deformation energyfunction (W......). To simulate the inflation action of the core, Yeoh’s model is used for modelling of W. Thestrength of the GFB is correlated with the pressure the bottle can hold and the cut off burst pressurefrom experiments is also reported in this work....

  3. Manufacture of silicon-based devices having disordered sulfur-doped surface layers

    Science.gov (United States)

    Carey, III; Edward, James [Newton, MA; Mazur, Eric [Concord, MA

    2008-04-08

    The present invention provides methods of fabricating a radiation-absorbing semiconductor wafer by irradiating at least one surface location of a silicon substrate, e.g., an n-doped crystalline silicon, by a plurality of temporally short laser pulses, e.g., femtosecond pulses, while exposing that location to a substance, e.g., SF.sub.6, having an electron-donating constituent so as to generate a substantially disordered surface layer (i.e., a microstructured layer) that incorporates a concentration of that electron-donating constituent, e.g., sulfur. The substrate is also annealed at an elevated temperature and for a duration selected to enhance the charge carrier density in the surface layer. For example, the substrate can be annealed at a temperature in a range of about 700 K to about 900 K.

  4. 27 CFR 40.1 - Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco.

    Science.gov (United States)

    2010-04-01

    ... 27 Alcohol, Tobacco Products and Firearms 2 2010-04-01 2010-04-01 false Manufacture of tobacco... MANUFACTURE OF TOBACCO PRODUCTS, CIGARETTE PAPERS AND TUBES, AND PROCESSED TOBACCO Scope of Regulations § 40.1 Manufacture of tobacco products, cigarette papers and tubes, and processed tobacco. This part contains...

  5. Proton-irradiation technology for high-frequency high-current silicon welding diode manufacturing

    Science.gov (United States)

    Lagov, P. B.; Drenin, A. S.; Zinoviev, M. A.

    2017-05-01

    Different proton irradiation regimes were tested to provide more than 20 kHz-frequency, soft reverse recovery “snap-less” behavior, low forward voltage drop and leakage current for 50 mm diameter 7 kA/400 V welding diode Al/Si/Mo structure. Silicon diode with such parameters is very suitable for high frequency resistance welding machines of new generation for robotic welding.

  6. Silicon Photonics for Signal Processing of Tbit/s Serial Data Signals

    DEFF Research Database (Denmark)

    Oxenløwe, Leif Katsuo; Ji, Hua; Galili, Michael

    2012-01-01

    In this paper, we describe our recent work on signal processing of terabit per second optical serial data signals using pure silicon waveguides. We employ nonlinear optical signal processing in nanoengineered silicon waveguides to perform demultiplexing and optical waveform sampling of 1.28-Tbit....../s data signals as well as wavelength conversion of up to 320-Gbit/s data signals. We demonstrate that the silicon waveguides are equally useful for amplitude and phase-modulated data signals....

  7. Data quality and processing for decision making: divergence between corporate strategy and manufacturing processes

    Science.gov (United States)

    McNeil, Ronald D.; Miele, Renato; Shaul, Dennis

    2000-10-01

    Information technology is driving improvements in manufacturing systems. Results are higher productivity and quality. However, corporate strategy is driven by a number of factors and includes data and pressure from multiple stakeholders, which includes employees, managers, executives, stockholders, boards, suppliers and customers. It is also driven by information about competitors and emerging technology. Much information is based on processing of data and the resulting biases of the processors. Thus, stakeholders can base inputs on faulty perceptions, which are not reality based. Prior to processing, data used may be inaccurate. Sources of data and information may include demographic reports, statistical analyses, intelligence reports (e.g., marketing data), technology and primary data collection. The reliability and validity of data as well as the management of sources and information is critical element to strategy formulation. The paper explores data collection, processing and analyses from secondary and primary sources, information generation and report presentation for strategy formulation and contrast this with data and information utilized to drive internal process such as manufacturing. The hypothesis is that internal process, such as manufacturing, are subordinate to corporate strategies. The impact of possible divergence in quality of decisions at the corporate level on IT driven, quality-manufacturing processes based on measurable outcomes is significant. Recommendations for IT improvements at the corporate strategy level are given.

  8. Development of the computer-aided process planning (CAPP system for polymer injection molds manufacturing

    Directory of Open Access Journals (Sweden)

    J. Tepić

    2011-10-01

    Full Text Available Beginning of production and selling of polymer products largely depends on mold manufacturing. The costs of mold manufacturing have significant share in the final price of a product. The best way to improve and rationalize polymer injection molds production process is by doing mold design automation and manufacturing process planning automation. This paper reviews development of a dedicated process planning system for manufacturing of the mold for injection molding, which integrates computer-aided design (CAD, computer-aided process planning (CAPP and computer-aided manufacturing (CAM technologies.

  9. Modeling the mechanical and aging properties of silicone rubber and foam - stockpile-historical & additively manufactured materials

    Energy Technology Data Exchange (ETDEWEB)

    Maiti, A; Weisgraber, T H; Gee, R H

    2014-09-30

    M97* and M9763 belong to the M97xx series of cellular silicone materials that have been deployed as stress cushions in some of the LLNL systems. Their purpose of these support foams is to distribute the stress between adjacent components, maintain relative positioning of various components, and mitigate the effects of component size variation due to manufacturing and temperature changes. In service these materials are subjected to a continuous compressive strain over long periods of time. In order to ensure their effectiveness, it is important to understand how their mechanical properties change over time. The properties we are primarily concerned about are: compression set, load retention, and stress-strain response (modulus).

  10. Advanced Manufacturing Technology Implementation Process in SME: Critical Success Factors

    Directory of Open Access Journals (Sweden)

    Jani Rahardjo

    2010-01-01

    Full Text Available The aim of this paper is to present critical factors that constitute a successful implementation of the Advanced Manufacturing Technologies (AMT in Small Medium Enterprise (SME. Many large companies have applied AMT and the applications have shown significant results in this global market era. Conveniently, these phenomenons are also engaged to Small Medium Enterprises (SME that of high demands on performing high quality product, fast delivery, reliable and more flexible. The implementation of AMT follow several processes namely pre installation, installation, improvement and mature. In order to guarantee the succesfull of running these processes, one should consider the Critical Success Factors (CSF. We conducted a survey to 125 SMEs that have implemented AMT, and found that the CSF for each process are moderately different. Good leadership is the main critical success factor for preparing and installation of the AMT. Once the AMT started or installed and arrived at growth stage, the financial availability factor turns into a critical success factor in the AMT implementation. In, mature stage, the support and commitment of top management becomes an important factor for gaining successful implementation. By means of factor analysis, we could point out that strategic factors are the main factors in pre-installation and installation stage. Finally, in the growth stage and mature stage, both tactical and strategic factors are the important factors in the successful of AMT implementation

  11. Additive manufacturing of stretchable tactile sensors: Processes, materials, and applications

    Science.gov (United States)

    Vatani, Morteza

    3D printing technology is becoming more ubiquitous every day especially in the area of smart structures. However, fabrication of multi-material, functional, and smart structures is problematic because of the process and material limitations. This thesis sought to develop a Direct Print Photopolymerization (DPP) fabrication technique that appreciably extends the manufacturing space for the 3D smart structures. This method employs a robotically controlled micro-extrusion of a filament equipped with a photopolymerization process. The ability to use polymers and ultimately their nanocomposites in this process is the advantage of the proposed process over the current fabrication methods in the fabrication of 3D structures featuring mechanical, physical, and electrical functionalities. In addition, this study focused to develop a printable, conductive, and stretchable nanocomposite based on a photocurable and stretchable liquid resin filled with multi-walled carbon nanotubes (MWNTs). This nanocomposite exhibited piezoresistivity, means its resistivity changes as it deforms. This property is a favorable factor in developing resistance based tactile sensors. They were also able to resist high tensile strains while they showed conductivity. Furthermore, this study offered a possible and low-cost method to have a unique and highly stretchable pressure sensitive polymer. This disruptive pressure sensitive polymer composed of an Ionic Liquid (IL) and a stretchable photopolymer embedded between two layers of Carbon Nanotube (CNTs) based stretchable electrodes. The developed IL-polymer showed both field effect property and piezoresistivity that can detect large tensile strains up 30%. In summary, this research study focused to present feasible methods and materials for printing a 3D smart structure especially in the context of flexible tactile sensors. This study provides a foundation for the future efforts in fabrication of skin like tactile sensors in three-dimensional motifs

  12. Surface Nano Structures Manufacture Using Batch Chemical Processing Methods for Tooling Applications

    DEFF Research Database (Denmark)

    Tosello, Guido; Calaon, Matteo; Gavillet, J.

    2011-01-01

    approaches were selected: (1) using Ø500 nm nano beads deposition for direct patterning of a 4” silicon wafer; (2) using Ø500 nm nano beads deposition as mask for 4” silicon wafer etching and subsequent nickel electroplating; (3) using the anodizing process to produce Ø500 nm structures on a 30x80 mm2...

  13. Impact Analysis of Large-Scale Lean Manufacturing Initiatives Upon Manufacturing Process Innovation in Irish Companies

    OpenAIRE

    McGrath, William; Sees, Mark

    2007-01-01

    Lean manufacturing is a strategic tool that is used to reduce waste and to generally improve the efficiency and competitiveness of many companies and organisations. Many industries that have implemented lean manufacturing have achieved improved performance over time. This dissertation focuses on two medical device companies based in the South of Ireland and their views on the many issues involved in implementing lean in their respective companies. The purpose of this dissertation is to d...

  14. Evaluation of Injection Molding Process Parameters for Manufacturing Polyethylene Terephthalate

    Directory of Open Access Journals (Sweden)

    Marwah O.M.F.

    2017-01-01

    Full Text Available Quality control is an important aspect in manufacturing process. The quality of product in injection moulding is influenced by injection moulding process parameter. In this study, the effect of injection moulding parameter on defects quantity of PET preform was investigated. Optimizing the parameter of injection moulding process is critical to enhance productivity where parameters must operate at an optimum level for an acceptable performance. Design of Experiment (DOE by factorial design approach was used to find an optimum parameter setting and reduce the defects. In this case study, Minitab 17 software was used to analyses the data. The selected input parameters were mould hot runner temperature, water cooling chiller temperature 1 and water cooling chiller temperature 2. Meanwhile, the output for the process was defects quantity of the preform. The relationship between input and output of the process was analyzed using regression method and Analysis of Variance (ANOVA. In order to interpolate the experiment data, mathematical modeling was used which consists of different types of regression equation. Next, from the model, 95% confidence level (p-value was considered and the significant parameter was figured out. This study involved a collaboration with a preform injection moulding company which was Nilai Legasi Plastik Sdn Bhd. The collaboration enabled the researchers to collect the data and also help the company to improve the quality of its production. The results of the study showed that the optimum parameter setting that could reduce the defect quantity of preform was MHR= 88°C, CT1= 24°C and CT2= 27°C. The comparison defect quantity analysis between current companies setting with the optimum setting showed improvement by 21% reduction of defect quantity at the optimum setting. Finally, from the optimization plot, the validation error between the prediction value and experiment was 1.72%. The result proved that quality of products

  15. An electron-multiplying ''Micromegas'' grid made in silicon wafer post-processing technology

    NARCIS (Netherlands)

    Chefdeville, M.A.; Colas, P.; Giomataris, Y.; van der Graaf, H.; Heijne, E.H.M.; van der Putten, S.; Salm, Cora; Schmitz, Jurriaan; Smits, Sander M.; Timmermans, J.; Timmermans, J.; Visschers, J.L.

    2005-01-01

    A technology for manufacturing an aluminium grid onto a silicon wafer has been developed. The grid is fixed parallel and precisely to the wafer (anode) surface at a distance of 50 mm by means of insulating pillars. When some 400V are applied between the grid and (anode) wafer, gas multiplication

  16. An electron-multiplying 'Micromegas' grid made in silicon wafer post-processing technology

    NARCIS (Netherlands)

    Chefdeville, M.; Chefdeville, M.A.; Colas, P.; Giomataris, Y.; van der Graaf, H.; Heijne, E.H.M.; van der Putten, S.; Salm, Cora; Schmitz, Jurriaan; Smits, Sander M.; Timmermans, J.; Visschers, J.L.

    A technology for manufacturing an aluminium grid onto a silicon wafer has been developed. The grid is fixed parallel and precisely to the wafer (anode) surface at a distance of 50 μm by means of insulating pillars. When some 400 V are applied between the grid and (anode) wafer, gas multiplication

  17. Rapid process for manufacturing of aluminum nitride powder

    Energy Technology Data Exchange (ETDEWEB)

    Weimer, A.W.; Cochran, G.A.; Eisman, G.A.; Henley, J.P.; Hook, B.D.; Mills, L.K. [Dow Chemical Co., Midland, MI (United States). Ceramics and Advanced Materials Research; Guiton, T.A.; Knudsen, A.K.; Nicholas, R.N.; Volmering, J.E.; Moore, W.G. [Dow Chemical Co., Midland, MI (United States). Advanced Ceramics Lab.

    1994-01-01

    A rapid, direct nitridation process for the manufacture of sinterable aluminum nitride (AIN) powder was developed at the pilot scale. Atomized aluminum metal and nitrogen gas were heated and reacted rapidly to synthesize AIN while they passed through the reaction zone of a transport flow reactor. The heated walls of the reactor simultaneously initiated the reaction and removed the generated heat to control the exotherm. Several variations of the process were required to achieve high conversion and reduce wall deposition of the product. The fine AIN powder produced did not require a postreaction grinding step to reduce particle size. However, a secondary heat treatment, following a mild milling step to expose fresh surface, was necessary to ensure complete conversion of the aluminum. In some instances, a final air classification step to remove large particles was necessary to promote densification by pressure less sintering. The AIN powder produced was pressure less sintered with 3 wt% yttria to fabricate fully dense parts which exhibited high thermal conductivity. The powder was shown to be less sinterable than commercially available carbothermally produced powders

  18. Optimization of a semiconductor manufacturing process using a reentrant model

    Directory of Open Access Journals (Sweden)

    Sarah Abuhab Valente

    2015-01-01

    Full Text Available The scope of this work is the simulation of a semiconductor manufacturing model in Arena® software and subsequent optimization and sensitivity analysis of this model. The process is considered extremely complex given the amount of steps, machinery, parameters, and highly reentrant characteristics, which makes it difficult to reach stability of production process. The production model used was the Intel Five-Machine Six-Step Mini-fab developed by Karl Kempf (1994. It was programmed in Arena® and optimized by OptQuest®, an add-on. We concluded that variation in the number of machines and operators reflects on cycle time only if there is an increase of one unit of resource more than obtained in the optimization. As a result, we highlighted the scenario where a reduction in cycle time stood out, in which one extra unit was added in the second machine group, representing a 7.41% reduction in cycle time.

  19. Thermal comfort study of plastics manufacturing industry in converting process

    Directory of Open Access Journals (Sweden)

    Sugiono Sugiono

    2017-09-01

    Full Text Available Thermal comfort is one of ergonomics factors that can create a significant impact to workers performance. For a better thermal comfort, several environment factors (air temperature, wind speed and relative humidity should be considered in this research. The object of the study is a building for converting process of plastics manufacturing industry located in Malang, Indonesia. The maximum air temperature inside the building can reach as high as 36°C. The result of this study shows that heat stress is dominantly caused by heat source from machine and wall building. The computational fluid dynamics (CFD simulation is used to show the air characteristic through inside the building. By using the CFD simulation, some scenarios of solution are successfully presented. Employees thermal comfort was investigated based on predicted mean vote model (PMV and predicted percentage of dissatisfied model (PPD. Existing condition gives PMV in range from 1.83 to 2.82 and PPD in range from 68.9 to 98%. Meanwhile, modification of ventilation and replacing ceiling material from clear glass into reflective clear glass gave significant impact to reduce PMV into range from 1.63 to 2.18 and PPD into range from 58.2 to 84.2%. In sort, new design converting building process has more comfortable for workers.

  20. Technical and economical aspects of the RAD silicon ribbon growth process

    Science.gov (United States)

    Belouet, C.; Darbon, P.; Dutois, F.; Fages, C.; Mautref, M.

    The preparation of self-supported silicon sheets typically 10 cm x 5 cm in surface area from supported silicon ribbons grown by the RAD process is now a well-established technology. Ribbons are currently grown in lengths of 15 to 20 m at a pull rate of 9 cm/min. Symmetrical silicon layers 80-micron thick can be achieved at that speed and subsequently separated from their carbon substrate with a yield which should exceed 0.8. The combination of these properties and the expected high efficiency of the solar cell makes this process very competitive for the production of low-cost silicon sheets.

  1. 14th Workshop on Crystalline Silicon Solar Cells& Modules: Materials and Processes; Extended Abstracts and Papers

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B. L.

    2004-08-01

    The 14th Workshop will provide a forum for an informal exchange of technical and scientific information between international researchers in the photovoltaic and relevant non-photovoltaic fields. It will offer an excellent opportunity for researchers in private industry and at universities to prioritize mutual needs for future collaborative research. The workshop is intended to address the fundamental properties of PV silicon, new solar cell designs, advanced solar cell processing techniques, and cell-related module issues. A combination of oral presentations by invited speakers, poster sessions, and discussion sessions will review recent advances in crystal growth, new cell designs, new processes and process characterization techniques, cell fabrication approaches suitable for future manufacturing demands, and solar cell encapsulation. This year's theme, ''Crystalline Si Solar Cells: Leapfrogging the Barriers,'' reflects the continued success of crystalline Si PV in overcoming technological barriers to improve solar cell performance and lower the cost of Si PV. The workshop will consist of presentations by invited speakers, followed by discussion sessions. In addition, there will be two poster sessions presenting the latest research and development results. Some presentations will address recent technologies in the microelectronics field that may have a direct bearing on PV. The sessions will include: Advances in crystal growth and material issues; Impurities and defects; Dynamics during device processing; Passivation; High-efficiency Si solar cells; Advanced processing; Thin Si solar cells; and Solar cell reliability and module issues.

  2. Processing technology for high efficiency silicon solar cells

    Science.gov (United States)

    Spitzer, M. B.; Keavney, C. J.

    1985-01-01

    Recent advances in silicon solar cell processing have led to attainment of conversion efficiency approaching 20%. The basic cell design is investigated and features of greatest importance to achievement of 20% efficiency are indicated. Experiments to separately optimize high efficiency design features in test structures are discussed. The integration of these features in a high efficiency cell is examined. Ion implantation has been used to achieve optimal concentrations of emitter dopant and junction depth. The optimization reflects the trade-off between high sheet conductivity, necessary for high fill factor, and heavy doping effects, which must be minimized for high open circuit voltage. A second important aspect of the design experiments is the development of a passivation process to minimize front surface recombination velocity. The manner in which a thin SiO2 layer may be used for this purpose is indicated without increasing reflection losses, if the antireflection coating is properly designed. Details are presented of processing intended to reduce recombination at the contact/Si interface. Data on cell performance (including CZ and ribbon) and analysis of loss mechanisms are also presented.

  3. MANAGING TRANSITION PROCESSES OF MANUFACTURING NETWORKS OF GLOBAL OPERATIONS

    DEFF Research Database (Denmark)

    Adeyemi, Oluseyi

    2012-01-01

    Western companies have now started to compete on the basis of value delivered by shifting their market focus from manufacturing to more product-service oriented systems. This is linked to the view that manufacturing companies are becoming more oriented to the use of the product-service offering r...

  4. Characterization of Ti and Co based biomaterials processed via laser based additive manufacturing

    Science.gov (United States)

    Sahasrabudhe, Himanshu

    Titanium and Cobalt based metallic materials are currently the most ideal materials for load-bearing metallic bio medical applications. However, the long term tribological degradation of these materials still remains a problem that needs a solution. To improve the tribological performance of these two metallic systems, three different research approaches were adapted, stemming out four different research projects. First, the simplicity of laser gas nitriding was utilized with a modern LENS(TM) technology to form an in situ nitride rich later in titanium substrate material. This nitride rich composite coating improved the hardness by as much as fifteen times and reduced the wear rate by more than a magnitude. The leaching of metallic ions during wear was also reduced by four times. In the second research project, a mixture of titanium and silicon were processed on a titanium substrate in a nitrogen rich environment. The results of this reactive, in situ additive manufacturing process were Ti-Si-Nitride coatings that were harder than the titanium substrate by more than twenty times. These coatings also reduced the wear rate by more than two magnitudes. In the third research approach, composites of CoCrMo alloy and Calcium phosphate (CaP) bio ceramic were processed using LENS(TM) based additive manufacturing. These composites were effective in reducing the wear in the CoCrMo alloy by more than three times as well as reduce the leaching of cobalt and chromium ions during wear. The novel composite materials were found to develop a tribofilm during wear. In the final project, a combination of hard nitride coating and addition of CaP bioceramic was investigated by processing a mixture of Ti6Al4V alloy and CaP in a nitrogen rich environment using the LENS(TM) technology. The resultant Ti64-CaP-Nitride coatings significantly reduced the wear damage on the substrate. There was also a drastic reduction in the metal ions leached during wear. The results indicate that the three

  5. Silicon Web Process Development. [for solar cell fabrication

    Science.gov (United States)

    Duncan, C. S.; Seidensticker, R. G.; Hopkins, R. H.; Mchugh, J. P.; Hill, F. E.; Heimlich, M. E.; Driggers, J. M.

    1979-01-01

    Silicon dendritic web, ribbon form of silicon and capable of fabrication into solar cells with greater than 15% AMl conversion efficiency, was produced from the melt without die shaping. Improvements were made both in the width of the web ribbons grown and in the techniques to replenish the liquid silicon as it is transformed to web. Through means of improved thermal shielding stress was reduced sufficiently so that web crystals nearly 4.5 cm wide were grown. The development of two subsystems, a silicon feeder and a melt level sensor, necessary to achieve an operational melt replenishment system, is described. A gas flow management technique is discussed and a laser reflection method to sense and control the melt level as silicon is replenished is examined.

  6. Tenth Workshop on Crystalline Silicon Solar Cell Materials and Processes: A Summary of Discussion Sessions

    Energy Technology Data Exchange (ETDEWEB)

    Tan, T.; Swanson, D.; Sinton, R.; Sopori, B.

    2001-01-22

    The 10th Workshop on Silicon Solar Cell Materials and Processes was held in Copper Mountain, Colorado, on August 13-16, 2000. The workshop was attended by 85 scientists and engineers from 15 international photovoltaic (PV) companies and 24 research institutions. Review and poster presentations were augmented by discussion sessions to address the recent progress and critical issues in meeting the goals for Si in the PV Industry Roadmap. The theme of the workshop was Si Photovoltaics: 10 Years of Progress and Opportunities for the Future. Two special sessions were held: Advanced Metallization and Interconnections - covering recent advances in solar cell metallization, printed contacts and interconnections, and addressing new metallization schemes for low-cost cell interconnections; and Characterization Methods - addressing the growing need for process monitoring techniques in the PV industry. The following major issues emerged from the discussion sessions: (1) Mechanical breakage in the P V industry involves a large fraction, about 5%-10%, of the wafers. (2) The current use of Al screen-printed back-contacts appears to be incompatible with the PV Industry Roadmap requirements. (3) The PV manufacturers who use hydrogen passivation should incorporate the plasma-enhanced chemical vapor deposited (PECVD) nitride for antireflection coating and hydrogenation. (4) There is an imminent need to dissolve metallic precipitates to minimize the electrical shunt problem caused by the ''bad'' regions in wafers. (5) Industry needs equipment for automated, in-line monitoring and testing. There are simply not many tools available to industry. (6) In the Wrap-Up Session of the workshop, there was consensus to create four industry/university teams that would address critical research topics in crystalline silicon. (7) The workshop attendees unanimously agreed that the workshop has served well the PV community by promoting the fundamental understanding of industrial

  7. Advanced Drying Process for Lower Manufacturing Cost of Electrodes

    Energy Technology Data Exchange (ETDEWEB)

    Ahmad, Iftikhar [Lambda Technologies, Inc., Morrisville, NC (United States); Zhang, Pu [Lambda Technologies, Inc., Morrisville, NC (United States)

    2016-11-30

    For this Vehicle Technologies Incubator/Energy Storage R&D topic, Lambda Technologies teamed with Navitas Systems and proposed a new advanced drying process that promised a 5X reduction in electrode drying time and significant reduction in the cost of large format lithium batteries used in PEV's. The operating principle of the proposed process was to use penetrating radiant energy source Variable Frequency Microwaves (VFM), that are selectively absorbed by the polar water or solvent molecules instantly in the entire volume of the electrode. The solvent molecules are thus driven out of the electrode thickness making the process more efficient and much faster than convective drying method. To evaluate the Advanced Drying Process (ADP) a hybrid prototype system utilizing VFM and hot air flow was designed and fabricated. While VFM drives the solvent out of the electrode thickness, the hot air flow exhausts the solvent vapors out of the chamber. The drying results from this prototype were very encouraging. For water based anodes there is a 5X drying advantage (time & length of oven) in using ADP over standard drying system and for the NMP based cathodes the reduction in drying time has 3X benefit. For energy savings the power consumption measurements were performed to ADP prototype and compared with the convection standard drying oven. The data collected demonstrated over 40% saving in power consumption with ADP as compared to the convection drying systems. The energy savings are one of the operational cost benefits possible with ADP. To further speed up the drying process, the ADP prototype was explored as a booster module before the convection oven and for the electrode material being evaluated it was possible to increase the drying speed by a factor of 4, which could not be accomplished with the standard dryer without surface defects and cracks. The instantaneous penetration of microwave in the entire slurry thickness showed a major advantage in rapid drying of

  8. Process for the manufacture of molded carbon bodies

    Energy Technology Data Exchange (ETDEWEB)

    Glaser, H.; Stolzenberg, K.

    1985-08-13

    A process for the manufacture of molded carbon bodies directly from high-boiling aromatic hydrocarbon fractions derived from coal or mineral oil, without additional binding agents and without using high pressures, is disclosed. Molds are filled with the starting material, distillation residues from the working-up of coal tar or pyrolysis products, these residues having a softening point (KS) in excess of 40/sup 0/ C. and a quinoline-insoluble content (QI) < 1.0%, and being in the liquid state, or in the solid state, and are heated, in the first step up to 550/sup 0/ C., the residues being converted into ''green'' coke. In the second step, the coke is heated up to at least 800/sup 0/ C. at a heating rate, depending on the diameter d (m), of 1.2 x 1/d/sup 2/ K/day. The molded bodies can be impregnated and graphitized. They are distinguished by high electrical conductivity, low thermal expansion, and high strength in the axial direction.

  9. 11th Workshop on Crystalline Silicon Solar Cell Materials and Processes, Extended Abstracts and Papers, 19-22 August 2001, Estes Park, Colorado

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B.

    2001-08-16

    The 11th Workshop will provide a forum for an informal exchange of technical and scientific information between international researchers in the photovoltaic and non-photovoltaic fields. Discussions will include the various aspects of impurities and defects in silicon--their properties, the dynamics during device processing, and their application for developing low-cost processes for manufacturing high-efficiency silicon solar cells. Sessions and panel discussions will review impurities and defects in crystalline-silicon PV, advanced cell structures, new processes and process characterization techniques, and future manufacturing demands. The workshop will emphasize some of the promising new technologies in Si solar cell fabrication that can lower PV energy costs and meet the throughput demands of the future. The three-day workshop will consist of presentations by invited speakers, followed by discussion sessions. Topics to be discussed are: Si Mechanical properties and Wafer Handling, Advanced Topics in PV Fundamentals, Gettering and Passivation, Impurities and Defects, Advanced Emitters, Crystalline Silicon Growth, and Solar Cell Processing. The workshop will also include presentations by NREL subcontractors who will review the highlights of their research during the current subcontract period. In addition, there will be two poster sessions presenting the latest research and development results. Some presentations will address recent technologies in the microelectronics field that may have a direct bearing on PV.

  10. Development of an Evaluating Method for Carbon Emissions of Manufacturing Process Plans

    Directory of Open Access Journals (Sweden)

    Yanhong Wang

    2015-01-01

    Full Text Available Carbon intensity reduction and energy utilization enhancement in manufacturing industry are becoming a timely topic. In a manufacturing system, the process planning is the combination of all production factors which influences the entail carbon emissions during manufacturing. In order to meet the current low carbon manufacturing requirements, a carbon emission evaluation method for the manufacturing process planning is highly desirable to be developed. This work presents a method to evaluate the carbon emissions of a process plan by aggregating the unit process to form a combined model for evaluating carbon emissions. The evaluating results can be used to decrease the resource and energy consumption and pinpoint detailed breakdown of the influences between manufacturing process plan and carbon emissions. Finally, the carbon emission analysis method is applied to a process plan of an axis to examine its feasibility and validity.

  11. High-flux solar furnace processing of crystalline silicon solar cells

    Science.gov (United States)

    Tsuo, Y. S.; Pitts, J. R.; Menna, P.; Landry, M. D.; Gee, J. M.; Ciszek, T. F.

    1997-02-01

    We studied the processing of crystalline-silicon solar cells using a 10-kW, high-flux solar furnace (HFSF). Major findings of this study include: (1) hydrogenated amorphous silicon films deposited on glass substrates can be converted to microcrystalline silicon by solid-phase crystallization in 5 seconds or less in the HFSF; (2) the presence of concentrated sunlight enhances the diffusion of phosphorus into silicon from a spin-on dopant source; (3) the combination of a porous-silicon surface layer and photo-enhanced impurity diffusion is very effective in gettering impurities from a metallurgical-grade silicon wafer or thin-layer silicon deposited using liquid-phase epitaxy; (4) a 14.1%-efficient crystalline-silicon solar cell with an area of 4.6 cm2 was fabricated using the HFSF for simultaneous diffusion of front n+-p and back p-p+ junctions; and (5) we have shown that the HFSF can be used to texture crystalline-silicon surfaces and to anneal metal contacts printed on a silicon solar cell.

  12. Intelligent Processing Equipment Developments Within the Navy's Manufacturing Technology Centers of Excellence

    Science.gov (United States)

    Nanzetta, Philip

    1992-01-01

    The U.S. Navy has had an active Manufacturing Technology (MANTECH) Program aimed at developing advanced production processes and equipment since the late-1960's. During the past decade, however, the resources of the MANTECH program were concentrated in Centers of Excellence. Today, the Navy sponsors four manufacturing technology Centers of Excellence: the Automated Manufacturing Research Facility (AMRF); the Electronics Manufacturing Productivity Facility (EMPF); the National Center for Excellence in Metalworking Technology (NCEMT); and the Center of Excellence for Composites Manufacturing Technology (CECMT). This paper briefly describes each of the centers and summarizes typical Intelligent Equipment Processing (IEP) projects that were undertaken.

  13. Silicon Carbide Temperature Monitor Processing Improvements. Status Report

    Energy Technology Data Exchange (ETDEWEB)

    Unruh, Troy Casey [Idaho National Lab. (INL), Idaho Falls, ID (United States); Daw, Joshua Earl [Idaho National Lab. (INL), Idaho Falls, ID (United States); Al Rashdan, Ahamad [Idaho National Lab. (INL), Idaho Falls, ID (United States)

    2016-01-29

    Silicon carbide (SiC) temperature monitors are used as temperature sensors in Advanced Test Reactor (ATR) irradiations at the Idaho National Laboratory (INL). Although thermocouples are typically used to provide real-time temperature indication in instrumented lead tests, other indicators, such as melt wires, are also often included in such tests as an independent technique of detecting peak temperatures incurred during irradiation. In addition, less expensive static capsule tests, which have no leads attached for real-time data transmission, often rely on melt wires as a post-irradiation technique for peak temperature indication. Melt wires are limited in that they can only detect whether a single temperature is or is not exceeded. SiC monitors are advantageous because a single monitor can be used to detect for a range of temperatures that occurred during irradiation. As part of the process initiated to make SiC temperature monitors available at the ATR, post-irradiation evaluations of these monitors have been previously completed at the High Temperature Test Laboratory (HTTL). INL selected the resistance measurement approach for determining irradiation temperature from SiC temperature monitors because it is considered to be the most accurate measurement. The current process involves the repeated annealing of the SiC monitors at incrementally increasing temperature, with resistivity measurements made between annealing steps. The process is time consuming and requires the nearly constant attention of a trained staff member. In addition to the expensive and lengthy post analysis required, the current process adds many potential sources of error in the measurement, as the sensor must be repeatedly moved from furnace to test fixture. This time-consuming post irradiation analysis is a significant portion of the total cost of using these otherwise inexpensive sensors. An additional consideration of this research is that, if the SiC post processing can be automated, it

  14. Manufacturing

    Directory of Open Access Journals (Sweden)

    Kovalenko Iaroslav

    2017-04-01

    Full Text Available This article describes a method of in-situ process monitoring in the digital light processing (DLP 3D printer. It is based on the continuous measurement of the adhesion force between printing surface and bottom of a liquid resin bath. This method is suitable only for the bottom-up DPL printers. Control system compares the force at the moment of unsticking of printed layer from the bottom of the tank, when it has the largest value in printing cycle, with theoretical value. Implementation of suggested algorithm can make detection of faults during the printing process possible.

  15. Process Machine Interactions Predicition and Manipulation of Interactions between Manufacturing Processes and Machine Tool Structures

    CERN Document Server

    Hollmann, Ferdinand

    2013-01-01

    This contributed volume collects the scientific results of the DFG Priority Program 1180 Prediction and Manipulation of Interactions between Structure and Process. The research program has been conducted during the years 2005 and 2012, whereas the primary goal was the analysis of the interactions between processes and structures in modern production facilities. This book presents the findings of the 20 interdisciplinary subprojects, focusing on different manufacturing processes such as high performance milling, tool grinding or metal forming. It contains experimental investigations as well as mathematical modeling of production processes and machine interactions. New experimental advancements and novel simulation approaches are also included.

  16. Comparison of Composites Properties Manufactured by Vacuum Process and Autoclave Process

    Directory of Open Access Journals (Sweden)

    MA Rufei

    2017-01-01

    Full Text Available Two kinds of prepregs ZT7G/LT-03A(unidirectional carbon fiber prepreg and ZT7G3198P/LT-03A(plain carbon fabric prepreg were used to manufacture three Bateches of composites by vacuum process and autoclave process respectively. The physical properties of the prepregs and mechanical properties of composite were tested. The performance, fiber volume content and porosity of composites manufactured by vacuum cure and autoclave process show that the physical property retention rates of vacuum cured composites are all over 75%, some even more than 100%. Interlaminar shear strength keeps the lowest retention rate and warp tensile strength keeps the highest retention in unidirectional carbon fiber composites. For fabric composite material, compression strength keeps the lowest and warp tensile strength keeps the highest retention. Vacuum cured composites perform lower fiber volume content and higher porosity, which are the main reasons of the lower performance.

  17. Fabrication and Characterisation of Silicon Waveguides for High-Speed Optical Signal Processing

    DEFF Research Database (Denmark)

    Jensen, Asger Sellerup

    silicon waveguides. As an alternative to crystalline silicon waveguides for nonlinear optical applications, amorphous silicon was explored using RF sputtering potentially allowing for low density of detrimental hydrogen content in the final material. Unfortunately, the linear optical loss in the material...... was too high for any practical applications. It is speculated that the attempt at creating a material with low density of dangling bonds was unsuccessful. Nevertheless, linear losses of 2.4dB/cm at 1550nm wavelength in the silicon waveguides remained sufficiently low that high speed nonlinear optical...... signal processing could be demonstrated. This includes four wave mixing based wavelength conversion of a 320Gb/s Nyquist OTDM signal and cross phase modulation based signal regeneration of a 40Gb/s OTDM signal. Finally, a new type of low loss electrically driven optical modulator in silicon and silicon...

  18. Micro-laser assisted machining: the future of manufacturing silicon optics

    Science.gov (United States)

    Ravindra, Deepak; Kode, Sai Kumar; Stroshine, Chris; Morrison, Don; Mitchell, Mike

    2017-10-01

    A wide range of materials including metals and alloys, ceramics, glasses, semiconductors and composites are manufactured to meet service requirements to a given geometry, accuracy, finish and surface integrity. Metals and alloys in general are easier to machine because of their high fracture toughness, low hardness, non-directional bonding, low porosity, large strain to fracture and high impact energy. Non-metals, on the other hand, such as ceramics, semiconductors and optical crystals are characterized by covalent or ionic bonding, limited slip systems for plastic deformation, high hardness and low fracture toughness. It is due to these major differences that ceramics, semiconductors and optical crystals are considered more challenging to machine.

  19. Amorphous silicon passivation for 23.3% laser processed back contact solar cells

    Science.gov (United States)

    Carstens, Kai; Dahlinger, Morris; Hoffmann, Erik; Zapf-Gottwick, Renate; Werner, Jürgen H.

    2017-08-01

    This paper presents amorphous silicon deposited at temperatures below 200 °C, leading to an excellent passivation layer for boron doped emitter and phosphorus doped back surface field areas in interdigitated back contact solar cells. A higher deposition temperature degrades the passivation of the boron emitter by an increased hydrogen effusion due to lower silicon hydrogen bond energy, proved by hydrogen effusion measurements. The high boron surface doping in crystalline silicon causes a band bending in the amorphous silicon. Under these conditions, at the interface, the intentionally undoped amorphous silicon becomes p-type conducting, with the consequence of an increased dangling bond defect density. For bulk amorphous silicon this effect is described by the defect pool model. We demonstrate, that the defect pool model is also applicable to the interface between amorphous and crystalline silicon. Our simulation shows the shift of the Fermi energy towards the valence band edge to be more pronounced for high temperature deposited amorphous silicon having a small bandgap. Application of optimized amorphous silicon as passivation layer for the boron doped emitter and phosphorus doped back surface field on the rear side of laser processed back contact solar cells, fabricated using four laser processing steps, yields an efficiency of 23.3%.

  20. Evaluation of Select Surface Processing Techniques for In Situ Application During the Additive Manufacturing Build Process

    Science.gov (United States)

    Book, Todd A.; Sangid, Michael D.

    2016-07-01

    Although additive manufacturing offers numerous performance advantages for different applications, it is not being used for critical applications due to uncertainties in structural integrity as a result of innate process variability and defects. To minimize uncertainty, the current approach relies on the concurrent utilization of process monitoring, post-processing, and non-destructive inspection in addition to an extensive material qualification process. This paper examines an alternative approach by evaluating the application of select surface process techniques, to include sliding severe plastic deformation (SPD) and fine particle shot peening, on direct metal laser sintering-produced AlSi10Mg materials. Each surface processing technique is compared to baseline as-built and post-processed samples as a proof of concept for surface enhancement. Initial results pairing sliding SPD with the manufacture's recommended thermal stress relief cycle demonstrated uniform recrystallization of the microstructure, resulting in a more homogeneous distribution of strain among the microstructure than as-built or post-processed conditions. This result demonstrates the potential for the in situ application of various surface processing techniques during the layerwise direct metal laser sintering build process.

  1. Multiple High-Fidelity Modeling Tools for Metal Additive Manufacturing Process Development Project

    Data.gov (United States)

    National Aeronautics and Space Administration — Despite the rapid commercialization of additive manufacturing technology such as selective laser melting, SLM, there are gaps in process modeling and material...

  2. Performance prediction for silicon photonics integrated circuits with layout-dependent correlated manufacturing variability.

    Science.gov (United States)

    Lu, Zeqin; Jhoja, Jaspreet; Klein, Jackson; Wang, Xu; Liu, Amy; Flueckiger, Jonas; Pond, James; Chrostowski, Lukas

    2017-05-01

    This work develops an enhanced Monte Carlo (MC) simulation methodology to predict the impacts of layout-dependent correlated manufacturing variations on the performance of photonics integrated circuits (PICs). First, to enable such performance prediction, we demonstrate a simple method with sub-nanometer accuracy to characterize photonics manufacturing variations, where the width and height for a fabricated waveguide can be extracted from the spectral response of a racetrack resonator. By measuring the spectral responses for a large number of identical resonators spread over a wafer, statistical results for the variations of waveguide width and height can be obtained. Second, we develop models for the layout-dependent enhanced MC simulation. Our models use netlist extraction to transfer physical layouts into circuit simulators. Spatially correlated physical variations across the PICs are simulated on a discrete grid and are mapped to each circuit component, so that the performance for each component can be updated according to its obtained variations, and therefore, circuit simulations take the correlated variations between components into account. The simulation flow and theoretical models for our layout-dependent enhanced MC simulation are detailed in this paper. As examples, several ring-resonator filter circuits are studied using the developed enhanced MC simulation, and statistical results from the simulations can predict both common-mode and differential-mode variations of the circuit performance.

  3. Linear all-optical signal processing using silicon micro-ring resonators

    DEFF Research Database (Denmark)

    Ding, Yunhong; Ou, Haiyan; Xu, Jing

    2016-01-01

    Silicon micro-ring resonators (MRRs) are compact and versatile devices whose periodic frequency response can be exploited for a wide range of applications. In this paper, we review our recent work on linear all-optical signal processing applications using silicon MRRs as passive filters. We focus...

  4. Optoelectronic properties of Black-Silicon generated through inductively coupled plasma (ICP) processing for crystalline silicon solar cells

    Energy Technology Data Exchange (ETDEWEB)

    Hirsch, Jens, E-mail: J.Hirsch@emw.hs-anhalt.de [Anhalt University of Applied Sciences, Faculty EMW, Bernburger Str. 55, DE-06366 Köthen (Germany); Fraunhofer Center for Silicon Photovoltaics CSP, Otto-Eißfeldt-Str. 12, DE-06120 Halle (Saale) (Germany); Gaudig, Maria; Bernhard, Norbert [Anhalt University of Applied Sciences, Faculty EMW, Bernburger Str. 55, DE-06366 Köthen (Germany); Lausch, Dominik [Fraunhofer Center for Silicon Photovoltaics CSP, Otto-Eißfeldt-Str. 12, DE-06120 Halle (Saale) (Germany)

    2016-06-30

    Highlights: • Fabrication of black silicon through inductively coupled plasma (ICP) processing. • Suppressed formation a self-bias and therefore a reduced ion bombardment of the silicon sample. • Reduction of the average hemispherical reflection between 300 and 1120 nm up to 8% within 5 min ICP process time. • Reflection is almost independent of the angle of incidence up to 60°. • 2.5 ms effective lifetime at 10{sup 15} cm{sup −3} MCD after ALD Al{sub 2}O{sub 3} surface passivation. - Abstract: The optoelectronic properties of maskless inductively coupled plasma (ICP) generated black silicon through SF{sub 6} and O{sub 2} are analyzed by using reflection measurements, scanning electron microscopy (SEM) and quasi steady state photoconductivity (QSSPC). The results are discussed and compared to capacitively coupled plasma (CCP) and industrial standard wet chemical textures. The ICP process forms parabolic like surface structures in a scale of 500 nm. This surface structure reduces the average hemispherical reflection between 300 and 1120 nm up to 8%. Additionally, the ICP texture shows a weak increase of the hemispherical reflection under tilted angles of incidence up to 60°. Furthermore, we report that the ICP process is independent of the crystal orientation and the surface roughness. This allows the texturing of monocrystalline, multicrystalline and kerf-less wafers using the same parameter set. The ICP generation of black silicon does not apply a self-bias on the silicon sample. Therefore, the silicon sample is exposed to a reduced ion bombardment, which reduces the plasma induced surface damage. This leads to an enhancement of the effective charge carrier lifetime up to 2.5 ms at 10{sup 15} cm{sup −3} minority carrier density (MCD) after an atomic layer deposition (ALD) with Al{sub 2}O{sub 3}. Since excellent etch results were obtained already after 4 min process time, we conclude that the ICP generation of black silicon is a promising technique

  5. Processes and applications of silicon carbide nanocomposite fibers

    Science.gov (United States)

    Shin, D. G.; Cho, K. Y.; Jin, E. J.; Riu, D. H.

    2011-10-01

    Various types of SiC such as nanowires, thin films, foam, and continuous fibers have been developed since the early 1980s, and their applications have been expanded into several new applications, such as for gas-fueled radiation heater, diesel particulate filter (DPF), ceramic fiber separators and catalyst/catalyst supports include for the military, aerospace, automobile and electronics industries. For these new applications, high specific surface area is demanded and it has been tried by reducing the diameter of SiC fiber. Furthermore, functional nanocomposites show potentials in various harsh environmental applications. In this study, silicon carbide fiber was prepared through electrospinning of the polycarbosilane (PCS) with optimum molecular weight distribution which was synthesized by new method adopting solid acid catalyst such as ZSM-5 and γ-Al2O3. Functional elements such as aluminum, titanium, tungsten and palladium easily doped in the precursor fiber and remained in the SiC fiber after pyrolysis. The uniform SiC fibers were produced at the condition of spinning voltage over 20 kV from the PCS solution as the concentration of 1.3 g/ml in DMF/Toluene (3:7) and pyrolysis at 1200°C. Pyrolyzed products were processed into several interesting applications such as thermal batteries, hydrogen sensors and gas filters.

  6. Global optimization of silicon nanowires for efficient parametric processes

    DEFF Research Database (Denmark)

    Vukovic, Dragana; Xu, Jing; Mørk, Jesper

    2013-01-01

    We present a global optimization of silicon nanowires for parametric single-pump mixing. For the first time, the effect of surface roughness-induced loss is included in the analysis, significantly influencing the optimum waveguide dimensions....

  7. Influence of the Manufacturing Process on Defects in the Galvanized Coating of High Carbon Steel Wires.

    Science.gov (United States)

    Gelfi, Marcello; Solazzi, Luigi; Poli, Sandro

    2017-03-06

    This study is a detailed failure analysis of galvanized high carbon steel wires, which developed coating cracks during the torsion test performed as a quality control at the end of the manufacturing process. Careful visual inspections showed that the cracks are already present in the coating before the torsion test. In order to explain the origin of these cracks, systematic metallographic investigations were performed by means of optical and scanning electron microscope on both the wires and the rods that have been cold drawn to produce the wire. The chemical composition of the galvanized coatings was evaluated by means of energy dispersive spectroscopy. Micro bidimensional X-ray diffraction experiments were also performed to measure the residual stresses in the galvanized coating. The results showed that the failure is related to two main factors: the relatively high content of silicon in the steel and the unsuitable cooling rate of the rods at the exit from the galvanizing bath. The mechanism proposed to explain the origin of the defects was supported by Finite Elements Methods simulations and verified with in-plant tests. The proper countermeasures were then applied and the problem successfully solved.

  8. Influence of the Manufacturing Process on Defects in the Galvanized Coating of High Carbon Steel Wires

    Directory of Open Access Journals (Sweden)

    Marcello Gelfi

    2017-03-01

    Full Text Available This study is a detailed failure analysis of galvanized high carbon steel wires, which developed coating cracks during the torsion test performed as a quality control at the end of the manufacturing process. Careful visual inspections showed that the cracks are already present in the coating before the torsion test. In order to explain the origin of these cracks, systematic metallographic investigations were performed by means of optical and scanning electron microscope on both the wires and the rods that have been cold drawn to produce the wire. The chemical composition of the galvanized coatings was evaluated by means of energy dispersive spectroscopy. Micro bidimensional X-ray diffraction experiments were also performed to measure the residual stresses in the galvanized coating. The results showed that the failure is related to two main factors: the relatively high content of silicon in the steel and the unsuitable cooling rate of the rods at the exit from the galvanizing bath. The mechanism proposed to explain the origin of the defects was supported by Finite Elements Methods simulations and verified with in-plant tests. The proper countermeasures were then applied and the problem successfully solved.

  9. Plasmaless cleaning process of silicon surface using chlorine trifluoride

    Science.gov (United States)

    Saito, Yoji; Yamaoka, Osamu; Yoshida, Akira

    1990-03-01

    Plasmaless etching using ClF3 gas around room temperature has been investigated for the silicon substrates with the various thicknesses of native oxide. The native oxide can be removed with ClF3 gas. A specular surface is obtained by ultraviolet light irradiation which remarkably accelerates the removal of the native oxide without changing the etch rate of silicon. The etched surface is analyzed with Auger electron measurement, indicating the existence of Cl atoms on it.

  10. Similarities in the electrical conduction processes in hydrogenated amorphous silicon oxynitride and silicon nitride

    CERN Document Server

    Kato, H; Ohki, Y; Seol, K S; Noma, T

    2003-01-01

    Electrical conduction at high fields was examined in a series of hydrogenated amorphous silicon oxynitride and silicon nitride films with different nitrogen contents deposited by plasma-enhanced chemical vapour deposition. It was shown that the conduction is attributable to the Poole-Frenkel (PF) emission in the two materials. The energy depths of the PF sites and the dependences on the sample's chemical composition are quite similar for the two samples. It is considered that the PF sites in the two materials are identical.

  11. Advances in silicon nanophotonics

    DEFF Research Database (Denmark)

    Hvam, Jørn Märcher; Pu, Minhao

    plasma effect have been tested up to 40 Gbit/s, and hybrid evanescent silicon lasers have been realized both in the form of distributed feed-back lasers and micro-disk lasers. For enhancing the impact of silicon photonics in future ultrafast and energy-efficient all-optical signal processing, e......Silicon has long been established as an ideal material for passive integrated optical circuitry due to its high refractive index, with corresponding strong optical confinement ability, and its low-cost CMOS-compatible manufacturability. However, the inversion symmetry of the silicon crystal lattice...... has been an obstacle for a simple realization of electro-optic modulators, and its indirect band gap has prevented the realization of efficient silicon light emitting diodes and lasers. Still, significant progress has been made in the past few years. Electro-optic modulators based on the free carrier...

  12. Silicon-Carbide Power MOSFET Performance in High Efficiency Boost Power Processing Unit for Extreme Environments

    Science.gov (United States)

    Ikpe, Stanley A.; Lauenstein, Jean-Marie; Carr, Gregory A.; Hunter, Don; Ludwig, Lawrence L.; Wood, William; Del Castillo, Linda Y.; Fitzpatrick, Fred; Chen, Yuan

    2016-01-01

    Silicon-Carbide device technology has generated much interest in recent years. With superior thermal performance, power ratings and potential switching frequencies over its Silicon counterpart, Silicon-Carbide offers a greater possibility for high powered switching applications in extreme environment. In particular, Silicon-Carbide Metal-Oxide- Semiconductor Field-Effect Transistors' (MOSFETs) maturing process technology has produced a plethora of commercially available power dense, low on-state resistance devices capable of switching at high frequencies. A novel hard-switched power processing unit (PPU) is implemented utilizing Silicon-Carbide power devices. Accelerated life data is captured and assessed in conjunction with a damage accumulation model of gate oxide and drain-source junction lifetime to evaluate potential system performance at high temperature environments.

  13. 16th Workshop on Crystalline Silicon Solar Cells and Modules: Materials and Processes; Program, Extended Abstracts, and Papers

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B. L.

    2006-08-01

    The National Center for Photovoltaics sponsored the 16th Workshop on Crystalline Silicon Solar Cells and Modules: Materials and Processes held August 6-9, 2006 in Denver, Colorado. The workshop addressed the fundamental properties of PV-Si, new solar cell designs, and advanced solar cell processing techniques. It provided a forum for an informal exchange of technical and scientific information between international researchers in the photovoltaic and relevant non-photovoltaic fields. The Workshop Theme was: "Getting more (Watts) for Less ($i)". A combination of oral presentations by invited speakers, poster sessions, and discussion sessions reviewed recent advances in crystal growth, new cell structures, new processes and process characterization techniques, and cell fabrication approaches suitable for future manufacturing demands. The special sessions included: Feedstock Issues: Si Refining and Purification; Metal-impurity Engineering; Thin Film Si; and Diagnostic Techniques.

  14. Organic conductors as novel ``molecular rulers`` for advanced manufacturing processes

    Energy Technology Data Exchange (ETDEWEB)

    Williams, J.M.

    1995-12-31

    Future advanced manufacturing equipment used in high technology programs will require ultra-high precision and associated machining tool operations that require placement accuracy of {approximately} 1--100 nm (1 nm = 10 {angstrom}). There is consensus among engineers that this equipment will be based on STM (Scanning Tunneling Microscope) technology. All such STM-based ``drivers`` must contain a metrology system that requires absolute length standards referenced to atomic spacings for calibration. Properly designed organic conductor substrate crystals have the potential to be molecular rulers for STM-based advanced manufacturing equipment. The major challenges in future organic conductor research aimed at STM metrology application are listed.

  15. Processes for manufacturing multifocal diffractive-refractive intraocular lenses

    Science.gov (United States)

    Iskakov, I. A.

    2017-09-01

    Manufacturing methods and design features of modern diffractive-refractive intraocular lenses are discussed. The implantation of multifocal intraocular lenses is the most optimal method of restoring the accommodative ability of the eye after removal of the natural lens. Diffractive-refractive intraocular lenses are the most widely used implantable multifocal lenses worldwide. Existing methods for manufacturing such lenses implement various design solutions to provide the best vision function after surgery. The wide variety of available diffractive-refractive intraocular lens designs reflects the demand for this method of vision correction in clinical practice and the importance of further applied research and development of new technologies for designing improved lens models.

  16. TOPICAL REVIEW Textured silicon nitride: processing and anisotropic properties

    Directory of Open Access Journals (Sweden)

    Xinwen Zhu and Yoshio Sakka

    2008-01-01

    Full Text Available Textured silicon nitride (Si3N4 has been intensively studied over the past 15 years because of its use for achieving its superthermal and mechanical properties. In this review we present the fundamental aspects of the processing and anisotropic properties of textured Si3N4, with emphasis on the anisotropic and abnormal grain growth of β-Si3N4, texture structure and texture analysis, processing methods and anisotropic properties. On the basis of the texturing mechanisms, the processing methods described in this article have been classified into two types: hot-working (HW and templated grain growth (TGG. The HW method includes the hot-pressing, hot-forging and sinter-forging techniques, and the TGG method includes the cold-pressing, extrusion, tape-casting and strong magnetic field alignment techniques for β-Si3N4 seed crystals. Each processing technique is thoroughly discussed in terms of theoretical models and experimental data, including the texturing mechanisms and the factors affecting texture development. Also, methods of synthesizing the rodlike β-Si3N4 single crystals are presented. Various anisotropic properties of textured Si3 N4 and their origins are thoroughly described and discussed, such as hardness, elastic modulus, bending strength, fracture toughness, fracture energy, creep behavior, tribological and wear behavior, erosion behavior, contact damage behavior and thermal conductivity. Models are analyzed to determine the thermal anisotropy by considering the intrinsic thermal anisotropy, degree of orientation and various microstructure factors. Textured porous Si3N4 with a unique microstructure composed of oriented elongated β-Si3N4 and anisotropic pores is also described for the first time, with emphasis on its unique mechanical and thermal-mechanical properties. Moreover, as an important related material, textured α-Sialon is also reviewed, because the presence of elongated α-Sialon grains allows the production of textured

  17. Innovative Manufacturing of Launch Vehicle Structures - Integrally Stiffened Cylinder Process

    Science.gov (United States)

    Wagner, John; Domack, Marcia; Tayon, Wesley; Bird, Richard K.

    2017-01-01

    Reducing launch costs is essential to ensuring the success of NASA's visions for planetary exploration and earth science, economical support of the International Space Station, and competitiveness of the U.S. commercial launch industry. Reducing launch vehicle manufacturing cost supports NASA's budget and technology development priorities.

  18. CFD model of laser additive manufacturing process of cylinders

    CSIR Research Space (South Africa)

    Tamsaout, T

    2017-11-01

    Full Text Available A theoretical approach based on a numerical simulation using experimental data is proposed as a contribution to the study of laser-based additive manufacturing by direct energy deposition (DED). The aim is to simulate the stages of layer...

  19. Effect of Surfactants and Manufacturing Methods on the Electrical and Thermal Conductivity of Carbon Nanotube/Silicone Composites

    Directory of Open Access Journals (Sweden)

    Martina Hřibová

    2012-11-01

    Full Text Available The effect of ionic surfactants and manufacturing methods on the separation and distribution of multi-wall carbon nanotubes (CNTs in a silicone matrix are investigated. The CNTs are dispersed in an aqueous solution of the anionic surfactant dodecylbenzene sulfonic acid (DBSA, the cationic surfactant cetyltrimethylammonium bromide (CTAB, and in a DBSA/CTAB surfactant mixture. Four types of CNT-based composites of various concentrations from 0 to 6 vol.% are prepared by simple mechanical mixing and sonication. The morphology, electrical and thermal conductivity of the CNT-based composites are analyzed. The incorporation of both neat and modified CNTs leads to an increase in electrical and thermal conductivity. The dependence of DC conductivity versus CNT concentration shows percolation behaviour with a percolation threshold of about 2 vol.% in composites with neat CNT. The modification of CNTs by DBSA increases the percolation threshold to 4 vol.% due to the isolation/separation of individual CNTs. This, in turn, results in a significant decrease in the complex permittivity of CNT–DBSA-based composites. In contrast to the percolation behaviour of DC conductivity, the concentration dependence of thermal conductivity exhibits a linear dependence, the thermal conductivity of composites with modified CNTs being lower than that of composites with neat CNTs. All these results provide evidence that the modification of CNTs by DBSA followed by sonication allows one to produce composites with high homogeneity.

  20. Tailoring femtosecond 1.5-μm Bessel beams for manufacturing high-aspect-ratio through-silicon vias.

    Science.gov (United States)

    He, Fei; Yu, Junjie; Tan, Yuanxin; Chu, Wei; Zhou, Changhe; Cheng, Ya; Sugioka, Koji

    2017-01-18

    Three-dimensional integrated circuits (3D ICs) are an attractive replacement for conventional 2D ICs as high-performance, low-power-consumption, and small-footprint microelectronic devices. However, one of the major remaining challenges is the manufacture of high-aspect-ratio through-silicon vias (TSVs), which is a crucial technology for the assembly of 3D Si ICs. Here, we present the fabrication of high-quality TSVs using a femtosecond (fs) 1.5-μm Bessel beam. To eliminate the severe ablation caused by the sidelobes of a conventional Bessel beam, a fs Bessel beam is tailored using a specially designed binary phase plate. We demonstrate that the tailored fs Bessel beam can be used to fabricate a 2D array of approximately ∅10-μm TSVs on a 100-μm-thick Si substrate without any sidelobe damage, suggesting potential application in the 3D assembly of 3D Si ICs.

  1. 75 FR 61418 - Milk for Manufacturing Purposes and Its Production and Processing; Requirements Recommended for...

    Science.gov (United States)

    2010-10-05

    ... market milk or of processing plants to produce dairy products in their State. AMS is publishing this... Agricultural Marketing Service Milk for Manufacturing Purposes and Its Production and Processing; Requirements...: Notice; request for comments. SUMMARY: This document proposes to amend the recommended manufacturing milk...

  2. 76 FR 36078 - Milk for Manufacturing Purposes and Its Production and Processing; Requirements Recommended for...

    Science.gov (United States)

    2011-06-21

    ... Agricultural Marketing Service Milk for Manufacturing Purposes and Its Production and Processing; Requirements... in place for Grade A producer herd goat milk. Due to inherent differences between cows and goats... Change the document, ``Milk for Manufacturing Purposes and Its Production and Processing; Recommended...

  3. Quantifying the robustness of process manufacturing concept – A medical product case study

    DEFF Research Database (Denmark)

    Boorla, Srinivasa Murthy; Troldtoft, M.E.; Eifler, Tobias

    2017-01-01

    Product robustness refers to the consistency of performance of all of the units produced. It is often the case that process manufactured products are not designed concurrently, so by the end of the product design phase the Process Manufacturing Concept (PMC) has yet to be decided. Allocating proc...

  4. [Application of near-infrared spectroscopy technology in quality control of TCM manufacturing process].

    Science.gov (United States)

    Tu, Yaosheng; Liu, Jun; Zhang, Jianjun

    2011-09-01

    With the development of research in near-infrared spectroscopy technology, near-infrared spectroscopy are increasingly employed in quality control of traditional Chinese medicine (TCM) manufacturing process. The recent researches in relative field were summarized in this paper. Perspective of near-infrared spectroscopy technology in quality control of TCM manufacturing process was also presented in this paper.

  5. A DMAIC approach for process capability improvement an engine crankshaft manufacturing process

    Science.gov (United States)

    Sharma, G. V. S. S.; Rao, P. Srinivasa

    2014-05-01

    The define-measure-analyze-improve-control (DMAIC) approach is a five-strata approach, namely DMAIC. This approach is the scientific approach for reducing the deviations and improving the capability levels of the manufacturing processes. The present work elaborates on DMAIC approach applied in reducing the process variations of the stub-end-hole boring operation of the manufacture of crankshaft. This statistical process control study starts with selection of the critical-to-quality (CTQ) characteristic in the define stratum. The next stratum constitutes the collection of dimensional measurement data of the CTQ characteristic identified. This is followed by the analysis and improvement strata where the various quality control tools like Ishikawa diagram, physical mechanism analysis, failure modes effects analysis and analysis of variance are applied. Finally, the process monitoring charts are deployed at the workplace for regular monitoring and control of the concerned CTQ characteristic. By adopting DMAIC approach, standard deviation is reduced from 0.003 to 0.002. The process potential capability index ( C P) values improved from 1.29 to 2.02 and the process performance capability index ( C PK) values improved from 0.32 to 1.45, respectively.

  6. Silicon photonics fundamentals and devices

    CERN Document Server

    Deen, M Jamal

    2012-01-01

    The creation of affordable high speed optical communications using standard semiconductor manufacturing technology is a principal aim of silicon photonics research. This would involve replacing copper connections with optical fibres or waveguides, and electrons with photons. With applications such as telecommunications and information processing, light detection, spectroscopy, holography and robotics, silicon photonics has the potential to revolutionise electronic-only systems. Providing an overview of the physics, technology and device operation of photonic devices using exclusively silicon and related alloys, the book includes: * Basic Properties of Silicon * Quantum Wells, Wires, Dots and Superlattices * Absorption Processes in Semiconductors * Light Emitters in Silicon * Photodetectors , Photodiodes and Phototransistors * Raman Lasers including Raman Scattering * Guided Lightwaves * Planar Waveguide Devices * Fabrication Techniques and Material Systems Silicon Photonics: Fundamentals and Devices outlines ...

  7. Manufacturing process optimization of nuclear fuel guide tube using HANA alloys

    Energy Technology Data Exchange (ETDEWEB)

    Jeong, Yong Hwan; Park, S. Y.; Choi, B. K.; Park, J. Y.; Kim, H. G.; Jeong, Y. I.; Park, D. J.; Lim, J. K. [KAERI, Daejeon (Korea, Republic of)

    2010-08-15

    From this project, the advanced manufacturing parameters which were contained of heat-treatment, reduction rate, and new process (2 step) were considered to increase the guide tube performance of HANA material. It was obtained that the strength and corrosion resistance of HANA material were improved by applying the improve manufacturing parameters when compared to the commercial guide tube material. {center_dot} Manufacturing parameter study to increase mechanical property -Tensile strength increase of 30% by manufacturing parameter setup when compared to the guide tube specification {center_dot} Manufacturing parameter study to decrease irradiation growth -Theoretical study of the texture effect on sample specimens related to the irradiation growth {center_dot} Manufacturing parameter study to increase corrosion resistance -Corrosion resistance increase of 30% by manufacturing parameter setup when compared to the commercial guide tube

  8. Silicon Carbide (SiC) Power Processing Unit (PPU) for Hall Effect Thrusters Project

    Data.gov (United States)

    National Aeronautics and Space Administration — In this SBIR project, APEI, Inc. is proposing to develop a high efficiency, rad-hard 3.8 kW silicon carbide (SiC) Power Processing Unit (PPU) for Hall Effect...

  9. Upgrading off-grades from the silicon process: Increasing the silicon yield from Elkem Thamshavn using mechanical or metallurgical separation

    OpenAIRE

    Østensen, Ole Jørgen

    2011-01-01

    The aim of the thesis is to produce high grade silicon from off-grade materials like sculls and process slags from Elkem Thamshavn. The methods investigated are dense medium separation, optical separation, flotation and metallurgical separation by remelting. Dense medium separation trials are conducted using magnetite suspended in water and aim to find the suspension density where only one phase will float. Optical separation experiments are done to identify light intensity thresholds between...

  10. Study of the deposition process of vinpocetine on the surface of porous silicon

    Directory of Open Access Journals (Sweden)

    A.S. Lenshin

    Full Text Available Currently the most prospective way in pharmacotherapy is the obtaining of nanoparticles involving pharmaceutical substances. Application of porous inorganic materials on the basis of silicon is among the main features in solving of this problem. The present work is concerned with the problem of the deposition of pharmaceutical drug with nootropic activity – vinpocetine – into porous silicon. Silicon nanoparticles were obtained by electrochemical anodic etching of Si plates. The process of vinpocetine deposition was studied in dependence of the deposition time. As a result of the investigations it was found that infrared transmission spectra of porous silicon with the deposited vinpocetine revealed the absorption bands characteristic of vinpocetine substance. Keywords: Nanoparticles, Porous silicon, Vinpocetine

  11. 15th Workshop on Crystalline Silicon Solar Cells and Modules: Materials and Processes; Extended Abstracts and Papers

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B. L.

    2005-11-01

    The National Center for Photovoltaics sponsored the 15th Workshop on Crystalline Silicon Solar Cells & Modules: Materials and Processes, held in Vail, CO, August 7-10, 2005. This meeting provided a forum for an informal exchange of technical and scientific information between international researchers in the photovoltaic and relevant non-photovoltaic fields. The workshop addressed the fundamental properties of PV silicon, new solar cell designs, and advanced solar cell processing techniques. A combination of oral presentations by invited speakers, poster sessions, and discussion sessions reviewed recent advances in crystal growth, new cell designs, new processes and process characterization techniques, and cell fabrication approaches suitable for future manufacturing demands. The theme of this year's meeting was 'Providing the Scientific Basis for Industrial Success.' Specific sessions during the workshop included: Advances in crystal growth and material issues; Impurities and defects in Si; Advanced processing; High-efficiency Si solar cells; Thin Si solar cells; and Cell design for efficiency and reliability module operation. The topic for the Rump Session was ''Si Feedstock: The Show Stopper'' and featured a panel discussion by representatives from various PV companies.

  12. Advanced Material Intelligent Processing Center: Next Generation Scalable Lean Manufacturing

    Science.gov (United States)

    2012-09-04

    assisted consolidation of fibre reinforced polymer composites. Composites Part A: Applied Science and Manufacturing. 42 (2011) 320-327. 3. Alms, J. B...34Automating aerospace composites production with fibre placement." Reinforced Plastics, pp. 32-37, May-June 201 I. [13] Christian Böge, "Robotic unit for...336. 14. Chen G, Mu H. Pommerenke D. Drewniak JL. Damage Detection of Reinforced Concrete Beams with Novel Distributed Crack/Strain Sensors

  13. Aerosol-Jet-Printing silicone layers and electrodes for stacked dielectric elastomer actuators in one processing device

    Science.gov (United States)

    Reitelshöfer, Sebastian; Göttler, Michael; Schmidt, Philip; Treffer, Philipp; Landgraf, Maximilian; Franke, Jörg

    2016-04-01

    In this contribution we present recent findings of our efforts to qualify the so called Aerosol-Jet-Printing process as an additive manufacturing approach for stacked dielectric elastomer actuators (DEA). With the presented system we are able to print the two essential structural elements dielectric layer and electrode in one machine. The system is capable of generating RTV-2 silicone layers made of Wacker Elastosil P 7670. Therefore, two aerosol streams of both precursor components A and B are generated in parallel and mixed in one printing nozzle that is attached to a 4-axis kinematic. At maximum speed the printing of one circular Elastosil layer with a calculated thickness of 10 μm and a diameter of 1 cm takes 12 seconds while the process keeps stable for 4.5 hours allowing a quite high overall material output and the generation of numerous silicone layers. By adding a second printing nozzle and the infrastructure to generate a third aerosol, the system is also capable of printing inks with conductive particles in parallel to the silicone. We have printed a reduced graphene oxide (rGO) ink prepared in our lab to generate electrodes on VHB 4905, Elastosil foils and finally on Aerosol-Jet-Printed Elastosil layers. With rGO ink printed on Elastosil foil, layers with a 4-point measured sheet resistance as low as 4 kΩ can be realized leaving room for improving the electrode printing time, which at the moment is not as good as the quite good time-frame for printing the silicone layers. Up to now we have used the system to print a fully functional two-layer stacked DEA to demonstrate the principle of continuously 3D printing actuators.

  14. Solar Grade Silicon by a Direct Metallurgical Process

    Energy Technology Data Exchange (ETDEWEB)

    Ovrelid, E.; Waernes, A.; Raaness, O.; Solheim, I.; Jensen, R.; Tang, K. [SINTEF Materials and Chemistry, Trondheim (Norway); Geerligs, L.J. [ECN Solar Energy, Petten (Netherlands); Santeen, S. [Scanarc Plasma Technologies, Hofors (Sweden); Wiersma, B. [Sunergy Investco, Rotterdam (Netherlands)

    2006-06-15

    The paper gives a background on solar grade silicon and presents the SOLSILC concept. A theoretical description of the design criteria for engineering of the refining reactors is given. C, Ti and Al are used in the calculations because they are important with respect to cell efficiency and yield.

  15. [Data integration, data mining and visualization analysis of traditional Chinese medicine manufacturing process].

    Science.gov (United States)

    Li, Zheng; Kang, Li-Yuan; Fan, Xiao-Hui

    2014-08-01

    Huge amount of data becomes available from the pharmaceutical manufacturing process with wide application of in- dustrial automatic control technology in traditional Chinese medicine (TCM) industry. The industrial big data thus provides golden op- portunities to better understand the manufacturing process and improve the process performance. Therefore it is important to implement data integration and management systems in TCM plants to easily collect, integrate, store, analyze, communicate and visulize the data with high efficiency. It could break the data island and discover useful information and knowledge to improve the manufacturing process performance. The key supporting technologies for TCM manufacturing and industrial big data management were introduced in this paper, with a specific focus on data mining and visualization technologies. Using historic data collected from a manufacturing plant of Shengmai injection of SZYY group, we illustrated the usefulness and discussed future prospects of data mining and visualization technologies.

  16. METHODS AND PRINCIPLES OF OPTIMIZATION SPECIFIC TO THE DOMAIN OF EQUIPMENT AND MANUFACTURING PROCESSES

    Directory of Open Access Journals (Sweden)

    Radu Virgil GRIGORIU

    2011-11-01

    Full Text Available The objectives of the industrial products manufacturers are generally oriented to manufacture high quality level products, in less time and with maximum economic efficiency. The achievement of these objectives can be realized, generally, by optimizing the processes and the technological manufacturing equipment parameters. In order to optimize these parameters it is necessary to apply series of optimization methods and principles that allow the identification and establishment of the best solution from a variety of alternatives.

  17. Dimensional metrology for process and part quality control in micro manufacturing

    DEFF Research Database (Denmark)

    Hansen, Hans Nørgaard; Tosello, Guido; Gasparin, Stefania

    2011-01-01

    dimensions are scaled down and geometrical complexity of objects is increased, the available measurement technologies appear not sufficient. New solutions for measuring principles and instrumentation, tolerancing rules and procedures as well as traceability and calibration are necessary if micro...... manufacturing is to develop into industrial manufacturing solutions. In this paper the application of dimensional precision metrology to both component and process quality control will be demonstrated. The parts investigated are micro injection moulded polymer parts, typical for the field of micro manufacturing....

  18. Crystalline-Silicon Solar Cells for the 21st Century

    Energy Technology Data Exchange (ETDEWEB)

    Tsuo, Y. S.; Wang, T. H.; Ciszek, T. F.

    1999-05-10

    The worldwide market share for crystalline-silicon solar cells has increased steadily in the last 10 years. In 1998, about 87% of the photovoltaic modules shipped worldwide are based on crystalline silicon. This dominance will likely continue into at least the first few years of the 21st century. The long-term growth of crystalline-silicon solar cells will depend on the development of low-cost polysilicon feedstock, silicon films, and advanced cell and module manufacturing processes.

  19. Development of Integrated Programs for Aerospace-vehicle Design (IPAD): Product manufacture interactions with the design process

    Science.gov (United States)

    Crowell, H. A.

    1979-01-01

    The product manufacturing interactions with the design process and the IPAD requirements to support the interactions are described. The data requirements supplied to manufacturing by design are identified and quantified. Trends in computer-aided manufacturing are discussed and the manufacturing process of the 1980's is anticipated.

  20. Silicon material technology status. [assessment for electronic and photovoltaic applications

    Science.gov (United States)

    Lutwack, R.

    1983-01-01

    Silicon has been the basic element for the electronic and photovoltaic industries. The use of silicon as the primary element for terrestrial photovoltaic solar arrays is projected to continue. The reasons for this projection are related to the maturity of silicon technology, the ready availability of extremely pure silicon, the performance of silicon solar cells, and the considerable present investment in technology and manufacturing facilities. The technologies for producing semiconductor grade silicon and, to a lesser extent, refined metallurgical grade silicon are considered. It is pointed out that nearly all of the semiconductor grade silicon is produced by processes based on the Siemens deposition reactor, a technology developed 26 years ago. The state-of-the-art for producing silicon by this process is discussed. It is expected that efforts to reduce polysilicon process costs will continue.

  1. [Criteria of good manufacturing practice conforming electronic data processing].

    Science.gov (United States)

    Gabriel, C

    1996-01-01

    Good manufacturing practices (GMP) are not only supported by data management systems but also implicate that they must meet the supplier qualification criteria in terms of GMP. Elements which technically support a GMP-conformity are multiuser-operating systems, relational data bases, object-oriented languages and data parameters. The most important part is covered by human resources of a bloodbank, which starts with the definition and ends with validation tests. Only the required profile of the end-user makes the GMP-conformity of a data management system constructable and realizable. Competence in project-management and clearly structured projects let such systems perform as planned.

  2. An Introduction to Intelligent Processing Programs Developed by the Air Force Manufacturing Technology Directorate

    Science.gov (United States)

    Sampson, Paul G.; Sny, Linda C.

    1992-01-01

    The Air Force has numerous on-going manufacturing and integration development programs (machine tools, composites, metals, assembly, and electronics) which are instrumental in improving productivity in the aerospace industry, but more importantly, have identified strategies and technologies required for the integration of advanced processing equipment. An introduction to four current Air Force Manufacturing Technology Directorate (ManTech) manufacturing areas is provided. Research is being carried out in the following areas: (1) machining initiatives for aerospace subcontractors which provide for advanced technology and innovative manufacturing strategies to increase the capabilities of small shops; (2) innovative approaches to advance machine tool products and manufacturing processes; (3) innovative approaches to advance sensors for process control in machine tools; and (4) efforts currently underway to develop, with the support of industry, the Next Generation Workstation/Machine Controller (Low-End Controller Task).

  3. PURPOSE – PROCESS – PEOPLE A LEAN APPROACH TO BIOMEDICAL MANUFACTURING

    Directory of Open Access Journals (Sweden)

    A.D. Kahlen

    2012-01-01

    Full Text Available

    ENGLISH ABSTRACT: Opportunities to improve production processes and access to markets through the implementation of lean manufacturing in biomedical manufacturing are presented. The importance of a unified definition of manufacturing, to which biomedical manufacturing is party, is emphasized, and the theory of “lean”, summarized as “purpose, process, people”, is elaborated. The requirements for the creation of value through the creation of flow and the elimination of wastes are highlighted in the context of biomedical manufacturing. Finally, case studies are presented to illustrate the approaches to “purpose, process, people”.

    AFRIKAANSE OPSOMMING: Geleenthede vir die verbetering van produksieprosesse en marktoegang via die implementering van skraalvervaardiging in die biomediese vervaardigingsbedryf word voorgehou. Aandag word geskenk aan die betekenis van terme soos “skraal, doel, proses, menes” in die konteks van biomediese vervaardiging. Waardeskepping, vloei en vermorsing word onder die loep geneem. Gevallestudies word ter illustrasie van begrippe aangebied.

  4. Context-Based Orchestration for Control of Resource-Efficient Manufacturing Processes

    Directory of Open Access Journals (Sweden)

    Michael Schwarz

    2012-08-01

    Full Text Available The increasing competition between manufacturers, the shortening of innovation cycles and the growing importance of resource-efficient manufacturing demand a higher versatility of factory automation. Service-oriented approaches depict a promising possibility to realize new control architectures by encapsulating the functionality of mechatronic devices into services. An efficient discovery, context-based selection and dynamic orchestration of these services are the key features for the creation of highly adaptable manufacturing processes. We describe a semantic service discovery and ad-hoc orchestration system, which is able to react to new process variants and changed contextual information (e.g., failure of field devices, requirements on the consumption of resources. Because a standardized vocabulary, especially for the description of mechatronic functionalities, is still missing in the manufacturing domain, the semantic description of services, processes and manufacturing plants as well as the semantic interpretation of contextual information play an important part.

  5. The roles of communication process for an effective lean manufacturing implementation

    Directory of Open Access Journals (Sweden)

    Perumal Puvanasvaran

    2009-07-01

    Full Text Available Many companies are implementing lean manufacturing concept in order to remain competitive and sustainable, however, not many of them are successful in the process due to various reasons. Communication is an important aspect of lean process in order to successfully implement lean manufacturing.  This paper determines the roles of communication process in ensuring a successful implementation of leanness in manufacturing companies. All the information of lean manufacturing practices and roles of communication in the implementation were compiled from related journals, books and websites. A study was conducted in an aerospace manufacturing in Malaysia. A five-point scale questionnaire is used as the study instrument. These questionnaires were distributed to 45 employees working in a kitting department and to 8 top management people. The results indicate that the degree of leanness were moderate.

  6. Structural and photoluminescence properties of silicon nanowires extracted by means of a centrifugation process from plasma torch synthesized silicon nanopowder

    Science.gov (United States)

    Le Borgne, Vincent; Agati, Marta; Boninelli, Simona; Castrucci, Paola; De Crescenzi, Maurizio; Dolbec, Richard; El Khakani, My Ali

    2017-07-01

    We report on a method for the extraction of silicon nanowires (SiNWs) from the by-product of a plasma torch based spheroidization process of silicon. This by-product is a nanopowder which consists of a mixture of SiNWs and silicon particles. By optimizing a centrifugation based process, we were able to extract substantial amounts of highly pure Si nanomaterials (mainly SiNWs and Si nanospheres (SiNSs)). While the purified SiNWs were found to have typical outer diameters in the 10-15 nm range and lengths of up to several μm, the SiNSs have external diameters in the 10-100 nm range. Interestingly, the SiNWs are found to have a thinner Si core (2-5 nm diam.) and an outer silicon oxide shell (with a typical thickness of ˜5-10 nm). High resolution transmission electron microscopy (HRTEM) observations revealed that many SiNWs have a continuous cylindrical core, whereas others feature a discontinuous core consisting of a chain of Si nanocrystals forming a sort of ‘chaplet-like’ structures. These plasma-torch-produced SiNWs are highly pure with no trace of any metal catalyst, suggesting that they mostly form through SiO-catalyzed growth scheme rather than from metal-catalyzed path. The extracted Si nanostructures are shown to exhibit a strong photoluminescence (PL) which is found to blue-shift from 950 to 680 nm as the core size of the Si nanostructures decreases from ˜5 to ˜3 nm. This near IR-visible PL is shown to originate from quantum confinement (QC) in Si nanostructures. Consistently, the sizes of the Si nanocrystals directly determined from HRTEM images corroborate well with those expected by QC theory.

  7. Microstructure characterisation of Ti-6Al-4V from different additive manufacturing processes

    Science.gov (United States)

    Neikter, M.; Åkerfeldt, P.; Pederson, R.; Antti, M.-L.

    2017-10-01

    The focus of this work has been microstructure characterisation of Ti-6Al-4V manufactured by five different additive manufacturing (AM) processes. The microstructure features being characterised are the prior β size, grain boundary α and α lath thickness. It was found that material manufactured with powder bed fusion processes has smaller prior β grains than the material from directed energy deposition processes. The AM processes with fast cooling rate render in thinner α laths and also thinner, and in some cases discontinuous, grain boundary α. Furthermore, it has been observed that material manufactured with the directed energy deposition processes has parallel bands, except for one condition when the parameters were changed, while the powder bed fusion processes do not have any parallel bands.

  8. Surface wettability enhancement of silicone hydrogel lenses by processing with polar plastic molds.

    Science.gov (United States)

    Lai, Y C; Friends, G D

    1997-06-05

    In the quest for hydrogel contact lenses with improved extended wear capability, the use of siloxane moieties in the lens materials was investigated. However, the introduction of hydrophobic siloxane groups gave rise to wettability and lipidlike deposit problems. It was found that when polysiloxane-based compositions for hydrogels were processed with polar plastic molds, such as those fabricated from an acrylonitrile-based polymer, the hydrogel lenses fabricated were wettable, with minimized lipidlike deposits. These findings were supported by the wettability of silicone hydrogel films, silicon, and nitrogen element contents near lens surfaces, as well as the results from clinical assessment of silicone hydrogel lenses.

  9. 75 FR 13766 - Food and Drug Administration and Process Analytical Technology for Pharma Manufacturing: Food and...

    Science.gov (United States)

    2010-03-23

    ... Technology for Pharma Manufacturing: Food and Drug Administration--Partnering With Industry; Public... Pharmacy entitled ``FDA and PAT for Pharma Manufacturing: FDA-- Partnering with Industry.'' This 2-day... intended to disseminate current and accurate information on process analytical technology (PAT) to the...

  10. 78 FR 5496 - Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain...

    Science.gov (United States)

    2013-01-25

    ... COMMISSION Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain Products Containing Same and Certain Parts Thereof AGENCY: U.S. International Trade Commission. ACTION... manufacturing or relating to same and certain products containing same and certain parts thereof by reason of...

  11. Closing the Competency Gap in Manufacturing Processes as It Applies to New Engineering Graduates

    Science.gov (United States)

    Ssemakula, Mukasa; Liao, Gene; Ellis, Darin

    2010-01-01

    Industry has consistently identified lack of experience in manufacturing processes as one of the key competency gaps among new engineering graduates. This paper discusses a laboratory-based course that provides realistic hands-on manufacturing experiences to students. The course uses team-based projects that help students gain hands-on experience…

  12. A product-process approach for development of the manufacturing footprint

    DEFF Research Database (Denmark)

    Farooq, Sami; Yang, Cheng; Johansen, John

    2009-01-01

    This paper explores the concept of manufacturing footprint from a product-process approach. The paper starts with a brief introduction followed by a literature review aimed at classifying and clarifying the concept of manufacturing footprint from different perspectives. A comprehensive case study...

  13. Silicon photonics and challenges for fabrication

    Science.gov (United States)

    Feilchenfeld, N. B.; Nummy, K.; Barwicz, T.; Gill, D.; Kiewra, E.; Leidy, R.; Orcutt, J. S.; Rosenberg, J.; Stricker, A. D.; Whiting, C.; Ayala, J.; Cucci, B.; Dang, D.; Doan, T.; Ghosal, M.; Khater, M.; McLean, K.; Porth, B.; Sowinski, Z.; Willets, C.; Xiong, C.; Yu, C.; Yum, S.; Giewont, K.; Green, W. M. J.

    2017-03-01

    Silicon photonics is rapidly becoming the key enabler for meeting the future data speed and volume required by the Internet of Things. A stable manufacturing process is needed to deliver cost and yield expectations to the technology marketplace. We present the key challenges and technical results from both 200mm and 300mm facilities for a silicon photonics fabrication process which includes monolithic integration with CMOS. This includes waveguide patterning, optical proximity correction for photonic devices, silicon thickness uniformity and thick material patterning for passive fiber to waveguide alignment. The device and process metrics show that the transfer of the silicon photonics process from 200mm to 300mm will provide a stable high volume manufacturing platform for silicon photonics designs.

  14. Analytic network process model for sustainable lean and green manufacturing performance indicator

    Science.gov (United States)

    Aminuddin, Adam Shariff Adli; Nawawi, Mohd Kamal Mohd; Mohamed, Nik Mohd Zuki Nik

    2014-09-01

    Sustainable manufacturing is regarded as the most complex manufacturing paradigm to date as it holds the widest scope of requirements. In addition, its three major pillars of economic, environment and society though distinct, have some overlapping among each of its elements. Even though the concept of sustainability is not new, the development of the performance indicator still needs a lot of improvement due to its multifaceted nature, which requires integrated approach to solve the problem. This paper proposed the best combination of criteria en route a robust sustainable manufacturing performance indicator formation via Analytic Network Process (ANP). The integrated lean, green and sustainable ANP model can be used to comprehend the complex decision system of the sustainability assessment. The finding shows that green manufacturing is more sustainable than lean manufacturing. It also illustrates that procurement practice is the most important criteria in the sustainable manufacturing performance indicator.

  15. Process optimization for the manufacture of angoori petha.

    Science.gov (United States)

    Singh, Sudhir; Kumar, Umesh; Rai, Ashutosh

    2014-05-01

    Angoori petha (AP) is delicacy which is relished by large section of Indian population. Fully ripened ash gourd fruits were osmotically dehydrated at different lime water concentration, lime water treatment time and sugar concentration for the manufacture of AP. The response variables consisted of sensory parameter for flavour, body and texture, colour and appearance and overall acceptability and physico-chemical properties. A central composite rotatable design (CCRD) was used as experimental design to predict the optimum conditions for manufacture of petha. The interaction of lime water concentration and lime water treatment time had significant (P < 0.05) effect for flavour, body and texture, colour and appearance and overall acceptability score (OAA) score in AP. The colour and appearance score had declining trend with increase the lime water treatment time and lime water concentration. Reducing sugar varied from 1.0% to 2.0%. The mean values for total invert sugar, sucrose and total sugar were in the range of 31.6-68.3%, 30.6-66.9% and 31.6-68.4%, respectively in different runs of AP samples. The optimum osmotic diffusion treatment consisted of lime water concentration of 12.6%, lime water treatment time of 54.1 min and sugar concentration of 87.9% for maximum acceptability in AP.

  16. Characterization of high-pressure resin transfer molding process variants for manufacturing high-performance composites

    OpenAIRE

    Chaudhari, Raman

    2014-01-01

    The current developments in the Resin Transfer Molding (RTM) process for the automotive industry are strongly driven by the need for automotive light-weight design and high volume manufacturing capacity. In order to adapt the RTM process for industrial scale manufacturing of the automotive components it is essential to implement newly developed fast curing resin systems. If such resin systems shall be implemented in the RTM process, then it raises the necessity to achieve shorter resin inject...

  17. Radiation hardness of silicon detectors manufactured on epitaxial material and FZ bulk enriched with oxygen, carbon, tin and platinum

    CERN Document Server

    Ruzin, A; Glaser, M; Lemeilleur, F; Talamonti, R; Watts, S; Zanet, A

    1999-01-01

    Recent results on the radiation hardness of silicon detectors fabricated on epitaxial and float zone bulk silicon enriched by various impurities, such as carbon, oxygen, tin and platinum are reported. A new methodology of measurements of electrical properties of the devices has been utilized in the experiment. It has been shown that in the case of irradiation by protons, oxygen enriched silicon has better radiation hardness than standard float zone silicon. The carbon enriched silicon detectors, on the other hand, exhibited significantly inferior radiation hardness compared to standard detectors. This study shows for the first time, a violation of the widely used normalization technique of the various particle irradiations by NIEL coefficients. The study has been carried out in the framework of the RD48 (ROSE) collaboration, which studies the radiation hardening of silicon detectors. (5 refs).

  18. Evaluation of selected chemical processes for production of low-cost silicon. Second quarterly progress report, December 15, 1975--March 31, 1976

    Energy Technology Data Exchange (ETDEWEB)

    Blocher, J.M.; Jr.; Browning, M.F.; Wilson, W.J.; Carmichael, D.C.

    1976-04-08

    Plant construction costs and manufacturing costs have been estimated for the production of solar-grade silicon by the reduction of silicon tetrachloride in a fluidized bed of seed particles, and several modifications of the iodide process using either thermal decomposition on heated filaments (rods) or hydrogen reduction in a fluidized bed of seed particles. The objective was to evaluate the economics of the zinc reduction process and to determine whether any of the potential economies in the modifications of the iodide process would make it competitive in spite of the high relative cost of recycled iodine in the process intermediate. The estimated cost of the zinc reduction process, $9.12 kg/sup -1/ silicon is within the target of $10.00 kg/sup -1/; however, none of the modifications of the iodide processes yielded costs below $20 kg/sup -1/ Si. Although optimization of one of the iodide process modifications should bring the cost to below $20 kg/sup -1/ Si, it would not be possible to reduce the cost to below that of the zinc reduction product. Energy consumption data for the zinc reduction process and each of the iodide process options are given and all appear to be acceptable from the standpoint of energy pay back. Information is presented on the experimental zinc reduction of SiCl/sub 4/ and electrolytic recovery of zinc from ZnCl/sub 2/. All of the experimental work performed thus far has supported the initial assumption as to technical feasibility of producing semiconductor silicon by the zinc reduction or iodide processes proposed. The results of a more thorough thermodynamic evaluation of the iodination of silicon oxide/carbon mixtures are presented which explain apparent inconsistencies in an earlier cursory examination of the system.

  19. Optimizing process time of laser drilling processes in solar cell manufacturing by coaxial camera control

    Science.gov (United States)

    Jetter, Volker; Gutscher, Simon; Blug, Andreas; Knorz, Annerose; Ahrbeck, Christopher; Nekarda, Jan; Carl, Daniel

    2014-03-01

    In emitter wrap through (EWT) solar cells, laser drilling is used to increase the light sensitive area by removing emitter contacts from the front side of the cell. For a cell area of 156 x 156 mm2, about 24000 via-holes with a diameter of 60 μm have to be drilled into silicon wafers with a thickness of 200 μm. The processing time of 10 to 20 s is determined by the number of laser pulses required for safely opening every hole on the bottom side. Therefore, the largest wafer thickness occurring in a production line defines the processing time. However, wafer thickness varies by roughly +/-20 %. To reduce the processing time, a coaxial camera control system was integrated into the laser scanner. It observes the bottom breakthrough from the front side of the wafer by measuring the process emissions of every single laser pulse. To achieve the frame rates and latency times required by the repetition rate of the laser (10 kHz), a camera based on cellular neural networks (CNN) was used where the images are processed directly on the camera chip by 176 x 144 sensor-processor-elements. One image per laser pulse is processed within 36 μs corresponding to a maximum pulse rate of 25 kHz. The laser is stopped when all of the holes are open on the bottom side. The result is a quality control system in which the processing time of a production line is defined by average instead of maximum wafer thickness.

  20. Process to produce silicon carbide fibers using a controlled concentration of boron oxide vapor

    Science.gov (United States)

    Barnard, Thomas Duncan (Inventor); Lipowitz, Jonathan (Inventor); Nguyen, Kimmai Thi (Inventor)

    2001-01-01

    A process for producing polycrystalline silicon carbide by heating an amorphous ceramic fiber that contains silicon and carbon in an environment containing boron oxide vapor. The boron oxide vapor is produced in situ by the reaction of a boron containing material such as boron carbide and an oxidizing agent such as carbon dioxide, and the amount of boron oxide vapor can be controlled by varying the amount and rate of addition of the oxidizing agent.

  1. Innovative processes adapted to PERC thin-film crystalline silicon solar cells

    OpenAIRE

    Gérenton, Félix

    2016-01-01

    The cost of fabrication of photovoltaic modules is a critical figure for settling solar power into the energy mix. One way to lower this cost is to decrease silicon use in photovoltaic cells. It is technically possible to produce crystalline silicon solar cells only a few dozens of microns thick, although this represents a challenge both for their fabrication process and their optimization. This last one is different from cells of standard thickness, especially by the need of high level light...

  2. Properties and behavior of quartz for the silicon process

    Energy Technology Data Exchange (ETDEWEB)

    Aasly, Kurt

    2008-07-01

    This PhD-thesis is a result of the study on important properties of quartz as a raw material for the metallurgical production of ferrosilicon and silicon metal. This includes defining mechanical properties important for the size reduction experienced during transport and storage and thermo-mechanical properties of quartz that is important for how the quartz reacts to the high temperatures experienced as it is charged on the furnace. Additionally, softening properties of quartz have been briefly discussed in some of the papers. Another important goal has been to test analytical and experimental methods for investigating the various properties. The investigations of important factors for the mechanical properties of ores and industrial minerals have been carried out as a literature study. The mining operation and transport from mine to smelter has been discussed and several factors that are significant for achieving best possible mechanical properties of the quartz have been identified. The most important factors are related to production in the mine and processing plant, which should be carefully planned to minimize the amount of blast-induced damage in the rock and thus achieve the best possible mechanical strength of the raw material. The amount of fines can be minimized by controlling the handling of the raw materials during the transport and storage. It is especially important to avoid high drops, both high single drops and accumulated height of all the drops in total. Investigations of the thermo-mechanical properties of quartz have been carried out by using different experimental and characterization methods. The petrographic investigations of the raw materials by polarized light microscopy have been important. Thermo-mechanical investigations have been high-temperature microthermometry and shock heating of quartz samples in an induction furnace with subsequent investigations of the heated material. The subsequent investigation included polarized- and

  3. Microeconomics of yield learning and process control in semiconductor manufacturing

    Science.gov (United States)

    Monahan, Kevin M.

    2003-06-01

    Simple microeconomic models that directly link yield learning to profitability in semiconductor manufacturing have been rare or non-existent. In this work, we review such a model and provide links to inspection capability and cost. Using a small number of input parameters, we explain current yield management practices in 200mm factories. The model is then used to extrapolate requirements for 300mm factories, including the impact of technology transitions to 130nm design rules and below. We show that the dramatic increase in value per wafer at the 300mm transition becomes a driver for increasing metrology and inspection capability and sampling. These analyses correlate well wtih actual factory data and often identify millions of dollars in potential cost savings. We demonstrate this using the example of grating-based overlay metrology for the 65nm node.

  4. Optimization of energy input for massive forming manufacturing processes. Optimaler Energieeinsatz bei der Fertigung durch Massivumformung

    Energy Technology Data Exchange (ETDEWEB)

    Herlan, T. (Stuttgart Univ. (Germany, F.R.). Inst. fuer Umformtechnik)

    1989-01-01

    The specific end or primary energy consumption of single manufacturing stages is determined with the help of process chain analysis. The overall system considered is divided into process chain segments which themselves are represented in units of process stages. For the investigation of the energy used in single-piece manufacture by massive forming, there is a projected process stage which shows the energy consumption of the initial semi-finished product. The second process stage determines the energy used for manufacturing by means of massive forming. The materials examined are steel and aluminium materials from which workpieces are produced almost waste-free by means of cold, warm or hot extrusion. The required energy consumption as well as the manufacturing and energy costs for any manufacturing by means of massive forming are determined with the help of a computer program. From surveys of several manufacturing sequences it can be shown that 10-20% of the energy consumption can be saved under existing operational conditions, without investments having to be made. On a long-term basis, up to 40% of the energy consumption may be saved by adjusting the manufacturing equipment. (orig./MM).

  5. 3D Machine Vision and Additive Manufacturing: Concurrent Product and Process Development

    Science.gov (United States)

    Ilyas, Ismet P.

    2013-06-01

    The manufacturing environment rapidly changes in turbulence fashion. Digital manufacturing (DM) plays a significant role and one of the key strategies in setting up vision and strategic planning toward the knowledge based manufacturing. An approach of combining 3D machine vision (3D-MV) and an Additive Manufacturing (AM) may finally be finding its niche in manufacturing. This paper briefly overviews the integration of the 3D machine vision and AM in concurrent product and process development, the challenges and opportunities, the implementation of the 3D-MV and AM at POLMAN Bandung in accelerating product design and process development, and discusses a direct deployment of this approach on a real case from our industrial partners that have placed this as one of the very important and strategic approach in research as well as product/prototype development. The strategic aspects and needs of this combination approach in research, design and development are main concerns of the presentation.

  6. U.S. Department of Energy integrated manufacturing & processing predoctoral fellowships. Final Report

    Energy Technology Data Exchange (ETDEWEB)

    Petrochenkov, Margaret

    2003-03-31

    The objective of this program was threefold: to create a pool of PhDs trained in the integrated approach to manufacturing and processing, to promote academic interest in the field, and to attract talented professionals to this challenging area of engineering. It was anticipated that the program would result in the creation of new manufacturing methods that would contribute to improved energy efficiency, to better utilization of scarce resources, and to less degradation of the environment. Emphasis in the competition was on integrated systems of manufacturing and the integration of product design with manufacturing processes. Research addressed such related areas as aspects of unit operations, tooling and equipment, intelligent sensors, and manufacturing systems as they related to product design. This is the final report to close out the contract.

  7. United States Department of Energy Integrated Manufacturing & Processing Predoctoral Fellowships. Final Report

    Energy Technology Data Exchange (ETDEWEB)

    Petrochenkov, M.

    2003-03-31

    The objective of the program was threefold: to create a pool of PhDs trained in the integrated approach to manufacturing and processing, to promote academic interest in the field, and to attract talented professionals to this challenging area of engineering. It was anticipated that the program would result in the creation of new manufacturing methods that would contribute to improved energy efficiency, to better utilization of scarce resources, and to less degradation of the environment. Emphasis in the competition was on integrated systems of manufacturing and the integration of product design with manufacturing processes. Research addressed such related areas as aspects of unit operations, tooling and equipment, intelligent sensors, and manufacturing systems as they related to product design.

  8. Fuzzy linguistic hedges for the selection of manufacturing process for prosthetic sockets

    Directory of Open Access Journals (Sweden)

    Richa Pandey

    2014-08-01

    Full Text Available In this paper, a comparison is presented between two prime methods of producing prosthetic sockets by using the fuzzy linguistic hedges approach on the qualitative feedback of Indian prosthetic users. Recent trends indicate that the Indian manufacturers have tried to adopt the newer technologies like reverse engineering (RE approach to achieve the desired goals. However, the satisfaction of the user is of utmost importance for the unique and customized products for rehabilitation. In order to analyze the effectiveness of the manufacturing approaches, user case studies are taken, based on the linguistic feedbacks, and a comparative study is conducted. Thirteen users from four different manufacturing units are taken for study and sockets made by conventional as well as RE are experimented. Fuzzy membership functions are constructed using the linguistic hedges based on the user feedbacks. An analytical hierarchy process (AHP is applied to arrive at a decision to select the manufacturing process for user satisfaction and manufacturing excellence.

  9. Lean Manufacturing - A Powerfull Tool for Reducing Waste During the Processes

    Directory of Open Access Journals (Sweden)

    Mihai Apreutesei

    2010-01-01

    Full Text Available Lean manufacturing provides a new management approach for many small and medium size manufacturers, especially older firms organized and managed under traditional push systems. Improvement results can be dramatic in terms of quality, cycle times, and customer responsiveness. Lean manufacturing is more than a set of tools and techniques and has been widely adopted by many production companies. Lean manufacturing is a culture in which all employees continuously look for ways to improve processes. In the present article are presented the Lean Manufacturing tools, like kaizen, Kanban, poka-yoke witch a company can use to reduce the waste(muda during a production process. The paper contains also, the most common seven types of waste from production and some examples from our daily activity.

  10. Low cost solar array project: Experimental process system development unit for producing semiconductor-grade silicon using silane-to-silicon process

    Science.gov (United States)

    1980-01-01

    The design, fabrication, and installation of an experimental process system development unit (EPSDU) were analyzed. Supporting research and development were performed to provide an information data base usable for the EPSDU and for technological design and economical analysis for potential scale-up of the process. Iterative economic analyses were conducted for the estimated product cost for the production of semiconductor grade silicon in a facility capable of producing 1000-MT/Yr.

  11. Flat-plate solar-array project. Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

    Science.gov (United States)

    1981-01-01

    The engineering design, fabrication, assembly, operation, economic analysis, and process support R and D for an Experimental Process System Development Unit (EPSDU) are reported. About 95% of purchased equipment is received and will be reshipped to the West Coast location. The Data Collection System is completed. In the area of melting/consolidation, to the system using silicon powder transfer, melting and shotting on a pseudocontinuous basis is demonstrated. It is proposed to continue the very promising fluid bed work.

  12. Numerical simulation of complex part manufactured by selective laser melting process

    Science.gov (United States)

    Van Belle, Laurent

    2017-10-01

    Selective Laser Melting (SLM) process belonging to the family of the Additive Manufacturing (AM) technologies, enable to build parts layer by layer, from metallic powder and a CAD model. Physical phenomena that occur in the process have the same issues as conventional welding. Thermal gradients generate significant residual stresses and distortions in the parts. Moreover, the large and complex parts to manufacturing, accentuate the undesirable effects. Therefore, it is essential for manufacturers to offer a better understanding of the process and to ensure production reliability of parts with high added value. This paper focuses on the simulation of manufacturing turbine by SLM process in order to calculate residual stresses and distortions. Numerical results will be presented.

  13. 12th Workshop on Crystalline Silicon Solar Cell Materials and Processes: Extended Abstracts and Papers, August 11-14, 2002, Breckenridge, Colorado

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B. L.

    2002-08-01

    The 12th Workshop will provide a forum for an informal exchange of technical and scientific information between international researchers in the photovoltaic and relevant non-photovoltaic fields. Discussions will include various aspects of impurities and defects in silicon-their properties, the dynamics during processing, and their application for developing low-cost processes for manufacturing high-efficiency silicon solar cells. The workshop will emphasize some of the promising new technologies in Si solar cell fabrication that can lower PV energy costs and meet the production demands of the future. It will also provide an excellent opportunity for researchers, in private industry and at universities, to prioritize mutual needs for future collaborative research. Sessions and panel discussions will review recent advances in crystal growth, new cell structures, new processes and process characterization techniques, and manufacturing approaches suitable for future manufacturing demands . Some presentations will address recent technologies in the microelectronics field that may have a direct bearing on PV. The three-day workshop will consist of presentations by invited speakers, followed by discussion sessions. In addition, there will be two poster sessions presenting the latest research and development results.

  14. Effective process design and robust manufacturing for hydroformed parts

    Energy Technology Data Exchange (ETDEWEB)

    Werner, Stefan; Carleer, Bart [AutoForm Engineering Deutschland GmbH, Dortmund (Germany); Jung, Dong Won [Jeju National University, Jeju (Korea, Republic of)

    2007-02-15

    A general trend and one of the important strategies in the automotive industry is reducing the lead time of a new car development. In order to obtain this goal the efficient use of simulation software is needed to effectively design a hydroformed part. The stages of the design chain are integrated in one simulation tool. The outcome of this feasibility analysis is a virtual prototype saying that it is possible to produce the part. In fact one process point has been defined whereas when going into production a process window must be know to guarantee a stable production process. In order to achieve this latter we are suggesting a process performance analysis. Based on multiple simulations the influence and sensitivity various process parameters on the forming process can be identified. Besides combining the analysis with statistical process control evaluation the process capability (Cpk-values) can be defined. This design chain analysis will be applied on a hydroformed part. The process performance analysis is the identification of the process window and process capability in advance, so before any tool has been milled. This will be demonstrated on a second hydroformed part

  15. Quantifying the robustness of process manufacturing concept – A medical product case study

    DEFF Research Database (Denmark)

    Boorla, Srinivasa Murthy; Troldtoft, M.E.; Eifler, Tobias

    2017-01-01

    Product robustness refers to the consistency of performance of all of the units produced. It is often the case that process manufactured products are not designed concurrently, so by the end of the product design phase the Process Manufacturing Concept (PMC) has yet to be decided. Allocating...... the unit-to-unit robustness of an early-stage for a PMC is proposed. The method uses variability and adjustability information from the manufacturing concept in combination with sensitivity information from products' design to predict its functional performance variation. A Technology maturation factor...

  16. Optimization of the Manufacturing Process of Conical Shell Structures Using Prepreg Laminatees

    Science.gov (United States)

    Khakimova, Regina; Zimmermann, Rolf; Burau, Florian; Siebert, Marc; Arbelo, Mariano; Castro, Saullo; Degenhardt, Richard

    2014-06-01

    The design and manufacture of an unstiffened composite conical structure which is a scaled-down version of the Ariane 5 Midlife Evolution Equipment Bay Structure is presented. For such benchmarking structures the fiber orientation error is critical and then the manufacturing process becomes a big challenge. The paper therefore is focused on the implementation of a tailoring study and on the manufacturing process. The conical structure will be tested to validate a new design approach.This study contributes to the European Union (EU) project DESICOS, whose aim is to develop less conservative design guidelines for imperfection sensitive thin-walled structures.

  17. Ultrasonic online monitoring of additive manufacturing processes based on selective laser melting

    Science.gov (United States)

    Rieder, Hans; Dillhöfer, Alexander; Spies, Martin; Bamberg, Joachim; Hess, Thomas

    2015-03-01

    Additive manufacturing processes have become commercially available and are particularly interesting for the production of free-formed parts. Selective laser melting allows to manufacture components by localized melting of successive layers of metal powder. In order to be able to describe and to understand the complex dynamics of selective laser melting processes more accurately, online measurements using ultrasound have been performed for the first time. In this contribution, we report on the integration of the measurement technique into the manufacturing facility and on a variety of promising monitoring results.

  18. Stable surface passivation of silicon by low-temperature processing

    Energy Technology Data Exchange (ETDEWEB)

    Leguijt, C.; Loelgen, P. (FOM Institute for Atomic and Molecular Physics, Amsterdam (Netherlands)); Eikelboom, J.A.; Van der Heide, A.S.H.; Steeman, R.A.; Sinke, W.C. (Unit ECN Renewable Energy, Petten (Netherlands)); Sarro, P.M. (Delft Institute for Microelectronics and Submicron Technology DIMES, Delft (Netherlands)); Verhoef, L.A.; Michiels, P.P. (R+S Renewable Energy Systems, Helmond (Netherlands)

    1994-04-01

    Low-temperature passivation of silicon surfaces has been achieved by Plasma Enhanced Chemical Vapour Deposition (PECVD) of Si-oxide and Si-nitride in a batch reactor. An anneal at 400[sup o]C is shown to be crucial to obtain low surface recombination velocities. The obtained passivation has no correlation with the plasma power used for the deposition. The recombination velocity of a surface passivated with PECVD Si-oxide increases after the anneal on a timescale of hours, whereas the passivation with PECVD Si-nitride is stable. The interface chemistry and the role of hydrogen in the passivation mechanism is discussed. 2 figs., 3 tabs., 7 refs.

  19. Apparatus and method of manufacture for depositing a composite anti-reflection layer on a silicon surface

    Science.gov (United States)

    Pain, Bedabrata (Inventor)

    2012-01-01

    An apparatus and associated method are provided. A first silicon layer having at least one of an associated passivation layer and barrier is included. Also included is a composite anti-reflection layer including a stack of layers each with a different thickness and refractive index. Such composite anti-reflection layer is disposed adjacent to the first silicon layer.

  20. Critical factors in manufacturing multi-layer tablets--assessing material attributes, in-process controls, manufacturing process and product performance.

    Science.gov (United States)

    Vaithiyalingam, Sivakumar R; Sayeed, Vilayat A

    2010-10-15

    Advancement in the fields of material science, analytical methodologies, instrumentation, automation, continuous monitoring, feed forward/feed back control and comprehensive data collection have led to continual improvement of pharmaceutical tablet manufacturing technology, notably the multi-layer tablets. This review highlights the material attributes, formulation design, process parameters that impact the performance, and manufacturability of the multi-layer tablets. It also highlights on critical-to-quality elements that needs to be addressed in the regulatory submission. Published by Elsevier B.V.

  1. Additive advantage in characteristics of MIMCAPs on flexible silicon (100) fabric with release-first process

    KAUST Repository

    Ghoneim, Mohamed T.

    2013-11-20

    We report the inherent increase in capacitance per unit planar area of state-of-the art high-κ integrated metal/insulator/metal capacitors (MIMCAPs) fabricated on flexible silicon fabric with release-first process. We methodically study and show that our approach to transform bulk silicon (100) into a flexible fabric adds an inherent advantage of enabling higher integration density dynamic random access memory (DRAM) on the same chip area. Our approach is to release an ultra-thin silicon (100) fabric (25 μm thick) from the bulk silicon wafer, then build MIMCAPs using sputtered aluminium electrodes and successive atomic layer depositions (ALD) without break-ing the vacuum of a high-κ aluminium oxide sandwiched between two tantalum nitride layers. This result shows that we can obtain flexible electronics on silicon without sacrificing the high density integration aspects and also utilize the non-planar geometry associated with fabrication process to obtain a higher integration density compared to bulk silicon integration due to an increased normalized capacitance per unit planar area. © 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  2. THE COMBINED PROCESSES STUDY FOR MANUFACTURING AIRCRAFT PARTS

    Directory of Open Access Journals (Sweden)

    Mr. Boris N. Maryin

    2016-06-01

    Full Text Available The article is devoted to research of the combined processes of forming tubular billets with various media in the process of bending-expanding, breaking-down -expanding while using thermal effects. The paper discusses the processes of forming tubular billets of hard punches, using elastic-granular materials, the peculiarities of forming tubular billets, while the breaking-down -expanding of crimp in a hard punch using elastic-granular bodies. The article presents experimental studies of the bending-expanding of tubular billets in horn-shaped blanks. The authors established the main features of billet distorting in the combined process. The article shows a diagram of the true distorting distribution in the process of stretching and compression in the horn-shaped blanks. The recommendations allow increasing the bending moment and realizing better shaping. The authors make conclusions about the prospects of the application of combined processes in air and rocket.

  3. An Open Source-Based Real-Time Data Processing Architecture Framework for Manufacturing Sustainability

    Directory of Open Access Journals (Sweden)

    Muhammad Syafrudin

    2017-11-01

    Full Text Available Currently, the manufacturing industry is experiencing a data-driven revolution. There are multiple processes in the manufacturing industry and will eventually generate a large amount of data. Collecting, analyzing and storing a large amount of data are one of key elements of the smart manufacturing industry. To ensure that all processes within the manufacturing industry are functioning smoothly, the big data processing is needed. Thus, in this study an open source-based real-time data processing (OSRDP architecture framework was proposed. OSRDP architecture framework consists of several open sources technologies, including Apache Kafka, Apache Storm and NoSQL MongoDB that are effective and cost efficient for real-time data processing. Several experiments and impact analysis for manufacturing sustainability are provided. The results showed that the proposed system is capable of processing a massive sensor data efficiently when the number of sensors data and devices increases. In addition, the data mining based on Random Forest is presented to predict the quality of products given the sensor data as the input. The Random Forest successfully classifies the defect and non-defect products, and generates high accuracy compared to other data mining algorithms. This study is expected to support the management in their decision-making for product quality inspection and support manufacturing sustainability.

  4. 40 CFR 723.175 - Chemical substances used in or for the manufacture or processing of instant photographic and peel...

    Science.gov (United States)

    2010-07-01

    ... manufacture or processing of instant photographic and peel-apart film articles. 723.175 Section 723.175... manufacture or processing of instant photographic and peel-apart film articles. (a) Purpose and scope. (1... chemical substances used in or for the manufacture or processing of instant photographic and peel-apart...

  5. Identification of in-line defects and failures during Additive Manufacturing Powder Bed Fusion processes

    Directory of Open Access Journals (Sweden)

    Fulga Simina

    2017-01-01

    Full Text Available Additive Manufacturing (AM processes are enablers of new approaches in the field of production and design engineering, product design and business modelling. Beginning to view additive manufacturing in an industrial environment, reliable statements about the product quality are indispensable. Statements regarding compliance with geometric tolerances and exact quantifiable physical parameters, in terms of product certification are therefore imperative. The quality of the components must not only be sustainably secured but also reproducible at any time. Quality control and quality assurance are the prerequisite for highly customized unique parts, or even batch size 1 product, that can be produced by additive manufacturing as efficiently as conventional mass-produced parts. This paper will discuss an approach for the identification of in-line defects and failures during Additive Manufacturing Powder Bed Fusion processes using the example of the Selective Laser Sintering process.

  6. The impact of the manufacturing process on the hardness and sensory properties of milk chocolate

    Directory of Open Access Journals (Sweden)

    Zarić Danica B.

    2012-01-01

    Full Text Available The aim of this paper was to examine the impact of the manufacturing process on the textural characteristics and sensory properties of milk chocolate. The research was conducted on the samples of chocolate produced in a ball mill during 30, 60 and 90 minutes of refining, each of them being pre-crystallized at 26, 28 and 30°C. A chocolate mass of identical ingredient composition was also produced using a standard manufacturing process at the same pre-crystallization temperatures. Chocolate hardness was examined using a piece of equipment called Texture Analyser, measuring the stress intensity which leads to chocolate crushing. Sensory analysis was performed using the point scoring method. The new manufacturing process, i.e. the manufacturing of chocolate in a ball mill improves sensory properties and hardness of milk chocolate. [Projekat Ministarstva nauke Republike Srbije, br. TR 31014

  7. Choices of capture chromatography technology in antibody manufacturing processes.

    Science.gov (United States)

    DiLeo, Michael; Ley, Arthur; Nixon, Andrew E; Chen, Jie

    2017-11-15

    The capture process employed in monoclonal antibody downstream purification is not only the most critically impacted process by increased antibody titer resulting from optimized mammalian cell culture expression systems, but also the most important purification step in determining overall process throughput, product quality, and economics. Advances in separation technology for capturing antibodies from complex feedstocks have been one focus of downstream purification process innovation for past 10 years. In this study, we evaluated new generation chromatography resins used in the antibody capture process including Protein A, cation exchange, and mixed mode chromatography to address the benefits and unique challenges posed by each chromatography approach. Our results demonstrate the benefit of improved binding capacity of new generation Protein A resins, address the concern of high concentration surge caused aggregation when using new generation cation exchange resins with over 100mg/mL binding capacity, and highlight the potential of multimodal cation exchange resins for capture process design. The new landscape of capture chromatography technologies provides options to achieve overall downstream purification outcome with high product quality and process efficiency. Copyright © 2017 Elsevier B.V. All rights reserved.

  8. Shared and service-oriented CNC machining system for intelligent manufacturing process

    Science.gov (United States)

    Li, Yao; Liu, Qiang; Tong, Ronglei; Cui, Xiaohong

    2015-11-01

    To improve efficiency, reduce cost, ensure quality effectively, researchers on CNC machining have focused on virtual machine tool, cloud manufacturing, wireless manufacturing. However, low level of information shared among different systems is a common disadvantage. In this paper, a machining database with data evaluation module is set up to ensure integrity and update. An online monitoring system based on internet of things and multi-sensors "feel" a variety of signal features to "percept" the state in CNC machining process. A high efficiency and green machining parameters optimization system "execute" service-oriented manufacturing, intelligent manufacturing and green manufacturing. The intelligent CNC machining system is applied in production. CNC machining database effectively shares and manages process data among different systems. The prediction accuracy of online monitoring system is up to 98.8% by acquiring acceleration and noise in real time. High efficiency and green machining parameters optimization system optimizes the original processing parameters, and the calculation indicates that optimized processing parameters not only improve production efficiency, but also reduce carbon emissions. The application proves that the shared and service-oriented CNC machining system is reliable and effective. This research presents a shared and service-oriented CNC machining system for intelligent manufacturing process.

  9. CASE STUDY ON THE DEMONSTRATION OF CAPABILITY TO MANUFACTURING PROCESS

    Directory of Open Access Journals (Sweden)

    Liviu Marius CIRTINA

    2014-05-01

    Full Text Available There are two factors that reduce the opportunity for certification process as capable. The first factor is the volume of production and the second factor is related to the level of precision required by the client runtime, ie the size tolerances. The tolerance is low, the capability value decreases and the process must be improved to meet the minimum capability values. Both aspects of production volumes and related capabilities accuracy (precision and accuracy of the estimate process capability are combined in a calculation of economic efficiency, it finally generates design quality system.

  10. Silicon on ceramic process. Silicon sheet growth development for the Large-Area Silicon Sheet Task of the Low-Cost Silicon Solar Array Project. Annual report No. 2, September 17, 1976--September 19, 1977

    Energy Technology Data Exchange (ETDEWEB)

    Zook, J.D.; Heaps, J.D.; Maciolek, R.B.; Koepke, B.; Butter, C.D.; Schuldt, S.B.

    1977-09-30

    The objective of this research program is to investigate the technical and economic feasibility of producing solar-cell-quality sheet silicon by coating one surface of carbonized ceramic substrates with a thin layer of large-grain polycrystalline silicon from the melt. In the past year significant progress was made in all areas of the program. The physical and chemical properties of the standard mullite refractory used for the majority of the coating runs (McDanel MV20 and Coors S1SI) have been characterized. A number of experimental compositions have been identified and procured from Coors. Characterization of the standard compositions revealed that the thermal expansion of mullite depends on both relative amounts of glass phase and on the impurity level in the glass. Since the thermal expansion in mullite exceeds that of silicon, the silicon coating should be in a state of compression. This was confirmed by x-ray measurements. After modifying and cleaning the dip-coating facility, silicon on ceramic (SOC) solar cells were fabricated which demonstrate that the SOC process can produce silicon of solar cell quality. SOC cells having 1 cm/sup 2/ active areas demonstrated measured conversion efficiencies as high as 7.2 percent. Typical open-ciruit voltages (V/sub oc/) and short-circuit current densities (J/sub sc/) were 0.51 volt and 20 mA/cm/sup 2/, respectively. Since the active surface of these solar cells is a highly reflective ''as-grown'' surface, one can expect improvement in J/sub sc/ after an anti-reflection (AR) coating is applied. Results of an economic analysis of the SOC process are presented.

  11. An Integrated Environment for Batch Process Development - From Recipe to Manufacture

    DEFF Research Database (Denmark)

    Batch process development involves the process of converting a chemical synthesis into an optimum, safe, robust, and economical process for manufacturing the chemical of desired quality at the ultimate desired scale. In this paper we describe a strategy for developing a set of integrated decision...

  12. Global Production Planning Process considering the Supply Risk of Overseas Manufacturing Sites

    Directory of Open Access Journals (Sweden)

    Hosang Jung

    2015-01-01

    Full Text Available Although global manufacturers can produce most of their final products in local plants, they need to source components or parts from desirable overseas manufacturing partners at low cost in order to fulfill customer orders. In this global manufacturing environment, capacity information for planning is usually imprecise owing to the various risks of overseas plants (e.g., foreign governments’ policies and labor stability. It is therefore not easy for decision-makers to generate a global production plan showing the production amounts at local plants and overseas manufacturing facilities operated by manufacturing partners. In this paper, we present a new global production planning process considering the supply risk of overseas manufacturing sites. First, local experts estimate the supply capacity of an overseas plant using their judgment to determine when the risk could occur and how large the risk impact would be. Next, we run a global production planning model with the estimated supply capacities. The proposed process systematically adopts the qualitative judgments of local experts in the global production planning process and thus can provide companies with a realistic global production plan. We demonstrate the applicability of the proposed process with a real world case.

  13. Key technologies for manufacturing and processing sheet materials: A global perspective

    Science.gov (United States)

    Demeri, Mahmoud Y.

    2001-02-01

    Modern industrial technologies continue to seek new materials and processes to produce products that meet design and functional requirements. Sheet materials made from ferrous and non-ferrous metals, laminates, composites, and reinforced plastics constitute a large percentage of today’s products, components, and systems. Major manufacturers of sheet products include automotive, aerospace, appliance, and food-packaging industries. The Second Global Symposium on Innovations in Materials Processing & Manufacturing: Sheet Materials is organized to provide a forum for presenting advances in sheet processing and manufacturing by worldwide researchers and engineers from industrial, research, and academic centers. The symposium, sponsored by the TMS Materials Processing & Manufacturing Division (MPMD), was planned for the 2001 TMS Annual Meeting, New Orleans, Louisiana, February 11 15, 2001. This article is a review of key papers submitted for publication in the concurrent volume. The selected papers present significant developments in the rapidly expanding areas of advanced sheet materials, innovative forming methods, industrial applications, primary and secondary processing, composite processing, and numerical modeling of manufacturing processes.

  14. Multivariate modelling of the tablet manufacturing process with wet granulation for tablet optimization and in-process control

    NARCIS (Netherlands)

    Westerhuis, J.A; Coenegracht, P.M J; Lerk, C.F

    1997-01-01

    The process of tablet manufacturing with granulation is described as a two-step process. The first step comprises wet granulation of the powder mixture, and in the second step the granules are compressed into tablets. For the modelling of the pharmaceutical process of wet granulation and tableting,

  15. Aluminum gettering in single and multicrystalline silicon

    Energy Technology Data Exchange (ETDEWEB)

    McHugo, S.A.; Hieslmair, H.; Weber, E.R. [Univ. of California, Berkeley, CA (United States)

    1995-08-01

    Al gettering has been performed on integrated circuit (I.C.) quality silicon and a variety of single and multicrystalline silicon solar cell materials. The minority carrier diffusion length, Ln, has been used to quantify the gettering response. Vast differences in response to the Al gettering treatment are observed between the I.C. quality silicon and the solar cell materials. The I.C. silicon generally responds well while the solar cell silicon performance progressively degrades with increasing gettering temperature. Preliminary data shows that by performing a Rapid Thermal Annealing treatment prior to the Al gettering, an improved or further degraded Ln emerges in solar cell material depending on the material`s manufacturer. We explain these observed phenomena by suggesting that Al gettering in solar cell silicon is an impurity emission-limited process while for I.C. quality silicon it is diffusion limited.

  16. Manufacturing process of electrode catalyst layer for fuel cell

    Energy Technology Data Exchange (ETDEWEB)

    Nomoto, Hideyuki; Sakurai, Masahiro

    1988-10-17

    In order to make the electrochemical reaction of the fuel cell efficient, it is necessary that fine catalyst particles in the electrode catalyst layer and fine fluororesin particles are well dispersed and mixed uniformly and the three phase interface is big. In order to achieve this, there is a method to make an aggregate by applying a water soluble organic solvent to the dispersed system of these particles, but it has problems including a high danger of fire due to inflamation of the organic solvent. In view of this, this invention offers a method to remove the solvent of the dispersed system without using the aggregation method. In other words, this invention is composed of a process to disperse fine catalyst particles and fluororesin dispersion by adding them to the aqueous solution including a predetermined amount of interfacial active agent, a process to obtain the viscous mixed concentrate of fine catalyst particles and fine fluororesin particles by concentrating or drying the above dispersed system and then adding the water, a process to make the fine fluororesin particles fibrous and paste by kneading the above mixed concentrate, and a process to form electrode catalyst layers by rolling the above paste. 3 figures.

  17. Improving manufacturing by cost-effective process modeling

    Science.gov (United States)

    Delgado, Hugo E.; Ramakrishnan, Ramanath I.; Howson, Timothy E.

    1994-09-01

    Computer-aided engineering tools are routinely used to simulate forging and heat-treatment operations and to perform thermal and stress analyses. This review gives a few examples of the current uses of process modeling tools and outlines some developing capabilities and near-term applications.

  18. Pellet manufacturing by extrusion-spheronization using process analytical technology

    DEFF Research Database (Denmark)

    Sandler, Niklas; Rantanen, Jukka; Heinämäki, Jyrki

    2005-01-01

    The aim of this study was to investigate the phase transitions occurring in nitrofurantoin and theophylline formulations during pelletization by extrusion-spheronization. An at-line process analytical technology (PAT) approach was used to increase the understanding of the solid-state behavior...

  19. Organic Foods manufacturing and Processing: The New Way of Life

    OpenAIRE

    Jalan, Vishal

    2007-01-01

    Organic is the fastest growing sector of the food industry with global sales approaching US $40 billion in 2006. Growing health-consciousness among consumers globally has resulted in high demand for Fresh and more importantly Processed Organic Food. This value-addition can generate large number of jobs in rural areas in India and Africa.

  20. Part height control of laser metal additive manufacturing process

    Science.gov (United States)

    Pan, Yu-Herng

    Laser Metal Deposition (LMD) has been used to not only make but also repair damaged parts in a layer-by-layer fashion. Parts made in this manner may produce less waste than those made through conventional machining processes. However, a common issue of LMD involves controlling the deposition's layer thickness. Accuracy is important, and as it increases, both the time required to produce the part and the material wasted during the material removal process (e.g., milling, lathe) decrease. The deposition rate is affected by multiple parameters, such as the powder feed rate, laser input power, axis feed rate, material type, and part design, the values of each of which may change during the LMD process. Using a mathematical model to build a generic equation that predicts the deposition's layer thickness is difficult due to these complex parameters. In this thesis, we propose a simple method that utilizes a single device. This device uses a pyrometer to monitor the current build height, thereby allowing the layer thickness to be controlled during the LMD process. This method also helps the LMD system to build parts even with complex parameters and to increase material efficiency.

  1. Processing study of injection molding of silicon nitride for engine applications

    Science.gov (United States)

    Rorabaugh, M. E.; Yeh, H. C.

    1985-01-01

    The high hardness of silicon nitride, which is currently under consideration as a structural material for such hot engine components as turbine blades, renders machining of the material prohibitively costly; the near net shape forming technique of injection molding is accordingly favored as a means for component fabrication. Attention is presently given to the relationships between injection molding processing parameters and the resulting microstructural and mechanical properties of the resulting engine parts. An experimental program has been conducted under NASA sponsorship which tests the quality of injection molded bars of silicon nitride at various stages of processing.

  2. Tracking the course of the manufacturing process in selective laser melting

    Science.gov (United States)

    Thombansen, U.; Gatej, A.; Pereira, M.

    2014-02-01

    An innovative optical train for a selective laser melting based manufacturing system (SLM) has been designed under the objective to track the course of the SLM process. In this, the thermal emission from the melt pool and the geometric properties of the interaction zone are addressed by applying a pyrometer and a camera system respectively. The optical system is designed such that all three radiations from processing laser, thermal emission and camera image are coupled coaxially and that they propagate on the same optical axis. As standard f-theta lenses for high power applications inevitably lead to aberrations and divergent optical axes for increasing deflection angles in combination with multiple wavelengths, a pre-focus system is used to implement a focusing unit which shapes the beam prior to passing the scanner. The sensor system records synchronously the current position of the laser beam, the current emission from the melt pool and an image of the interaction zone. Acquired data of the thermal emission is being visualized after processing which allows an instant evaluation of the course of the process at any position of each layer. As such, it provides a fully detailed history of the product This basic work realizes a first step towards self-optimization of the manufacturing process by providing information about quality relevant events during manufacture. The deviation from the planned course of the manufacturing process to the actual course of the manufacturing process can be used to adapt the manufacturing strategy from one layer to the next. In the current state, the system can be used to facilitate the setup of the manufacturing system as it allows identification of false machine settings without having to analyze the work piece.

  3. 2nd International Conference on Mechanical, Manufacturing and Process Plant Engineering

    CERN Document Server

    2017-01-01

    This volume presents selected papers from the 2nd International Conference on Mechanical, Manufacturing and Process Plant Engineering (ICMMPE 2016) which was held from 23rd to 24th November, 2016 in Kuala Lumpur, Malaysia. The proceedings discuss genuine problems of joining technologies that are heart of manufacturing sectors. It discusses the findings of experimental and numerical works from soldering, arc welding to solid state joining technology that faced by current industry. .

  4. Validation of Contamination Control in Rapid Transfer Port Chambers for Pharmaceutical Manufacturing Processes

    OpenAIRE

    Shih-Cheng Hu; Angus Shiue; Han-Yang Liu; Rong-Ben Chiu

    2016-01-01

    There is worldwide concern with regard to the adverse effects of drug usage. However, contaminants can gain entry into a drug manufacturing process stream from several sources such as personnel, poor facility design, incoming ventilation air, machinery and other equipment for production, etc. In this validation study, we aimed to determine the impact and evaluate the contamination control in the preparation areas of the rapid transfer port (RTP) chamber during the pharmaceutical manufacturing...

  5. Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing

    OpenAIRE

    Everton, Sarah K.; Hirsch, Matthias; Stravroulakis, Petros; Leach, Richard K.; Clare, Adam T.

    2016-01-01

    Lack of assurance of quality with additively manufactured (AM) parts is a key technological barrier that prevents manufacturers from adopting AM technologies, especially for high-value applications where component failure cannot be tolerated. Developments in process control have allowed significant enhancement of AM techniques and marked improvements in surface roughness and material properties, along with a reduction in inter-build variation and the occurrence of embedded material discontinu...

  6. Laser-assisted machining process simulation for precision mould/die manufacturing

    OpenAIRE

    Zeng Quanren; Qin Yi

    2015-01-01

    Laser-assisted machining (LAM) is a kind of thermally assisted manufacturing process which preheats workpiece material with a highly-localized laser beam and then is followed by a conventional machining operation. It could greatly improve the machinability and gives better machining quality, especially suitable for hard-to-cut materials such as superalloys, tool steels. For manufacturing the high-precision moulds/dies that could fabricate micro and precision components, the thermal assistance...

  7. Electrochemical process for the manufacturing of titanium alloy matrix composites

    Directory of Open Access Journals (Sweden)

    V. Soare

    2009-07-01

    Full Text Available The paper presents a new method for precursors’ synthesis of titanium alloys matrix composites through an electrochemical process in molten calcium chloride. The cathode of the cell was made from metallic oxides powders and reinforcement ceramic particles, which were pressed and sintered into disk form and the anode from graphite. The process occurred at 850 °C, in two stages, at 2,7 / 3,2 V: the ionization of the oxygen in oxides and the reduction with calcium formed by electrolysis of calcium oxide fed in the electrolyte. The obtained composite precursors, in a form of metallic sponge, were consolidated by pressing and sintering. Chemical and structural analyses on composites samples were performed.

  8. Ultrasound assisted manufacturing of paraffin wax nanoemulsions: process optimization.

    Science.gov (United States)

    Jadhav, A J; Holkar, C R; Karekar, S E; Pinjari, D V; Pandit, A B

    2015-03-01

    This work reports on the process optimization of ultrasound-assisted, paraffin wax in water nanoemulsions, stabilized by modified sodium dodecyl sulfate (SDS). This work focuses on the optimization of major emulsification process variables including sonication time, applied power and surfactant concentration. The effects of these variables were investigated on the basis of mean droplet diameter and stability of the prepared emulsion. It was found that the stable emulsion with droplet diameters about 160.9 nm could be formed with the surfactant concentration of 10 mg/ml and treated at 40% of applied power (power density: 0.61 W/ml) for 15 min. Scanning electron microscopy (SEM) was used to study the morphology of the emulsion droplets. The droplets were solid at room temperature, showing bright spots under polarized light and a spherical shape under SEM. The electrophoretic properties of emulsion droplets showed a negative zeta potential due to the adsorption of head sulfate groups of the SDS surfactant. For the sake of comparison, paraffin wax emulsion was prepared via emulsion inversion point method and was checked its intrinsic stability. Visually, it was found that the emulsion get separated/creamed within 30 min. while the emulsion prepared via ultrasonically is stable for more than 3 months. From this study, it was found that the ultrasound-assisted emulsification process could be successfully used for the preparation of stable paraffin wax nanoemulsions.

  9. Fungal community succession and major components change during manufacturing process of Fu brick tea.

    Science.gov (United States)

    Li, Qin; Huang, Jianan; Li, Yongdi; Zhang, Yiyang; Luo, Yu; Chen, Yuan; Lin, Haiyan; Wang, Kunbo; Liu, Zhonghua

    2017-07-31

    Fu brick tea is a unique post-fermented tea product which is fermented with microorganism during the manufacturing process. Metabolic analysis showed that most metabolites content were decreased during the manufacturing process of Fu brick tea, except GA (gallic acid). Illumina MiSeq sequencing of ITS gene amplicons was applied to analyze the fungal community succession. The genera Aspergillus, Cyberlindnera and Candida were predominant at the early stage of manufacturing process (from "primary dark tea" to "fermentation for 3 days"), but after the stage of "fermentation for 3 days" only Aspergillus was still dominated, and maintain a relatively constant until to the end of manufacturing process. The effects of metabolites on the structure of the fungal community were analyzed by redundancy analysis (RDA) and variation partitioning analysis (VPA). The results indicated that GCG (gallocatechin gallate), EGCG (epigallocatechin gallate) and GA as well as the interactions among them were the most probably ones to influence, or be influenced by the fungal communities during the fermentation process of Fu brick tea. This study revealed fungal succession, metabolite changes and their relationships, provided new insights into the mechanisms for manufacturing process of Fu brick tea.

  10. Thermographic process monitoring in powderbed based additive manufacturing

    Science.gov (United States)

    Krauss, Harald; Zeugner, Thomas; Zaeh, Michael F.

    2015-03-01

    Selective Laser Melting is utilized to build metallic parts directly from CAD-Data by solidification of thin powder layers through application of a fast scanning laser beam. In this study layerwise monitoring of the temperature distribution is used to gather information about the process stability and the resulting part quality. The heat distribution varies with different kinds of parameters including scan vector length, laser power, layer thickness and inter-part distance in the job layout which in turn influence the resulting part quality. By integration of an off-axis mounted uncooled thermal detector the solidification as well as the layer deposition are monitored and evaluated. Errors in the generation of new powder layers usually result in a locally varying layer thickness that may cause poor part quality. For effect quantification, the locally applied layer thickness is determined by evaluating the heat-up of the newly deposited powder. During the solidification process space and time-resolved data is used to characterize the zone of elevated temperatures and to derive locally varying heat dissipation properties. Potential quality indicators are evaluated and correlated to the resulting part quality: Thermal diffusivity is derived from a simplified heat dissipation model and evaluated for every pixel and cool-down phase of a layer. This allows the quantification of expected material homogeneity properties. Maximum temperature and time above certain temperatures are measured in order to detect hot spots or delamination issues that may cause a process breakdown. Furthermore, a method for quantification of sputter activity is presented. Since high sputter activity indicates unstable melt dynamics this can be used to identify parameter drifts, improper atmospheric conditions or material binding errors. The resulting surface structure after solidification complicates temperature determination on the one hand but enables the detection of potential surface defects

  11. Thermographic process monitoring in powderbed based additive manufacturing

    Energy Technology Data Exchange (ETDEWEB)

    Krauss, Harald, E-mail: harald.krauss@iwb.tum.de; Zaeh, Michael F. [AMLab, iwb Application Center Augsburg, Technische Universität München (Germany); Zeugner, Thomas [Augsburg University (Germany)

    2015-03-31

    Selective Laser Melting is utilized to build metallic parts directly from CAD-Data by solidification of thin powder layers through application of a fast scanning laser beam. In this study layerwise monitoring of the temperature distribution is used to gather information about the process stability and the resulting part quality. The heat distribution varies with different kinds of parameters including scan vector length, laser power, layer thickness and inter-part distance in the job layout which in turn influence the resulting part quality. By integration of an off-axis mounted uncooled thermal detector the solidification as well as the layer deposition are monitored and evaluated. Errors in the generation of new powder layers usually result in a locally varying layer thickness that may cause poor part quality. For effect quantification, the locally applied layer thickness is determined by evaluating the heat-up of the newly deposited powder. During the solidification process space and time-resolved data is used to characterize the zone of elevated temperatures and to derive locally varying heat dissipation properties. Potential quality indicators are evaluated and correlated to the resulting part quality: Thermal diffusivity is derived from a simplified heat dissipation model and evaluated for every pixel and cool-down phase of a layer. This allows the quantification of expected material homogeneity properties. Maximum temperature and time above certain temperatures are measured in order to detect hot spots or delamination issues that may cause a process breakdown. Furthermore, a method for quantification of sputter activity is presented. Since high sputter activity indicates unstable melt dynamics this can be used to identify parameter drifts, improper atmospheric conditions or material binding errors. The resulting surface structure after solidification complicates temperature determination on the one hand but enables the detection of potential surface defects

  12. Electricity-Independent Generation of Silicon Based on the Use of Rice Husk: A Concept Process

    Science.gov (United States)

    Barati, Mansoor

    The present paper is based on a term project for final year undergraduate students, requiring them to evaluate a process for producing silicon from rice husk. The traditional method for production of silicon involves carbothermal reduction of quartz in electric arc furnaces at temperatures exceeding 2000 °C. The technology consumes a considerable amount of electrical energy as well as fossil fuels, resulting in significant CO2 emissions. A flowsheet for production of silicon metal from rice husk is laid out in this paper. The technology will consist of combustors, which will generate steam using the rice husk biomass, power generator, and electric furnace for reduction of the rice husk. Materials and energy balance calculations presented here indicate that such process can be operated independent of external electricity.

  13. Differential photoacoustic cell to study the wetting process during porous silicon formation

    Energy Technology Data Exchange (ETDEWEB)

    German Espinosa-Arbelaez, Diego [Instituto de Investigaciones en Materiales, Universidad Nacional Autonoma de Mexico, Posgrado en Ciencia e Ingenieria de Materiales, Edificio de Posgrado, Coyoacan, CP 04530, Mexico D. F. (Mexico); Departamento de Nanotecnologia, Centro de Fisica Aplicada y Tecnologia Avanzada, Universidad Nacional Autonoma de Mexico, Blvd Juriquilla 3001, Campus Juriquilla, CP 76230, Queretaro, Qro. (Mexico); Velazquez-Hernandez, Ruben [Division de Investigacion y Posgrado, Facultad de Ingenieria, Universidad Autonoma de Queretaro, Cerro de las Campanas, CP 76010, Queretaro, Qro (Mexico); Petricioli-Carranco, Julio; Quintero-Torres, Rafael; Rodriguez-Garcia, Mario Enrique [Departamento de Nanotecnologia, Centro de Fisica Aplicada y Tecnologia Avanzada, Universidad Nacional Autonoma de Mexico, Blvd Juriquilla 3001, Campus Juriquilla, CP 76230, Queretaro, Qro. (Mexico)

    2011-06-15

    This paper shows the in-situ study of the wetting process in Silicon during anodization process using an electrochemical Differential photoacoustic Cell (DPC). The Photoacoustic amplitude and phase signals were obtained for samples in air, ethanol, ethanol/HF and finally air. According to these results ethanol is responsible for a mechanical contact reducing the superficial tension and ethanol/HF produce the removing of the SiO{sub x} and SiO{sub 2}species on the Silicon surface. It was found that the DPC is a powerful technique to study the wet surface before the formation of the porous silicon layer (copyright 2011 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim) (orig.)

  14. Manufacturing process modeling for composite materials and structures, Sandia blade reliability collaborative

    Energy Technology Data Exchange (ETDEWEB)

    Guest, Daniel A.; Cairns, Douglas S.

    2014-02-01

    The increased use and interest in wind energy over the last few years has necessitated an increase in the manufacturing of wind turbine blades. This increase in manufacturing has in many ways out stepped the current understanding of not only the materials used but also the manufacturing methods used to construct composite laminates. The goal of this study is to develop a list of process parameters which influence the quality of composite laminates manufactured using vacuum assisted resin transfer molding and to evaluate how they influence laminate quality. Known to be primary factors for the manufacturing process are resin flow rate and vacuum pressure. An incorrect balance of these parameters will often cause porosity or voids in laminates that ultimately degrade the strength of the composite. Fiber waviness has also been seen as a major contributor to failures in wind turbine blades and is often the effect of mishandling during the lay-up process. Based on laboratory tests conducted, a relationship between these parameters and laminate quality has been established which will be a valuable tool in developing best practices and standard procedures for the manufacture of wind turbine blade composites.

  15. Effect of the packing structure of silicon chunks on the melting process and carbon reduction in Czochralski silicon crystal growth

    Science.gov (United States)

    Liu, Xin; Nakano, Satoshi; Kakimoto, Koichi

    2017-06-01

    Carbon (C) contamination in Czochralski silicon (CZ-Si) crystal growth mainly originates from carbon monoxide (CO) generation on the graphite components, which reaches a maximum during the melting stage. Loading a crucible with poly-Si feedstock includes many technical details for optimization of the melting and growth processes. To investigate the effect of the packing structure of Si chunks on C accumulation in CZ-Si crystal growth, transient global simulations of heat and mass transport were performed for the melting process with different packing structures of poly-Si. The heat transport modeling took into account the effective thermal conductivity (ETC) of the Si feedstock, which is affected by the packing structure. The effect of the chunk size on the melting process and C accumulation were investigated by parametric studies of different packing structures. The heat transport and melting process in the crucible were affected by the ETC and the emissivity of the Si feedstock. It was found that smaller Si chunks packed in the upper part could speed up the melting process and smooth the power profile. Decreasing the duration of the melting process is favorable for reduction of C contamination in the Si feedstock. Parametric studies indicated that optimization of the melting process by the packing structure is possible and essential for C reduction in CZ-Si crystal growth.

  16. Infrared thermography for laser-based powder bed fusion additive manufacturing processes

    Science.gov (United States)

    Moylan, Shawn; Whitenton, Eric; Lane, Brandon; Slotwinski, John

    2014-02-01

    Additive manufacturing (AM) has the potential to revolutionize discrete part manufacturing, but improvements in processing of metallic materials are necessary before AM will see widespread adoption. A better understanding of AM processes, resulting from physics-based modeling as well as direct process metrology, will form the basis for these improvements. Infrared (IR) thermography of AM processes can provide direct process metrology, as well as data necessary for the verification of physics-based models. We review selected works examining how IR thermography was implemented and used in various powder-bed AM processes. This previous work, as well as significant experience at the National Institute of Standards and Technology in temperature measurement and IR thermography for machining processes, shapes our own research in AM process metrology with IR thermography. We discuss our experimental design, as well as plans for future IR measurements of a laser-based powder bed fusion AM process.

  17. A comparison of BPMN 2.0 with other notations for manufacturing processes

    Science.gov (United States)

    García-Domínguez, A.; Marcos, Mariano; Medina, I.

    2012-04-01

    In order to study their current practices and improve on them, manufacturing firms need to view their processes from several viewpoints at various abstraction levels. Several notations have been developed for this purpose, such as Value Stream Mappings or IDEF models. More recently, the BPMN 2.0 standard from the Object Management Group has been proposed for modeling business processes. A process organizes several activities (manual or automatic) into a single higher-level entity, which can be reused elsewhere in the organization. Its potential for standardizing business interactions is well-known, but there is little work on using BPMN 2.0 to model manufacturing processes. In this work some of the previous notations are outlined and BPMN 2.0 is positioned among them after discussing it in more depth. Some guidelines on using BPMN 2.0 for manufacturing are offered, and its advantages and disadvantages in comparison with the other notations are presented.

  18. A Novel Processing Approach for Additive Manufacturing of Commercial Aluminum Alloys

    Science.gov (United States)

    Roberts, Christopher E.; Bourell, David; Watt, Trevor; Cohen, Julien

    Aluminum 6061 is of great commercial interest due to its ubiquitous use in manufacturing, advantageous mechanical properties, and its successful certification in aerospace applications. However, as an off-eutectic with accompanying large freezing range, attempts to process the material by additive manufacturing have resulted in part cracking and diminished mechanical properties. A unique approach using mixed powders is presented to process this historically difficult-to-process material. Expansion of this combined-powder approach to other materials systems not typically compatible with additive manufacturing is possible. Dense parts without solidification cracking have been produced by the SLM process, as verified using SEM and EDS. An overview of this approach is presented along with test results using an Al-Si mixture.

  19. Adaptive Process Controls and Ultrasonics for High Temperature PEM MEA Manufacture

    Energy Technology Data Exchange (ETDEWEB)

    Walczyk, Daniel F. [Rensselaer Polytechnic Inst., Troy, NY (United States)

    2015-08-26

    The purpose of this 5-year DOE-sponsored project was to address major process bottlenecks associated with fuel cell manufacturing. New technologies were developed to significantly reduce pressing cycle time for high temperature PEM membrane electrode assembly (MEA) through the use of novel, robust ultrasonic (U/S) bonding processes along with low temperature (<100°C) PEM MEAs. In addition, greater manufacturing uniformity and performance was achieved through (a) an investigation into the causes of excessive variation in ultrasonically and thermally bonded MEAs using more diagnostics applied during the entire fabrication and cell build process, and (b) development of rapid, yet simple quality control measurement techniques for use by industry.

  20. Characterization and Optimization of Mechanical Properties of ABS Parts Manufactured by the Fused Deposition Modelling Process

    Directory of Open Access Journals (Sweden)

    Godfrey C. Onwubolu

    2014-01-01

    Full Text Available While fused deposition modelling (FDM is one of the most used additive manufacturing (AM techniques today due to its ability to manufacture very complex geometries, the major research issues have been to balance ability to produce aesthetically appealing looking products with functionality. In this study, five important process parameters such as layer thickness, part orientation, raster angle, raster width, and air gap have been considered to study their effects on tensile strength of test specimen, using design of experiment (DOE. Using group method of data handling (GMDH, mathematical models relating the response with the process parameters have been developed. Using differential evolution (DE, optimal process parameters have been found to achieve good strength simultaneously for the response. The optimization of the mathematical model realized results in maximized tensile strength. Consequently, the additive manufacturing part produced is improved by optimizing the process parameters. The predicted models obtained show good correlation with the measured values and can be used to generalize prediction for process conditions outside the current study. Results obtained are very promising and hence the approach presented in this paper has practical applications for design and manufacture of parts using additive manufacturing technologies.

  1. Product and process for manufacturing an optical disc master

    Energy Technology Data Exchange (ETDEWEB)

    Dobbin, R.B.; Loeppky, D.G.; Norton, J.R.; Del Mar, B.E.

    1994-01-11

    The invention discloses a simplified four step process for making an optical disc master or alternatively a WORM disc by first making or obtaining a transparent polymer disc with a tracking groove of desired geometry molded therein, then spin coating an optically active lamina on the grooved side of the disc, then recording data on said polymer disc with groove controlled and tracked laser means by ablating active lamina, forming pits, the shape of which is determined by the groove geometry and finally depositing a conductive and reflective lamina over the pitted active lamina. To change the OD master to an OD WORM, a protective cover is added to the electrically conductive and optically reflective lamina. 12 figs.

  2. Process for producing organic products containing silicon, hydrogen, nitrogen, and carbon by the direct reaction between elemental silicon and organic amines and products formed thereby

    Science.gov (United States)

    Pugar, E.A.; Morgan, P.E.D.

    1988-04-04

    A process is disclosed for producing, at a low temperature, a high purity organic reaction product consisting essentially of silicon, hydrogen, nitrogen, and carbon. The process comprises reacting together a particulate elemental high purity silicon with a high purity reactive amine reactant in a liquid state at a temperature of from about O/degree/C up to about 300/degree/C. A high purity silicon carbide/silicon nitride ceramic product can be formed from this intermediate product, if desired, by heating the intermediate product at a temperature of from about 1200-1700/degree/C for a period from about 15 minutes up to about 2 hours or the organic reaction product may be employed in other chemical uses.

  3. Ninth Workshop on Crystalline Silicon Solar Cell Materials and Processes: Extended Abstracts and Papers of the Workshop, 9-11 August 1999, Breckenridge, Colorado

    Energy Technology Data Exchange (ETDEWEB)

    Sopori, B.L.; Gee, J.; Kalejs, J.; Saitoh, R.; Stavola, M.; Swanson, D.; Tan, T.; Weber, E.; Werner, J.

    2000-08-04

    Since 1997, the PV sales have exceeded 100 MW/yr with > 85% of the production coming from silicon photovoltaics (Si-PV). As the PV demands increase in the new millennium, there will be a host of challenges to Si-PV. The challenges will arise in developing strategies for cost reduction, increased production, higher throughput per manufacturing line, new sources of low-cost Si, and introduction of new manufacturing processes for cell fabrication. At the same time, newer thin-film technologies, based on CdTe and CIS, will come on board posing new competition. With these challenges come new opportunities for the Si-PV-to detach itself from the microelectronics industry, to embark on an aggressive program in thin-film Si solar cells, and to try new approaches to process monitoring. The 9th Workshop on Crystalline Silicon Solar Cell Materials and Processes addressed these issues in a number of sessions. In addition to covering the usual topics of impurity gettering, defects, passivation, and solar cell processing, there were sessions on poly feedstock, mechanical properties of Si, metallization, and process monitoring.

  4. Optimizing a manufacturing submicron CMOS process for low-voltage applications

    Science.gov (United States)

    Ma, Jun; Cheng, Sunny; Pryor, Bob; Klein, Kevin

    1996-09-01

    A low threshold voltage (Vt) is desired to improve a CMOS circuit performance when operating at reduced supply voltages to save power. In this paper, a practical approach to reduce Vt for a conventional, manufacturing submicron CMOS process is presented. This `evolutionary' approach to reduce Vt is taken so as the ensure manufacturability and to reduce process cost. This is found to be useful especially before a deep-submicron or a sophisticated process targeted for low voltage application becomes available and manufacturable. Vt reduction is achieved by the integration of a thinner, in the case presented here a 105 angstroms, gate oxide into a 0.65 micrometers process. The process is then optimized to provide the device with highest current-drive while obtaining lowest Vt with acceptable subthreshold leakage with conventional front-end and back-end process. It is shown that, with the minimal changes to the 0.65 micrometers conventional manufacturing process, the Vt's for nominal n- and p-channel devices can be reduced by 20% - 30%, with more than 1.5X improvement in current drive at 3.3 V compared to devices with 150 angstroms gate oxide. The enhancement of circuit performance is demonstrated with measurements of benchmark circuits including CPU, ROM, and FSRAM, where successful operation has been obtained near IV and operating frequencies are nearly doubled at supply voltage near 1.6 V compared to conventional 0.65 micrometers process.

  5. 77 FR 76518 - Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain...

    Science.gov (United States)

    2012-12-28

    ... Doc No: 2012-31160] INTERNATIONAL TRADE COMMISSION [Docket No. 2924] Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain Products Containing Same and Certain Parts.... International Trade Commission has received a complaint entitled Certain Paper Shredders, Certain Processes for...

  6. High performance poly(etherketoneketone) (PEKK) composite parts fabricated using Big Area Additive Manufacturing (BAAM) processes

    Energy Technology Data Exchange (ETDEWEB)

    Kunc, Vlastimil [ORNL; Kishore, Vidya [ORNL; Chen, Xun [ORNL; Ajinjeru, Christine [ORNL; Duty, Chad [University of Tennessee (UTK) and Oak Ridge National Laboratory (ORNL); Hassen, Ahmed A [ORNL

    2016-09-01

    ORNL collaborated with Arkema Inc. to investigate poly(etherketoneketone) (PEKK) and its composites as potential feedstock material for Big Area Additive Manufacturing (BAAM) system. In this work thermal and rheological properties were investigated and characterized in order to identify suitable processing conditions and material flow behavior for BAAM process.

  7. Inactivation of the BSE agent by the heat and pressure process for manufacturing gelatine

    NARCIS (Netherlands)

    Grobben, A.H.; Steele, P.J.; Somerville, R.A.; Taylor, D.; Schreuder, B.E.C.

    2005-01-01

    Dietary exposure to the bovine spongiform encephalopathy (BSE) agent is the probable cause of variant Creutzfeldt-Jakob disease in people. The industrial manufacturing process for the production of gelatine and colloidal protein by the heat and pressure process was downscaled accurately and its

  8. Functionality specific excipients influencing manufacturability and/or processing of pharmaceutical dosage forms: a wish list

    Directory of Open Access Journals (Sweden)

    Shireesh Apte

    2013-06-01

    Full Text Available The non-availability of suitable excipients that perform specific functions in manufacturing unit operations or during storage leads to suboptimal processes and formulations. A ‘wish list’ of excipients that may alleviate selected sub-optimal processes and formulations is presented.

  9. Novel fermentation processes for manufacturing plant natural products.

    Science.gov (United States)

    Zhou, Jingwen; Du, Guocheng; Chen, Jian

    2014-02-01

    Microbial production of plant natural products (PNPs), such as terpenoids, flavonoids from renewable carbohydrate feedstocks offers sustainable and economically attractive alternatives to their petroleum-based production. Rapid development of metabolic engineering and synthetic biology of microorganisms shows many advantages to replace the current extraction of these useful high price chemicals from plants. Although few of them were actually applied on a large scale for PNPs production, continuous research on these high-price chemicals and the rapid growing global market of them, show the promising future for the production of these PNPs by microorganisms with a more economic and environmental friendly way. Introduction of novel pathways and optimization of the native cellular processes by metabolic engineering of microorganisms for PNPs production are rapidly expanding its range of cell-factory applications. Here we review recent progress in metabolic engineering of microorganisms for the production of PNPs. Besides, factors restricting the yield improvement and application of lab-scale achievements to industrial applications have also been discussed. Copyright © 2013 Elsevier Ltd. All rights reserved.

  10. Investigation of Toshiba 130nm CMOS process as a possible candidate for active silicon sensors in HEP and X-ray experiments

    Energy Technology Data Exchange (ETDEWEB)

    Fu, Yunan; Hemperek, Tomasz; Kishishita, Testsuichi; Krueger, Hans; Rymaszewski, Piotr; Wermes, Norbert [University of Bonn, Bonn (Germany); Peric, Ivan [Karlsruhe Institute of Technology, Karlsruhe (Germany)

    2015-07-01

    Following the advances of commercial semiconductor manufacturing technologies there has recently been an increased interest within experimental physics community in applying CMOS manufacturing processes to developing active silicon sensors. Possibility of applying high voltage bias combined with high resistivity substrate allows for better depletion of sensor and therefore quicker and more efficient charge collection. One of processes that accommodates those features is Toshiba 130 nm CMOS technology (CMOS3E). Within our group a test chip was designed to examine the suitability of this technology for physics experiment (both for HEP and X-ray imaging). Design consisted of 4 pixel matrices with total of 12 different pixel flavors allowing for evaluation of various pixel geometries and architectures in terms of depletion depth, noise performance, charge collection efficiency, etc. During this talk initial outcome of this evaluation is presented, starting with brief introduction to technology itself, followed by results of TCAD simulations, description of final design and first measurements results.

  11. Manufacturing work and organizational stresses in export processing zones.

    Science.gov (United States)

    Lu, Jinky Leilanie

    2009-10-01

    In the light of global industrialization, much attention has been focused on occupational factors and their influence on the health and welfare of workers. This was a cross sectional study using stratified sampling technique based on industry sizes. The study sampled 24 industries, 6 were small scale industries and 9 each for medium and large scale industries. From the 24 industries, a total of 500 respondents for the questionnaire was taken. For occupational health and safety standards that industries have to comply with, there was low compliance among small-scale industries relative to the medium and large scale industries. Only one industry had an air cleaning device for cleaning contaminated air prior to emission into the external community. Among the 500 respondents, majority were female (88.8%), single (69.6%) and worked in the production or assembly-line station (87.4%). Sickness absenteeism was relative high among the workers in this study accounting for almost 54% among females and 48% among males. Many of the workers also reported of poor performance at work, boredom, tardiness and absenteeism. For association between work factors and personal factors, the following were found to be statistically significant at p=0.05. Boredom was associated with lack of skills training, lack of promotion, disincentives for sick leaves, poor relationship with boss and poor relationships with employers. On the other hand, poor performance was also associated with lack of skills training, lack of promotions, job insecurity, and poor relationship with employers. From the data generated, important issues that must be dealt with in work organizations include the quality of work life, and health and safety issues. Based on these findings, we can conclude that there are still issues on occupational health and safety (OHS) in the target site of export processing zones in the Philippines. There must be an active campaign for OHS in industries that are produce for the global market

  12. The use of LCA for modelling sustainability and environmental impact of manufacturing processes

    Energy Technology Data Exchange (ETDEWEB)

    Culaba, A.; Purvis, M. [Portsmouth Univ. (United Kingdom). Dept. of Mechanical and Manufacturing Engineering

    1995-12-31

    Most industries rely significantly on natural resources for raw materials and energy requirements. As a consequence of manufacturing activities, various pollutants are generated in the process. While effects on the environment can be detrimental, wastes and emissions account for a high percentage loss in the overall material balance. Unless these unnecessary losses are minimized and recovered, the environment would continue to be disadvantaged and long-term supply of raw materials and energy would likewise be affected. The key to the analysis of such problems concerns generalised procedures for the modelling of the sustainable use of resources in manufacturing processes and the development of associated sustainability criteria. This requires identifying the various aspects of manufacturing from the time the raw materials are extracted until they have been processed into products and then used or consumed and finally disposed of. The use of life cycle assessment (LCA) methodology encompasses these analyses and that of the identification of environmental effects associated with every stage of the manufacturing process. The presentation concludes that LCA is a very useful and effective tool in providing planners, legislator and decision-makers with the necessary information on the probable impacts of manufacture on the environment as well as underlying legislation, ecological, health standards and emission limits. (author)

  13. Raman spectroscopy as a process analytical technology for pharmaceutical manufacturing and bioprocessing.

    Science.gov (United States)

    Esmonde-White, Karen A; Cuellar, Maryann; Uerpmann, Carsten; Lenain, Bruno; Lewis, Ian R

    2017-01-01

    Adoption of Quality by Design (QbD) principles, regulatory support of QbD, process analytical technology (PAT), and continuous manufacturing are major factors effecting new approaches to pharmaceutical manufacturing and bioprocessing. In this review, we highlight new technology developments, data analysis models, and applications of Raman spectroscopy, which have expanded the scope of Raman spectroscopy as a process analytical technology. Emerging technologies such as transmission and enhanced reflection Raman, and new approaches to using available technologies, expand the scope of Raman spectroscopy in pharmaceutical manufacturing, and now Raman spectroscopy is successfully integrated into real-time release testing, continuous manufacturing, and statistical process control. Since the last major review of Raman as a pharmaceutical PAT in 2010, many new Raman applications in bioprocessing have emerged. Exciting reports of in situ Raman spectroscopy in bioprocesses complement a growing scientific field of biological and biomedical Raman spectroscopy. Raman spectroscopy has made a positive impact as a process analytical and control tool for pharmaceutical manufacturing and bioprocessing, with demonstrated scientific and financial benefits throughout a product's lifecycle.

  14. Development of a Manufacturing Process for High-Precision Cu EOS Targets

    Energy Technology Data Exchange (ETDEWEB)

    Bono, M J; Castro, C; Hibbard, R L

    2006-01-12

    This document describes the development of a manufacturing process and the production of Cu EOS targets. The development of a manufacturing process for these targets required a great deal of research, because the specifications for the targets required a level of precision an order of magnitude beyond Target Fabrication's capabilities at the time. Strict limitations on the dimensions of the components and the interfaces between them required research efforts to develop bonding and deposition processes consistent with a manufacturing plan with a dimensional precision on the order of 0.1 {micro}m. Several months into this effort, the specifications for the targets were relaxed slightly as a result of discussions between the Target Fabrication Group and the physicists. The level of precision required for these targets remained an order of magnitude beyond previous capabilities, but the changes made it possible to manufacture targets to the specifications. The development efforts and manufacturing processes described in this document successfully produced a complete Cu EOS target that satisfied all of the fabrication and metrology specifications.

  15. Conventional and Innovative Processing of Milk for Yogurt Manufacture; Development of Texture and Flavor: A Review

    OpenAIRE

    Panagiotis Sfakianakis; Constatnina Tzia

    2014-01-01

    Milk and yogurt are important elements of the human diet, due to their high nutritional value and their appealing sensory properties. During milk processing (homogenization, pasteurization) and further yogurt manufacture (fermentation) physicochemical changes occur that affect the flavor and texture of these products while the development of standardized processes contributes to the development of desirable textural and flavor characteristics. The processes that take place during milk process...

  16. Silicon Carbide (SiC) Power Processing Unit (PPU) for Hall Effect Thrusters Project

    Data.gov (United States)

    National Aeronautics and Space Administration — In this SBIR project, APEI, Inc. is proposing to develop a high efficiency, rad-hard 3.8 kW silicon carbide (SiC) power supply for the Power Processing Unit (PPU) of...

  17. Processing of n+/p-/p+ strip detectors with atomic layer deposition (ALD) grown Al2O3 field insulator on magnetic Czochralski silicon (MCz-si) substrates

    Science.gov (United States)

    Härkönen, J.; Tuovinen, E.; Luukka, P.; Gädda, A.; Mäenpää, T.; Tuominen, E.; Arsenovich, T.; Junkes, A.; Wu, X.; Li, Z.

    2016-08-01

    Detectors manufactured on p-type silicon material are known to have significant advantages in very harsh radiation environment over n-type detectors, traditionally used in High Energy Physics experiments for particle tracking. In p-type (n+ segmentation on p substrate) position-sensitive strip detectors, however, the fixed oxide charge in the silicon dioxide is positive and, thus, causes electron accumulation at the Si/SiO2 interface. As a result, unless appropriate interstrip isolation is applied, the n-type strips are short-circuited. Widely adopted methods to terminate surface electron accumulation are segmented p-stop or p-spray field implantations. A different approach to overcome the near-surface electron accumulation at the interface of silicon dioxide and p-type silicon is to deposit a thin film field insulator with negative oxide charge. We have processed silicon strip detectors on p-type Magnetic Czochralski silicon (MCz-Si) substrates with aluminum oxide (Al2O3) thin film insulator, grown with Atomic Layer Deposition (ALD) method. The electrical characterization by current-voltage and capacitance-voltage measurement shows reliable performance of the aluminum oxide. The final proof of concept was obtained at the test beam with 200 GeV/c muons. For the non-irradiated detector the charge collection efficiency (CCE) was nearly 100% with a signal-to-noise ratio (S/N) of about 40, whereas for the 2×1015 neq/cm2 proton irradiated detector the CCE was 35%, when the sensor was biased at 500 V. These results are comparable with the results from p-type detectors with the p-spray and p-stop interstrip isolation techniques. In addition, interestingly, when the aluminum oxide was irradiated with Co-60 gamma-rays, an accumulation of negative fixed oxide charge in the oxide was observed.

  18. Floating Silicon Method

    Energy Technology Data Exchange (ETDEWEB)

    Kellerman, Peter

    2013-12-21

    The Floating Silicon Method (FSM) project at Applied Materials (formerly Varian Semiconductor Equipment Associates), has been funded, in part, by the DOE under a “Photovoltaic Supply Chain and Cross Cutting Technologies” grant (number DE-EE0000595) for the past four years. The original intent of the project was to develop the FSM process from concept to a commercially viable tool. This new manufacturing equipment would support the photovoltaic industry in following ways: eliminate kerf losses and the consumable costs associated with wafer sawing, allow optimal photovoltaic efficiency by producing high-quality silicon sheets, reduce the cost of assembling photovoltaic modules by creating large-area silicon cells which are free of micro-cracks, and would be a drop-in replacement in existing high efficiency cell production process thereby allowing rapid fan-out into the industry.

  19. The role of radiative and nonradiative relaxation processes in the generation of light from silicon nanocrystals

    Energy Technology Data Exchange (ETDEWEB)

    Dovrat, M.; Goshen, Y.; Popov, I.; Jedrzejewski, J.; Balberg, I.; Sa' ar, A. [Racah Institute of Physics and the Center for Nanoscience and Nanotechnology, The Hebrew University of Jerusalem, Jerusalem 91904 (Israel)

    2005-06-01

    We report on the structural and the optical properties of silicon nanocrystals embedded in a silicon-dioxide matrix with a varying content of the crystalline silicon phase. Cross section transmission electron microscopy confirmed the presence of small crystalline silicon quantum dots with size distribution of {proportional_to}25%. Using continuous wave and time-resolved photoluminescence spectroscopy we were able to distinguish between characteristics of the PL decay that are associated with quantum confinement effects, and PL characteristics that are affected by the environment. In particular, we have found that the lifetime of the upper singlet state and the singlet-triplet energy splitting originate from quantum confinement of the carriers in the individual nanocrystals. On the other hand, we have found that the lower triplet state lifetime should be assigned to nonradiative processes that are affected the crystallites environment. Furthermore, the oscillator strength for the radiative transitions was found to be significantly weaker compared to that of direct gap semiconductors. As a result, we conclude that the efficient PL from silicon nanocrystals is due to exclusion of nonradiative channels that gives rise to very long nonradiative lifetimes. (copyright 2005 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim) (orig.)

  20. Silicon defects characterization for low temperature ion implantation and RTA process

    Energy Technology Data Exchange (ETDEWEB)

    Martirani Paolillo, Diego; Margutti, Giovanni; De Biase, Marco [LFoundry s.r.l. Avezzano (Italy); Barozzi, Mario; Giubertoni, Damiano [Fondazione Bruno Kessler, Trento (Italy); Spaggiari, Claudio [Axcelis Technologies Srl, Agrate Brianza (Italy)

    2015-12-15

    In the last years a lot of effort has been directed in order to reduce silicon defects eventually formed during the ion implantation/anneal sequence used in the fabrication of CMOS devices. In this work we explored the effect of ion implant dose rate and temperature on the formation of silicon defects for high fluence {sup 49}BF{sub 2} implantations. The considered processes (implantation and annealing) conditions are those typically used to form the source/drain regions of p-channel transistors in the submicron technology node and will be detailed in the document. Characterization of implant damage and extended silicon defects left after anneal has been performed by TEM. Dopant distribution and dopant activation has been investigated by SIMS and SRP analysis. We have verified that implant dose rate and temperature modulate the thickness of the amorphous silicon observed after implant, as well as the concentrations of silicon defects left after anneal. Effect of high dose rate low temperature implantation on product device was also evaluated, showing a reduction of leakage current on p-channel transistors. Experimental set up, results and possible explanation will be reported and discussed in the paper.

  1. Bench-Scale Silicone Process for Low-Cost CO{sub 2} Capture

    Energy Technology Data Exchange (ETDEWEB)

    Vipperla, Ravikumar; Yee, Michael; Steele, Ray

    2012-11-01

    This report presents system and economic analysis for a carbon capture unit which uses an amino-silicone solvent for CO{sub 2} capture and sequestration (CCS) in a pulverized coal (PC) boiler. The amino-silicone solvent is based on GAP-1 with Tri-Ethylene Glycol (TEG) as a co-solvent. The report also shows results for a CCS unit based on a conventional approach using mono-ethanol amine (MEA). Models were developed for both processes and used to calculate mass and energy balances. Capital costs and energy penalty were calculated for both systems, as well as the increase in cost of electricity. The amino-silicone solvent based system demonstrates significant advantages compared to the MEA system.

  2. Silicon Nanowires for All-Optical Signal Processing in Optical Communication

    DEFF Research Database (Denmark)

    Pu, Minhao; Hu, Hao; Ji, Hua

    2012-01-01

    such as four-wave mixing (FWM) which is an imperative process for optical signal processing. Since the current mature silicon fabrication technology enables a precise dimension control on nanowires, dispersion engineering can be performed by tailoring nanowire dimensions to realize an efficient nonlinear...... process. In the last four years, we investigated and demonstrated different ultra-fast all-optical nonlinear signal processing applications in silicon nanowires for optical time domain multiplexing (OTDM) systems, including wavelength conversion, signal regeneration, ultra-fast waveform sampling......, demultiplexing, and multicasting, which shows great potentials in the future optical communication systems. Although the strong light confinement in nanowires allows efficient nonlinear optical signal processing, it also leads to coupling difficulty between on-chip sub-micron nanowires and micro-size fibers due...

  3. Advanced Bio-Based Nanocomposites and Manufacturing Processes

    Science.gov (United States)

    Spinella, Stephen Matthew

    The aim of the PhD thesis concerns with the modification of cellulose nanocrystals (CNCs) via esterification or a radical grafting "from" approach to achieve polymeric nanocomposites of exceptional properties (Chapters 1 to 4). In addition to CNCs modification, other green routes have been introduced in this thesis in order to environmentally friendly polyester-based materials, i.e. Chapters five and six. The second chapter focuses on expanding on a one-pot cellulose acid hydrolysis/Fischer esterification to produce highly compatible CNCs without any organic solvent. It consists of modifying CNCs with acetic- and lactic- acid and exploring how such surface chemistry has an effect of dispersion in the case of polylactide (PLA)-based nanocomposites. The degree of substitution for AA-CNCs and LA-CNCs, determined by FTIR, are 0.12 and 0.13, respectively. PLA-based materials represent the best bioplastics relating to its high stiffness and biodegradability, but suffer from its poor thermal performances, namely its Heat Deflection Temperature (HDT). To improve the HDT of PLA, nanocomposites have been therefore prepared with modified cellulose nanocrystals (CNCs) by melt blending. After blending at 5 wt-% loading of CNCs, LA-CNCs gives superior reinforcement below and above the glass temperature of PLA. An increase in PLA's heat deflection temperature by 10°C and 20°C is achieved by melt-blending PLA with 5 and 20 wt-% LA-CNCs, respectively. Chapter three concerns with expanding this process to a series of hydrophilic and hydrophobic acids yielding functional CNCs for electronic and biomedical applications. Hydrophilic acids include citric-, malonic- and malic acid. Modification with the abovementioned organic acids allows for the introduction of free acids onto the surface of CNCs. Modification with citric-, malonic- and malic- acid is verified by Fourier Transform Infrared Spectroscopy and 13C solid state magic-angle spinning (MAS) NMR experiments. The degree of

  4. Energy requirement for the production of silicon solar arrays

    Science.gov (United States)

    Lindmayer, J.; Wihl, M.; Scheinine, A.; Morrison, A.

    1977-01-01

    An assessment of potential changes and alternative technologies which could impact the photovoltaic manufacturing process is presented. Topics discussed include: a multiple wire saw, ribbon growth techniques, silicon casting, and a computer model for a large-scale solar power plant. Emphasis is placed on reducing the energy demands of the manufacturing process.

  5. Business process integration between European manufacturers and transport and logistics service providers

    DEFF Research Database (Denmark)

    Mortensen, Ole; Lemoine, W

    2005-01-01

    The goal of the Supply Chain Management process is to create value for customers, stakeholders and all supply chain members, through the integration of disparate processes like manufacturing flow management, customer service and order fulfillment. However, many firms fail in the path of achieving...... a total integration. This study illustrates, from an empirical point of view, the problems associated to SC integration among European firms operating in global/international markets. The focus is on the relationship between two echelons in the supply chain: manufacturers and their transport and logistics...

  6. Drug-printing by flexographic printing technology--a new manufacturing process for orodispersible films.

    Science.gov (United States)

    Janssen, Eva Maria; Schliephacke, Ralf; Breitenbach, Armin; Breitkreutz, Jörg

    2013-01-30

    Orodispersible films (ODFs) are intended to disintegrate within seconds when placed onto the tongue. The common way of manufacturing is the solvent casting method. Flexographic printing on drug-free ODFs is introduced as a highly flexible and cost-effective alternative manufacturing method in this study. Rasagiline mesylate and tadalafil were used as model drugs. Printing of rasagiline solutions and tadalafil suspensions was feasible. Up to four printing cycles were performed. The possibility to employ several printing cycles enables a continuous, highly flexible manufacturing process, for example for individualised medicine. The obtained ODFs were characterised regarding their mechanical properties, their disintegration time, API crystallinity and homogeneity. Rasagiline mesylate did not recrystallise after the printing process. Relevant film properties were not affected by printing. Results were comparable to the results of ODFs manufactured with the common solvent casting technique, but the APIs are less stressed through mixing, solvent evaporation and heat. Further, loss of material due to cutting jumbo and daughter rolls can be reduced. Therefore, a versatile new manufacturing technology particularly for processing high-potent low-dose or heat sensitive drugs is introduced in this study. Copyright © 2012 Elsevier B.V. All rights reserved.

  7. Additive Manufacturing Processes: Selective Laser Melting, Electron Beam Melting and Binder Jetting—Selection Guidelines

    Science.gov (United States)

    Konda Gokuldoss, Prashanth; Kolla, Sri; Eckert, Jürgen

    2017-01-01

    Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties. PMID:28773031

  8. Additive Manufacturing Processes: Selective Laser Melting, Electron Beam Melting and Binder Jetting-Selection Guidelines.

    Science.gov (United States)

    Gokuldoss, Prashanth Konda; Kolla, Sri; Eckert, Jürgen

    2017-06-19

    Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties.

  9. Non-fossil reduction materials in the silicon process - properties and behaviour

    Energy Technology Data Exchange (ETDEWEB)

    Myrhaug, Edin Henrik

    2003-07-01

    The purpose of this work has been to clarify the effect of using biocarbon as a reduction material in the silicon process. It was decided to compare the biocarbon with fossil carbon and find possible differences both on process performance and eventually on product quality. The elements in the raw materials added to the silicon process goes into three different products: silicon metal, silica dust and into open air. Based on analysis of raw materials and of produced silicon metal and microsilica extensive material balances have been established. One important result from these are the distribution factors that indicate how much of the trace elements that goes into each medium. Another result is that the boiling point of an element or a compound gives a good indication of were it ends. A high boiling point indicates that the element ends up in the silicon metal, while a low boiling point indicates that the element goes with off-gas into air. With an intermediate boiling point, the element goes into the silica dust. The SiO-reactivity of the reduction materials are commonly acknowledged to affect strongly the productivity and consumption figures of the silicon process. Based on data from thermogravimetric experiments with chemical reaction between carbonaceous spheres and SiO-gas, kinetic parameters have been estimated from the shrinking core model for some selected reduction materials of various sizes and spanning a wide range of SiO-reactivity figures. This model describes the degree of conversion versus time for a single sphere where the chemical reaction progresses in a topochemical manner from the outer surface of the solid towards the centre forming a porous product layer around an unreacted shrinking core. This behaviour is for the selected reduction materials to a large extent supported by an investigation of cross section pictures of fully and 50% converted spheres obtained with a microprobe. The estimated kinetic parameters obtained from the

  10. Low cost solar aray project: Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

    Science.gov (United States)

    1981-01-01

    This phase consists of the engineering design, fabrication, assembly, operation, economic analysis, and process support R&D for an Experimental Process System Development Unit (EPSDU). The mechanical bid package was issued and the bid responses are under evaluation. Similarly, the electrical bid package was issued, however, responses are not yet due. The majority of all equipment is on order or has been received at the EPSDU site. The pyrolysis/consolidation process design package was issued. Preparation of process and instrumentation diagram for the free-space reactor was started. In the area of melting/consolidation, Kayex successfully melted chunk silicon and have produced silicon shot. The free-space reactor powder was successfully transported pneumatically from a storage bin to the auger feeder twenty-five feet up and was melted. The fluid-bed PDU has successfully operated at silane feed concentrations up to 21%. The writing of the operating manual has started. Overall, the design phase is nearing completion.

  11. Fundamental Theories and Key Technologies for Smart and Optimal Manufacturing in the Process Industry

    Directory of Open Access Journals (Sweden)

    Feng Qian

    2017-04-01

    Full Text Available Given the significant requirements for transforming and promoting the process industry, we present the major limitations of current petrochemical enterprises, including limitations in decision-making, production operation, efficiency and security, information integration, and so forth. To promote a vision of the process industry with efficient, green, and smart production, modern information technology should be utilized throughout the entire optimization process for production, management, and marketing. To focus on smart equipment in manufacturing processes, as well as on the adaptive intelligent optimization of the manufacturing process, operating mode, and supply chain management, we put forward several key scientific problems in engineering in a demand-driven and application-oriented manner, namely: ① intelligent sensing and integration of all process information, including production and management information; ② collaborative decision-making in the supply chain, industry chain, and value chain, driven by knowledge; ③ cooperative control and optimization of plant-wide production processes via human-cyber-physical interaction; and ④ life-cycle assessments for safety and environmental footprint monitoring, in addition to tracing analysis and risk control. In order to solve these limitations and core scientific problems, we further present fundamental theories and key technologies for smart and optimal manufacturing in the process industry. Although this paper discusses the process industry in China, the conclusions in this paper can be extended to the process industry around the world.

  12. Structural and morphological approach of Co-Cr dental alloys processed by alternative manufacturing technologies

    Science.gov (United States)

    Porojan, Sorin; Bîrdeanu, Mihaela; Savencu, Cristina; Porojan, Liliana

    2017-08-01

    The integration of digitalized processing technologies in traditional dental restorations manufacturing is an emerging application. The objective of this study was to identify the different structural and morphological characteristics of Co-Cr dental alloys processed by alternative manufacturing techniques in order to understand the influence of microstructure on restorations properties and their clinical behavior. Metallic specimens made of Co-Cr dental alloys were prepared using traditional casting (CST), and computerized milling (MIL), selective laser sintering (SLS) and selective laser melting (SLM). The structural information of the samples was obtained by X-ray diffraction, the morphology and the topography of the samples were investigated by Scanning Electron Microscopy and Atomic Force Microscope. Given that the microstructure was significantly different, further differences in the clinical behavior of prosthetic restorations manufactured using additive techniques are anticipated.

  13. A method for energy optimization and product quality improvement in manufacturing processes

    Energy Technology Data Exchange (ETDEWEB)

    Abou Khalil, Bachir; Berthou, Marc; Perrotin, Thomas [EDF R and D Les Renardieres Departement Eco-efficacite et Procedes Industriels (France); Clodic, Denis [Ecole des Mines de Paris, Centre Energetique et Procedes (France)

    2007-07-01

    Manufacturing processes are diverse by nature. Consequently, energy efficiency of each process requires a specific analysis leading to significant costs, SMEs (Small and Medium-sized-Enterprises) cannot always sustain such costs.The present paper introduces a method for Energy Optimisation of manufacturing processes and product quality improvement during manufacturing. This innovative method is based on a 4-step analysis that allows to rapidly identifying the potential energy savings in industrial processes. The 4-step method consists in: (1) the process definition, (2) the analysis of the detailed synopsis of production lines (considering energy and mass fluxes), (3) the analysis of energy consumptions and production volumes, and (4) energy efficiency assessment by identification of energy savings and technical option proposals.The first step is based on the preliminary expertise of the considered process. Process efficiency is analysed based on the theoretical minimum energy requirement, leading to the identification of the best available technologies (BATs) for the considered process, and the optimal energy efficiency. For the second and third steps, specific data of the process are collected. The process energy consumption and the production information are obtained from the production manager. When needed, measurements could be performed to complete the energy and mass balances. The actual energy efficiency of the manufacturing process is then calculated.The fourth step consists in the comparison of the different energy ratios. Based on these ratios and on the knowledge of the actual process, energy savings are evaluated, technical solutions for energy efficiency improvement are proposed and first economic analysis is carried out.

  14. Processing, physico-chemical characterisation and in vitro evaluation of silicon containing {beta}-tricalcium phosphate ceramics

    Energy Technology Data Exchange (ETDEWEB)

    Douard, N. [Universite de Limoges, CNRS, ENSCI, SPCTS, UMR 6638, 123 Avenue Albert Thomas, 87060 Limoges Cedex (France); Detsch, R. [BioCer Entwicklungs-GmbH, Ludwig-Thoma-Strasse 36c, 95447 Bayreuth (Germany); Chotard-Ghodsnia, R.; Damia, C. [Universite de Limoges, CNRS, ENSCI, SPCTS, UMR 6638, 123 Avenue Albert Thomas, 87060 Limoges Cedex (France); Deisinger, U. [Friedrich-Baur-Research Institute for Biomaterials, University of Bayreuth, Universitaetsstr. 30, 95440 Bayreuth (Germany); Champion, E., E-mail: eric.champion@unilim.fr [Universite de Limoges, CNRS, ENSCI, SPCTS, UMR 6638, 123 Avenue Albert Thomas, 87060 Limoges Cedex (France)

    2011-04-08

    For bone grafting applications, the elaboration of silicon containing beta-tricalcium phosphate ({beta}-TCP) was studied. The synthesis was performed using a wet precipitation method according to the hypothetical theoretical formula Ca{sub 3-x}(PO{sub 4}){sub 2-2x}(SiO{sub 4}){sub x}. Two silicon loaded materials (0.46 wt.% and 0.95 wt.%) were investigated and compared to a pure {beta}-TCP. The maturation time of the synthesis required in order to obtain {beta}-TCP decreased with the amount of silicon. Only restrictive synthesis conditions allow preparing silicon containing {beta}-TCP with controlled composition. To obtain dense ceramics, the sintering behaviour of the powders was evaluated. The addition of silicon slowed the densification process and decreased the grain size of the dense ceramics. Rietveld refinement may indicate a partial incorporation of silicon in the {beta}-TCP lattice. X-ray photoelectron spectroscopy and transmission electron microscopy analyses revealed that the remaining silicon formed amorphous clusters of silicon rich phase. The in vitro biological behaviour was investigated with MC3T3-E1 osteoblast-like cells. After the addition of silicon, the ceramics remained cytocompatible, highlighting the high potential of silicon containing {beta}-TCP as optimised bone graft material.

  15. Physical evaluations of Co-Cr-Mo parts processed using different additive manufacturing techniques

    Science.gov (United States)

    Ghani, Saiful Anwar Che; Mohamed, Siti Rohaida; Harun, Wan Sharuzi Wan; Noar, Nor Aida Zuraimi Md

    2017-12-01

    In recent years, additive manufacturing with highly design customization has gained an important technique for fabrication in aerospace and medical fields. Despite the ability of the process to produce complex components with highly controlled architecture geometrical features, maintaining the part's accuracy, ability to fabricate fully functional high density components and inferior surfaces quality are the major obstacles in producing final parts using additive manufacturing for any selected application. This study aims to evaluate the physical properties of cobalt chrome molybdenum (Co-Cr-Mo) alloys parts fabricated by different additive manufacturing techniques. The full dense Co-Cr-Mo parts were produced by Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS) with default process parameters. The density and relative density of samples were calculated using Archimedes' principle while the surface roughness on the top and side surface was measured using surface profiler. The roughness average (Ra) for top surface for SLM produced parts is 3.4 µm while 2.83 µm for DMLS produced parts. The Ra for side surfaces for SLM produced parts is 4.57 µm while 9.0 µm for DMLS produced parts. The higher Ra values on side surfaces compared to the top faces for both manufacturing techniques was due to the balling effect phenomenon. The yield relative density for both Co-Cr-Mo parts produced by SLM and DMLS are 99.3%. Higher energy density has influence the higher density of produced samples by SLM and DMLS processes. The findings of this work demonstrated that SLM and DMLS process with default process parameters have effectively produced full dense parts of Co-Cr-Mo with high density, good agreement of geometrical accuracy and better surface finish. Despite of both manufacturing process yield that produced components with higher density, the current finding shows that SLM technique could produce components with smoother surface quality compared to DMLS

  16. Simulation based energy-resource efficient manufacturing integrated with in-process virtual management

    Science.gov (United States)

    Katchasuwanmanee, Kanet; Cheng, Kai; Bateman, Richard

    2016-09-01

    As energy efficiency is one of the key essentials towards sustainability, the development of an energy-resource efficient manufacturing system is among the great challenges facing the current industry. Meanwhile, the availability of advanced technological innovation has created more complex manufacturing systems that involve a large variety of processes and machines serving different functions. To extend the limited knowledge on energy-efficient scheduling, the research presented in this paper attempts to model the production schedule at an operation process by considering the balance of energy consumption reduction in production, production work flow (productivity) and quality. An innovative systematic approach to manufacturing energy-resource efficiency is proposed with the virtual simulation as a predictive modelling enabler, which provides real-time manufacturing monitoring, virtual displays and decision-makings and consequentially an analytical and multidimensional correlation analysis on interdependent relationships among energy consumption, work flow and quality errors. The regression analysis results demonstrate positive relationships between the work flow and quality errors and the work flow and energy consumption. When production scheduling is controlled through optimization of work flow, quality errors and overall energy consumption, the energy-resource efficiency can be achieved in the production. Together, this proposed multidimensional modelling and analysis approach provides optimal conditions for the production scheduling at the manufacturing system by taking account of production quality, energy consumption and resource efficiency, which can lead to the key competitive advantages and sustainability of the system operations in the industry.

  17. An amorphous silicon photodiode with 2 THz gain-bandwidth product based on cycling excitation process

    Science.gov (United States)

    Yan, Lujiang; Yu, Yugang; Zhang, Alex Ce; Hall, David; Niaz, Iftikhar Ahmad; Raihan Miah, Mohammad Abu; Liu, Yu-Hsin; Lo, Yu-Hwa

    2017-09-01

    Since impact ionization was observed in semiconductors over half a century ago, avalanche photodiodes (APDs) using impact ionization in a fashion of chain reaction have been the most sensitive semiconductor photodetectors. However, APDs have relatively high excess noise, a limited gain-bandwidth product, and high operation voltage, presenting a need for alternative signal amplification mechanisms of superior properties. As an amplification mechanism, the cycling excitation process (CEP) was recently reported in a silicon p-n junction with subtle control and balance of the impurity levels and profiles. Realizing that CEP effect depends on Auger excitation involving localized states, we made the counter intuitive hypothesis that disordered materials, such as amorphous silicon, with their abundant localized states, can produce strong CEP effects with high gain and speed at low noise, despite their extremely low mobility and large number of defects. Here, we demonstrate an amorphous silicon low noise photodiode with gain-bandwidth product of over 2 THz, based on a very simple structure. This work will impact a wide range of applications involving optical detection because amorphous silicon, as the primary gain medium, is a low-cost, easy-to-process material that can be formed on many kinds of rigid or flexible substrates.

  18. Process Control and Development for Ultrasonic Additive Manufacturing with Embedded Fibers

    Science.gov (United States)

    Hehr, Adam J.

    Ultrasonic additive manufacturing (UAM) is a recent additive manufacturing technology which combines ultrasonic metal welding, CNC machining, and mechanized foil layering to create large gapless near net-shape metallic parts. The process has been attracting much attention lately due to its low formation temperature, the capability to join dissimilar metals, and the ability to create complex design features not possible with traditional subtractive processes alone. These process attributes enable light-weighting of structures and components in an unprecedented way. However, UAM is currently limited to niche areas due to the lack of quality tracking and inadequate scientific understanding of the process. As a result, this thesis work is focused on improving both component quality tracking and process understanding through the use of average electrical power input to the welder. Additionally, the understanding and application space of embedding fibers into metals using UAM is investigated, with particular focus on NiTi shape memory alloy fibers.

  19. New insights into the effects of silicon content on the oxidation process in silicon-containing steels

    Science.gov (United States)

    Yuan, Qing; Xu, Guang; Zhou, Ming-xing; He, Bei

    2016-09-01

    Simultaneous thermal analysis (STA) was used to investigate the effects of silicon content on the oxidation kinetics of silicon- containing steels under an atmosphere and heating procedures similar to those used in industrial reheating furnaces for the production of hot-rolled strips. Our results show that when the heating temperature was greater than the melting point of Fe2SiO4, the oxidation rates of steels with different silicon contents were the same; the total mass gain decreased with increasing silicon content, whereas it increased with increasing oxygen content. The oxidation rates for steels with different silicon contents were constant with respect to time under isothermal conditions. In addition, the starting oxidation temperature, the intense oxidation temperature, and the finishing oxidation temperature increased with increasing silicon content; the intense oxidation temperature had no correlation with the melting of Fe2SiO4. Moreover, the silicon distributed in two forms: as Fe2SiO4 at the interface between the innermost layer of oxide scale and the iron matrix, and as particles containing silicon in grains and grain boundaries in the iron matrix.

  20. Development of an In-Line Minority-Carrier Lifetime Monitoring Tool for Process Control during Fabrication of Crystalline Silicon Solar Cells: Annual Subcontract Report, June 2003 (Revised)

    Energy Technology Data Exchange (ETDEWEB)

    Sinton, R. A.

    2004-04-01

    Under the PV Manufacturing R&D subcontract''Development of an In-Line, Minority-Carrier Lifetime Monitoring Tool for Process Control during Fabrication of Crystalline Silicon Solar Cells'', Sinton Consulting developed prototypes for several new instruments for use in the manufacture of silicon solar cells. These instruments are based on two families of R&D instruments that were previously available, an illumination vs. open-circuit-voltage technique and the quasi-steady state RF photoconductance technique for measuring minority-carrier lifetime. Compared to the previous instruments, the new prototypes are about 20 times faster per measurement, and have automated data analysis that does not require user intervention even when confronted by challenging cases. For example, un-passivated multi-crystalline wafers with large variations in lifetime and trapping behavior can be measured sequentially without error. Five instruments have been prototyped in this project to date, including a block tester for evaluating cast or HEM silicon blocks, a CZ ingot tester, an FZ boule tester for use with long-lifetime silicon, and an in-line sample head for measuring wafers. The CZ ingot tester and the FZ boule tester are already being used within industry and there is interest in the other prototypes. For each instrument, substantial R&D work was required in developing the device physics and analysis as well as for the hardware. This work has been documented in a series of application notes and conference publications, and will result in significant improvements for both the R&D and the industrial types of instruments.

  1. Media milling process optimization for manufacture of drug nanoparticles using design of experiments (DOE).

    Science.gov (United States)

    Nekkanti, Vijaykumar; Marwah, Ashwani; Pillai, Raviraj

    2015-01-01

    Design of experiments (DOE), a component of Quality by Design (QbD), is systematic and simultaneous evaluation of process variables to develop a product with predetermined quality attributes. This article presents a case study to understand the effects of process variables in a bead milling process used for manufacture of drug nanoparticles. Experiments were designed and results were computed according to a 3-factor, 3-level face-centered central composite design (CCD). The factors investigated were motor speed, pump speed and bead volume. Responses analyzed for evaluating these effects and interactions were milling time, particle size and process yield. Process validation batches were executed using the optimum process conditions obtained from software Design-Expert® to evaluate both the repeatability and reproducibility of bead milling technique. Milling time was optimized to <5 h to obtain the desired particle size (d90 < 400 nm). The desirability function used to optimize the response variables and observed responses were in agreement with experimental values. These results demonstrated the reliability of selected model for manufacture of drug nanoparticles with predictable quality attributes. The optimization of bead milling process variables by applying DOE resulted in considerable decrease in milling time to achieve the desired particle size. The study indicates the applicability of DOE approach to optimize critical process parameters in the manufacture of drug nanoparticles.

  2. Interrelation of chemistry and process design in biodiesel manufacturing by heterogeneous catalysis

    NARCIS (Netherlands)

    Dimian, A.C.; Srokol, Z.W.; Mittelmeijer-Hazeleger, M.C.; Rothenberg, G.

    2010-01-01

    The pros and cons of using heterogeneous catalysis for biodiesel manufacturing are introduced, and explained from a chemistry and engineering viewpoint. Transesterification reactions of various feed types are then compared in batch and continuous process operation modes. The results show that the

  3. Decision-making of selectable process plans based on petri net with manufacturing constraints

    DEFF Research Database (Denmark)

    Xiao, Weiyue; Jones, Richard William; Yu, Fei

    2016-01-01

    Intelligent Computer-Aided process planning and decision making for manufacturing systems is a critical subject, that some might argue, has not received the attention it should have from the research community. Despite the progress made in the area of artificial intelligence, there has not been a...

  4. Nanomanufacturing Portfolio: Manufacturing Processes and Applications to Accelerate Commercial Use of Nanomaterials

    Energy Technology Data Exchange (ETDEWEB)

    Industrial Technologies Program

    2011-01-05

    This brochure describes the 31 R&D projects that AMO supports to accelerate the commercial manufacture and use of nanomaterials for enhanced energy efficiency. These cost-shared projects seek to exploit the unique properties of nanomaterials to improve the functionality of industrial processes and products.

  5. Economic trade-offs of additive manufacturing integration in injection moulding process chain

    DEFF Research Database (Denmark)

    Charalambis, Alessandro; Kerbache, Laoucine; Tosello, Guido

    2017-01-01

    additive manufacturing is used to support the fabrication of mould inserts for the product development phase of the injection moulding process chain. This study shows that fabrication of soft tooling by mean of AM is economically convenient with a cost reduction between 80% and 90%. Break-even points...

  6. 27 CFR 19.57 - Recovery and reuse of denatured spirits in manufacturing processes.

    Science.gov (United States)

    2010-04-01

    ... denatured spirits in manufacturing processes. 19.57 Section 19.57 Alcohol, Tobacco Products and Firearms ALCOHOL AND TOBACCO TAX AND TRADE BUREAU, DEPARTMENT OF THE TREASURY LIQUORS DISTILLED SPIRITS PLANTS Administrative and Miscellaneous Provisions Activities Not Subject to This Part § 19.57 Recovery and reuse of...

  7. Apparatus and method for converting biomass to feedstock for biofuel and biochemical manufacturing processes

    Science.gov (United States)

    Kania, John; Qiao, Ming; Woods, Elizabeth M.; Cortright, Randy D.; Myren, Paul

    2015-12-15

    The present invention includes improved systems and methods for producing biomass-derived feedstocks for biofuel and biochemical manufacturing processes. The systems and methods use components that are capable of transferring relatively high concentrations of solid biomass utilizing pressure variations between vessels, and allows for the recovery and recycling of heterogeneous catalyst materials.

  8. 77 FR 38083 - Certain Rubber Resins and Processes for Manufacturing Same Institution of Investigation Pursuant...

    Science.gov (United States)

    2012-06-26

    ... this notice of investigation shall be served: (a) The complainant is: SI Group, Inc., 2750 Balltown... COMMISSION Certain Rubber Resins and Processes for Manufacturing Same Institution of Investigation Pursuant..., under section 337 of the Tariff Act of 1930, as amended, 19 U.S.C. 1337, on behalf of SI Group, Inc. of...

  9. OPTIMIZATION OF THE TECHNOLOGICAL PROCESS FOR MANUFACTURING THE VALVE OF THE TAPS IN THE PETROLEUM INDUSTRY

    Directory of Open Access Journals (Sweden)

    EFTIMIE Dorin

    2012-11-01

    Full Text Available This paper presents the optimization of the technological process for a valve which is a subset of a tap from the oil industry, following the steps of CAD, finite element analysis, achieving digital manufacturing (CAM, and type implementation in machine tools CNC.

  10. Selection of Prediction Methods for Thermophysical Properties for Process Modeling and Product Design of Biodiesel Manufacturing

    DEFF Research Database (Denmark)

    Su, Yung-Chieh; Liu, Y. A.; Díaz Tovar, Carlos Axel

    2011-01-01

    To optimize biodiesel manufacturing, many reported studies have built simulation models to quantify the relationship between operating conditions and process performance. For mass and energy balance simulations, it is essential to know the four fundamental thermophysical properties of the feed oil...

  11. Biocompatibility of hydroxyapatite scaffolds processed by lithography-based additive manufacturing.

    Science.gov (United States)

    Tesavibul, Passakorn; Chantaweroad, Surapol; Laohaprapanon, Apinya; Channasanon, Somruethai; Uppanan, Paweena; Tanodekaew, Siriporn; Chalermkarnnon, Prasert; Sitthiseripratip, Kriskrai

    2015-01-01

    The fabrication of hydroxyapatite scaffolds for bone tissue engineering applications by using lithography-based additive manufacturing techniques has been introduced due to the abilities to control porous structures with suitable resolutions. In this research, the use of hydroxyapatite cellular structures, which are processed by lithography-based additive manufacturing machine, as a bone tissue engineering scaffold was investigated. The utilization of digital light processing system for additive manufacturing machine in laboratory scale was performed in order to fabricate the hydroxyapatite scaffold, of which biocompatibilities were eventually evaluated by direct contact and cell-culturing tests. In addition, the density and compressive strength of the scaffolds were also characterized. The results show that the hydroxyapatite scaffold at 77% of porosity with 91% of theoretical density and 0.36 MPa of the compressive strength are able to be processed. In comparison with a conventionally sintered hydroxyapatite, the scaffold did not present any cytotoxic signs while the viability of cells at 95.1% was reported. After 14 days of cell-culturing tests, the scaffold was able to be attached by pre-osteoblasts (MC3T3-E1) leading to cell proliferation and differentiation. The hydroxyapatite scaffold for bone tissue engineering was able to be processed by the lithography-based additive manufacturing machine while the biocompatibilities were also confirmed.

  12. Micro injection moulding process validation for high precision manufacture of thermoplastic elastomer micro suspension rings

    DEFF Research Database (Denmark)

    Calaon, M.; Tosello, G.; Elsborg Hansen, R.

    Micro injection moulding (μIM) is one of the most suitable micro manufacturing processes for flexible mass-production of multi-material functional micro components. The technology was employed in this research used to produce thermoplastic elastomer (TPE) micro suspension rings identified...

  13. Modeling printed circuit board curvature in relation to manufacturing process steps

    NARCIS (Netherlands)

    Schuerink, G.A.; Slomp, M.; Wits, Wessel Willems; Legtenberg, R.; Legtenberg, R.; Kappel, E.A.

    2013-01-01

    This paper presents an analytical method to predict deformations of Printed Circuit Boards (PCBs) in relation to their manufacturing process steps. Classical Lamination Theory (CLT) is used as a basis. The model tracks internal stresses and includes the results of subsequent production steps, such

  14. End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

    Directory of Open Access Journals (Sweden)

    Muhammed Nafis Osman Zahid

    2015-01-01

    Full Text Available Computer numerical controlled (CNC machining has been recognized as a manufacturing process that is capable of producing metal parts with high precision and reliable quality, whereas many additive manufacturing methods are less capable in these respects. The introduction of a new layer-removal methodology that utilizes an indexing device to clamp the workpiece can be used to extend CNC applications into the realm of rapid manufacturing (CNC-RM processes. This study aims to improve the implementation of CNC machining for RM by formulating a distinct approach to integrate end mill tools during finishing processes. A main objective is to enhance process efficiency by minimizing the staircasing effect of layer removal so as to improve the quality of machined parts. In order to achieve this, different types of end mill tools are introduced to cater for specific part surfaces during finishing operations. Virtual machining simulations are executed to verify the method and the implications. The findings indicate the advantages of the approach in terms of cutting time and excess volume left on the parts. It is shown that using different tools for finishing operations will improve the capabilities of CNC machining for rapid manufacturing applications.

  15. 78 FR 79006 - Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain...

    Science.gov (United States)

    2013-12-27

    ... COMMISSION Certain Paper Shredders, Certain Processes for Manufacturing or Relating to Same and Certain... Determination Terminating the Investigation Based on a Settlement Agreement, Consent Order, and Withdrawal of... consent order, and the withdrawal of the complaint. FOR FURTHER INFORMATION CONTACT: Robert Needham...

  16. Unveiling the fungal mycobiota present throughout the cork stopper manufacturing process

    NARCIS (Netherlands)

    Barreto, M.C.; Houbraken, J.; Samson, R.A.; Brito, D.; Gadanho, M.; San Romão, M.V.

    2012-01-01

    A particular fungal population is present in the main stages of the manufacturing process of cork discs. Its diversity was studied using both dependent (isolation) and independent culture methods (denaturing gel gradient electrophoresis and cloning of the ITS1-5.8S-ITS2 region). The mycobiota in the

  17. 78 FR 56734 - Certain Rubber Resins and Processes for Manufacturing Same; Commission Determination To Review...

    Science.gov (United States)

    2013-09-13

    ... COMMISSION Certain Rubber Resins and Processes for Manufacturing Same; Commission Determination To Review the Final Initial Determination of the Administrative Law Judge; Schedule for Filing Written Submissions on... presiding administrative law judge issued his final ID, finding a violation of Section 337. On July 1, 2013...

  18. 16 CFR 303.33 - Country where textile fiber products are processed or manufactured.

    Science.gov (United States)

    2010-01-01

    ... 16 Commercial Practices 1 2010-01-01 2010-01-01 false Country where textile fiber products are... UNDER SPECIFIC ACTS OF CONGRESS RULES AND REGULATIONS UNDER THE TEXTILE FIBER PRODUCTS IDENTIFICATION ACT § 303.33 Country where textile fiber products are processed or manufactured. (a) In addition to...

  19. General Tips Concerning What Has Been Learned About Cotton Processing in Traditional Textile Manufacturing

    Science.gov (United States)

    This article, under the following sub-headings, briefly describes a few important practical tips involving processing of cotton in traditional textile manufacturing: (1)Bale Selection and Fiber Mixing, (2) Fiber Opening and Cleaning, (3) Carding, (4) Drawing, (5) Combing (if necessary), (6) Roving, ...

  20. General Tips of What Little This Author has Learned of Cotton Processing in Traditional Textile Manufacturing

    Science.gov (United States)

    This article, under the following sub-headings, only lists a few very important tips that the author has experienced in his career involving processing of cotton in the traditional textile manufacturing: (1) Fiber Opening and Cleaning (2) Carding (3) Drawing (4) Combing, if necessary (5) Roving (6)...

  1. Influence of process and system parameters on the local oxidation of alkyl-terminated silicon

    Energy Technology Data Exchange (ETDEWEB)

    Baumgaertel, Thomas; Graaf, Harald; Borczyskowski, Christian von [Center for Nanostructured Materials and Analytics, Institut fuer Physik, TU Chemnitz, 09107 Chemnitz (Germany)

    2011-07-01

    The local anodic oxidation (LAO) of silicon substrates by an atomic force microscope (AFM) is an electrochemical process which is influenced by multiple parameters. These can be divided into two major groups: system parameters and process parameters. Process parameters such as oxidation voltage, duration and ambient humidity can be tuned over a wide range of values during the experiment. System parameters on the other hand depend on equipment and materials themselves and are only difficult to control e.g. AFM tip shape, substrate conductivity and surface hydrophobicity. We investigated the influence of these parameters on the LAO process of silicon which is passivated by a self-assembled alkyl monolayer. Such monolayers are not only characterized by high molecular order and an excellent physical and chemical stability but offer also a neat way to tune the surface properties by variation of the head groups of the alkenes. A detailed understanding of the dependencies of the LAO process is essential for the controlled generation of silicon oxide nanostructures which can be used to build up functional nanostructures by a combined bottom-up (anchoring of functional molecules) and top-down (AFM LAO lithography) approach.

  2. Assuring process safety in the transfer of hydrogen cyanide manufacturing technology.

    Science.gov (United States)

    Maxwell, Gary R; Edwards, Victor H; Robertson, Mark; Shah, Kamal

    2007-04-11

    This paper outlines the critical issues to be addressed in the transfer of hydrogen cyanide (HCN) manufacturing technology to a licensee. Process safety management (PSM) is of critical importance because of the toxicity, flammability and reactivity of HCN. The critical issues are based on experience that DuPont has gained (1) while safely manufacturing hydrogen cyanide for over 50 years, and (2) while DuPont has safely licensed HCN technology to other firms at locations around the world. DuPont's HCN experience has been combined with Aker Kvaerner's project engineering experience to insure the safe transfer of HCN technology to a licensee.

  3. Advanced Process Chains for Prototyping and Pilot Production based on Additive Manufacturing

    DEFF Research Database (Denmark)

    Mischkot, Michael

    2015-01-01

    For many years, Additive Manufacturing (AM) has been a well-established production technology used mainly for rapid prototyping. But the need for increased flexibility and economic low volume production led to the discovery of Additive Manufacturing as a suitable fabrication technique (Mellor 2013...... and better parts functionality (Ponche 2014). Also, the use of AM ma-chines for spare parts can potentially reduce costs and downtime, and lead to a higher robustness to supply chain disruptions (Khajavi 2013). Control and optimization of the involved process chains are crucial for a fast and robust...... implementation of AM technology in the industrial world....

  4. Process and Mechanical Properties: Applicability of a Scandium modified Al-alloy for Laser Additive Manufacturing

    Science.gov (United States)

    Schmidtke, K.; Palm, F.; Hawkins, A.; Emmelmann, C.

    The applicability of an aluminium alloy containing scandium for laser additive manufacturing (LAM) is considered. Modified aluminium alloys with a scandium content beyond the eutectic point offer great potential to become a high prioritized aerospace material. Depending on other alloying elements like magnesium or zirconium, strongly required weight reduction, corrosion resistance and improved strength properties of metallic light weight alloys can be achieved. The development, production and testing of parts built up by a laser powder bed process will be presented with regard to the qualification of the new material concept "ScalmalloyRP®" for laser additive manufacturing.

  5. Wavelength dependence of silicon avalanche photodiode fabricated by CMOS process

    Science.gov (United States)

    Mohammed Napiah, Zul Atfyi Fauzan; Hishiki, Takuya; Iiyama, Koichi

    2017-07-01

    Avalanche photodiodes fabricated by CMOS process (CMOS-APDs) have features of high avalanche gain below 10 V, wide bandwidth over 5 GHz, and easy integration with electronic circuits. In CMOS-APDs, guard ring structure is introduced for high-speed operation by canceling photo-generated carriers in the substrate at the sacrifice of the responsivity. We describe here wavelength dependence of the responsivity and the bandwidth of the CMOS-APDs with shorted and opened guard ring structure.

  6. DEVELOPMENT OF LOW-COST MANUFACTURING PROCESSES FOR PLANAR, MULTILAYER SOLID OXIDE FUEL CELL ELEMENTS

    Energy Technology Data Exchange (ETDEWEB)

    Scott Swartz; Matthew Seabaugh; William Dawson; Harlan Anderson; Tim Armstrong; Michael Cobb; Kirby Meacham; James Stephan; Russell Bennett; Bob Remick; Chuck Sishtla; Scott Barnett; John Lannutti

    2004-06-12

    This report summarizes the results of a four-year project, entitled, ''Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells'', jointly funded by the U.S. Department of Energy, the State of Ohio, and by project participants. The project was led by NexTech Materials, Ltd., with subcontracting support provided by University of Missouri-Rolla, Michael A. Cobb & Co., Advanced Materials Technologies, Inc., Edison Materials Technology Center, Gas Technology Institute, Northwestern University, and The Ohio State University. Oak Ridge National Laboratory, though not formally a subcontractor on the program, supported the effort with separate DOE funding. The objective of the program was to develop advanced manufacturing technologies for making solid oxide fuel cell components that are more economical and reliable for a variety of applications. The program was carried out in three phases. In the Phase I effort, several manufacturing approaches were considered and subjected to detailed assessments of manufacturability and development risk. Estimated manufacturing costs for 5-kW stacks were in the range of $139/kW to $179/kW. The risk assessment identified a number of technical issues that would need to be considered during development. Phase II development work focused on development of planar solid oxide fuel cell elements, using a number of ceramic manufacturing methods, including tape casting, colloidal-spray deposition, screen printing, spin-coating, and sintering. Several processes were successfully established for fabrication of anode-supported, thin-film electrolyte cells, with performance levels at or near the state-of-the-art. The work in Phase III involved scale-up of cell manufacturing methods, development of non-destructive evaluation methods, and comprehensive electrical and electrochemical testing of solid oxide fuel cell materials and components.

  7. How Does the Recruitment Process Affect Attitudes of Incoming Employees?Quantitative Analysis of Data from a Large Manufacturing Company

    National Research Council Canada - National Science Library

    林, 祐司

    2009-01-01

    Based on data from a large-scale manufacturing company in Japan, this study quantitatively analyzed the relationship between the recruitment process for prospective graduates and attitude formation...

  8. Comparative Analysis of the Principal Characteristics of Microsilica Obtained from Silicon Manufacture Wastes and Used in Concrete Production Technologies

    Science.gov (United States)

    Balabanov, V. B.; Putsenko, K. N.

    2017-11-01

    On the basis of the survey of foreign and domestic literature over the past 65 years devoted to the study of the properties and the technology of applying microsilica in the capacity of modifying additives to concretes. Microsilica obtained as a by-product from the waste of ferroalloy plants and from the plants involved in production of silicon compounds is discussed. Analysis of the principal characteristics of different types of microsilica obtained from different sources is conducted.

  9. Hot Isostatic Press Manufacturing Process Development for Fabrication of RERTR Monolithic Fuel Plates

    Energy Technology Data Exchange (ETDEWEB)

    Crapps, Justin M. [Los Alamos National Laboratory; Clarke, Kester D. [Los Alamos National Laboratory; Katz, Joel D. [Los Alamos National Laboratory; Alexander, David J. [Los Alamos National Laboratory; Aikin, Beverly [Los Alamos National Laboratory; Vargas, Victor D. [Los Alamos National Laboratory; Montalvo, Joel D. [Los Alamos National Laboratory; Dombrowski, David E. [Los Alamos National Laboratory; Mihaila, Bogdan [Los Alamos National Laboratory

    2012-06-06

    We use experimentation and finite element modeling to study a Hot Isostatic Press (HIP) manufacturing process for U-10Mo Monolithic Fuel Plates. Finite element simulations are used to identify the material properties affecting the process and improve the process geometry. Accounting for the high temperature material properties and plasticity is important to obtain qualitative agreement between model and experimental results. The model allows us to improve the process geometry and provide guidance on selection of material and finish conditions for the process strongbacks. We conclude that the HIP can must be fully filled to provide uniform normal stress across the bonding interface.

  10. Conventional and Innovative Processing of Milk for Yogurt Manufacture; Development of Texture and Flavor: A Review

    Directory of Open Access Journals (Sweden)

    Panagiotis Sfakianakis

    2014-03-01

    Full Text Available Milk and yogurt are important elements of the human diet, due to their high nutritional value and their appealing sensory properties. During milk processing (homogenization, pasteurization and further yogurt manufacture (fermentation physicochemical changes occur that affect the flavor and texture of these products while the development of standardized processes contributes to the development of desirable textural and flavor characteristics. The processes that take place during milk processing and yogurt manufacture with conventional industrial methods, as well as with innovative methods currently proposed (ultra-high pressure, ultrasound, microfluidization, pulsed electric fields, and their effect on the texture and flavor of the final conventional or probiotic/prebiotic products will be presented in this review.

  11. Conventional and Innovative Processing of Milk for Yogurt Manufacture; Development of Texture and Flavor: A Review.

    Science.gov (United States)

    Sfakianakis, Panagiotis; Tzia, Constatnina

    2014-03-11

    Milk and yogurt are important elements of the human diet, due to their high nutritional value and their appealing sensory properties. During milk processing (homogenization, pasteurization) and further yogurt manufacture (fermentation) physicochemical changes occur that affect the flavor and texture of these products while the development of standardized processes contributes to the development of desirable textural and flavor characteristics. The processes that take place during milk processing and yogurt manufacture with conventional industrial methods, as well as with innovative methods currently proposed (ultra-high pressure, ultrasound, microfluidization, pulsed electric fields), and their effect on the texture and flavor of the final conventional or probiotic/prebiotic products will be presented in this review.

  12. Media fill for validation of a good manufacturing practice-compliant cell production process.

    Science.gov (United States)

    Serra, Marta; Roseti, Livia; Bassi, Alessandra

    2015-01-01

    According to the European Regulation EC 1394/2007, the clinical use of Advanced Therapy Medicinal Products, such as Human Bone Marrow Mesenchymal Stem Cells expanded for the regeneration of bone tissue or Chondrocytes for Autologous Implantation, requires the development of a process in compliance with the Good Manufacturing Practices. The Media Fill test, consisting of a simulation of the expansion process by using a microbial growth medium instead of the cells, is considered one of the most effective ways to validate a cell production process. Such simulation, in fact, allows to identify any weakness in production that can lead to microbiological contamination of the final cell product as well as qualifying operators. Here, we report the critical aspects concerning the design of a Media Fill test to be used as a tool for the further validation of the sterility of a cell-based Good Manufacturing Practice-compliant production process.

  13. Numerical and experimental analyses of resin infusion manufacturing processes of composite materials

    CERN Document Server

    Wang, Peng; Molimard, Jérôme; Vautrin, Alain; Minni, Jean-Christophe; 10.1177/0021998311421990

    2012-01-01

    Liquid resin infusion (LRI) processes are promising manufacturing routes to produce large, thick, or complex structural parts. They are based on the resin flow induced, across its thickness, by a pressure applied onto a preform/resin stacking. However, both thickness and fiber volume fraction of the final piece are not well controlled since they result from complex mechanisms which drive the transient mechanical equilibrium leading to the final geometrical configuration. In order to optimize both design and manufacturing parameters, but also to monitor the LRI process, an isothermal numerical model has been developed which describes the mechanical interaction between the deformations of the porous medium and the resin flow during infusion.1, 2 With this numerical model, it is possible to investigate the LRI process of classical industrial part shapes. To validate the numerical model, first in 2D, and to improve the knowledge of the LRI process, this study details a comparison between numerical simulations and...

  14. Conventional and Innovative Processing of Milk for Yogurt Manufacture; Development of Texture and Flavor: A Review

    Science.gov (United States)

    Sfakianakis, Panagiotis; Tzia, Constatnina

    2014-01-01

    Milk and yogurt are important elements of the human diet, due to their high nutritional value and their appealing sensory properties. During milk processing (homogenization, pasteurization) and further yogurt manufacture (fermentation) physicochemical changes occur that affect the flavor and texture of these products while the development of standardized processes contributes to the development of desirable textural and flavor characteristics. The processes that take place during milk processing and yogurt manufacture with conventional industrial methods, as well as with innovative methods currently proposed (ultra-high pressure, ultrasound, microfluidization, pulsed electric fields), and their effect on the texture and flavor of the final conventional or probiotic/prebiotic products will be presented in this review. PMID:28234312

  15. Choosing optimal rapid manufacturing process for thin-walled products using expert algorithm

    Directory of Open Access Journals (Sweden)

    Filip Gorski

    2010-10-01

    Full Text Available Choosing right Rapid Prototyping technology is not easy, especially for companies inexperienced with that group of manufacturing techniques. Paper summarizes research focused on creating an algorithm for expert system, helping to choose optimal process and determine its parameters for thin-walled products rapid manufacturing. Research was based upon trial manufacturing of different thin-walled items using various RP technologies. Products were categorized, each category was defined by a set of requirements. Basing on research outcome, main algorithm has been created. Next step was developing detailed algorithms for optimizing particular methods. Implementation of these algorithms brings huge benefit for recipients, including cost reduction, supply time decrease and improvements in information flow.

  16. Processing of silicon nitride and alumina nanosize powders

    Energy Technology Data Exchange (ETDEWEB)

    Gonzalez, E.J.; Piermarini, G.; Hockey, B.; Malghan, S.G. [National Inst. of Standard and Technology, Gaithersburg, MD (United States)

    1995-08-01

    The effects of pressure on the compaction and subsequent processing of nanosize {gamma} alumina powders were studied. A 3 mm diameter piston/cylinder die was used to compact the nanosize powders to pressures of 1 and 2.5 GPa. The green bodies were sintered at temperatures up to 1600{degrees}C. Results show that green body density can be increased by higher compaction pressures. It appears that as a result of the {gamma}-to-{alpha} transformation in alumina, higher green density does not necessarily produce a higher density sintered alumina body. The microstructures of the sintered bodies are described in terms of porosity and phase content.

  17. Simple processing of back-contacted silicon heterojunction solar cells using selective-area crystalline growth

    KAUST Repository

    Tomasi, Andrea

    2017-04-24

    For crystalline-silicon solar cells, voltages close to the theoretical limit are nowadays readily achievable when using passivating contacts. Conversely, maximal current generation requires the integration of the electron and hole contacts at the back of the solar cell to liberate its front from any shadowing loss. Recently, the world-record efficiency for crystalline-silicon single-junction solar cells was achieved by merging these two approaches in a single device; however, the complexity of fabricating this class of devices raises concerns about their commercial potential. Here we show a contacting method that substantially simplifies the architecture and fabrication of back-contacted silicon solar cells. We exploit the surface-dependent growth of silicon thin films, deposited by plasma processes, to eliminate the patterning of one of the doped carrier-collecting layers. Then, using only one alignment step for electrode definition, we fabricate a proof-of-concept 9-cm2 tunnel-interdigitated back-contact solar cell with a certified conversion efficiency >22.5%.

  18. LONGEVITY IMPROVEMENT OF DRIVE TOOTHED BELTS USING METHOD FOR OPTIMIZATION OF TECHNOLOGICAL MANUFACTURING PROCESS PARAMETERS

    Directory of Open Access Journals (Sweden)

    A. G. Bakhanovich

    2006-01-01

    Full Text Available Impact of technological process parameters (pressing pressure, duration and vulcanization temperature on drive toothed belt longevity has been investigated. Optimum parameters of the technological process that permit to improve a belt resource have been determined. Methodology for determination of a number of cycles intended for loading of belt teeth according to a test duration and transmission parameters has been developed. The paper presents results of industrial resource tests of drive toothed belts manufactured in accordance with an optimized technology

  19. Characterization of high-pressure RTM processes for manufacturing of high performance composites

    OpenAIRE

    R. Chaudhari; Karcher, M.; Elsner, P.; Henning, F

    2012-01-01

    The current paper addresses new variants of the RTM process namely High Pressure-Injection Resin Transfer Molding (HP-IRTM) and High Pressure - Compression Resin Transfer Molding (HP-CRTM) for manufacturing of continuous fiber reinforced composites with high fiber volume content. Both these process utilize High Pressure RTM equipment for precise dosing and mixing of highly reactive epoxy resin and amine hardener with relatively high throughput rates. The objective of the proposed study was to...

  20. Defect annealing processes for polycrystalline silicon thin-film solar cells

    Energy Technology Data Exchange (ETDEWEB)

    Steffens, S., E-mail: simon.steffens@helmholtz-berlin.de [Helmholtz-Zentrum Berlin, Berlin (Germany); Becker, C. [Helmholtz-Zentrum Berlin, Berlin (Germany); Zollondz, J.-H., E-mail: hzollondz@masdarpv.com [CSG Solar AG, Thalheim (Germany); Chowdhury, A.; Slaoui, A. [L’Institut d’Électronique du Solide et des Systèmes, Strasbourg (France); Lindekugel, S. [Fraunhofer-Institut für Solare Energiesysteme, Freiburg (Germany); Schubert, U.; Evans, R. [Suntech R and D Australia Pty Ltd, Sydney (Australia); Rech, B. [Helmholtz-Zentrum Berlin, Berlin (Germany)

    2013-05-15

    Highlights: ► Defect annealing processes were applied to polycrystalline silicon thin films. ► Conventional rapid thermal annealing was compared to novel annealing processes using a laser system and a zone-melting recrystallization setup. ► The open circuit voltages could be enhanced from below 170 mV up to 482 mV. ► Increase in Sun's-V{sub OC} values with decrease in FWHM of the TO Raman phonon of crystalline silicon. ► Solar cells were fabricated for I–V-measurements: Best solar cell efficiency of 6.7%. -- Abstract: A variety of defect healing methods was analyzed for optimization of polycrystalline silicon (poly-Si) thin-film solar cells on glass. The films were fabricated by solid phase crystallization of amorphous silicon deposited either by plasma enhanced chemical vapor deposition (PECVD) or by electron-beam evaporation (EBE). Three different rapid thermal processing (RTP) set-ups were compared: A conventional rapid thermal annealing oven, a dual wavelength laser annealing system and a movable two sided halogen lamp oven. The two latter processes utilize focused energy input for reducing the thermal load introduced into the glass substrates and thus lead to less deformation and impurity diffusion. Analysis of the structural and electrical properties of the poly-Si thin films was performed by Suns-V{sub OC} measurements and Raman spectroscopy. 1 cm{sup 2} cells were prepared for a selection of samples and characterized by I–V-measurements. The poly-Si material quality could be extremely enhanced, resulting in increase of the open circuit voltages from about 100 mV (EBE) and 170 mV (PECVD) in the untreated case up to 480 mV after processing.