Abstract: Anodizing is an electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant, anodic oxide finish. Aluminum is ideally suited to anodizing, although other nonferrous metals, such as magnesium and titanium, also can be anodized. The anodic oxide structure originates from the aluminum substrate and is composed entirely of aluminum oxide. This aluminum oxide is not applied to the surface like paint or plating, but is fully integrated with the underlying aluminum substrate, so cannot chip or peel. It has a highly ordered, porous structure that allows for secondary processes such as coloring and sealing. In this experimental paper, we focus on a reliable method for fabricating nanoporous alumina with high regularity. Starting from study of nanostructure materials synthesize methods. After that, porous alumina fabricate in the laboratory by anodization of aluminum oxide. Hard anodization processes are employed to fabricate the nanoporous alumina using 0.3M oxalic acid and 90, 120 and 140 anodized voltages. The nanoporous templates were characterized by SEM and FFT. The nanoporous templates using 140 voltages have high ordered. The pore formation, influence of the experimental conditions on the pore formation, the structural characteristics of the pore and the oxide chemical reactions involved in the pore growth are discuss.
Abstract: The use of 3D computer-aided design (CAD) models
to support construction project planning has been increasing in the
previous year. 3D CAD models reveal more planning ideas by
visually showing the construction site environment in different stages
of the construction process. Using 3D CAD models together with
scheduling software to prepare construction plan can identify errors
in process sequence and spatial arrangement, which is vital to the
success of a construction project. A number of 4D (3D plus time)
CAD tools has been developed and utilized in different construction
projects due to the awareness of their importance. Virtual prototyping
extends the idea of 4D CAD by integrating more features for
simulating real construction process. Virtual prototyping originates
from the manufacturing industry where production of products such
as cars and airplanes are virtually simulated in computer before they
are built in the factory. Virtual prototyping integrates 3D CAD,
simulation engine, analysis tools (like structural analysis and
collision detection), and knowledgebase to streamline the whole
product design and production process. In this paper, we present the
application of a virtual prototyping software which has been used in
a few construction projects in Hong Kong to support construction
project planning. Specifically, the paper presents an implementation
of virtual prototyping in a residential building project in Hong Kong.
The applicability, difficulties and benefits of construction virtual
prototyping are examined based on this project.
Abstract: The process of wafer fabrication is arguably the most
technologically complex and capital intensive stage in semiconductor
manufacturing. This large-scale discrete-event process is highly reentrant,
and involves hundreds of machines, restrictions, and
processing steps. Therefore, production control of wafer fabrication
facilities (fab), specifically scheduling, is one of the most challenging
problems that this industry faces. Dispatching rules have been
extensively applied to the scheduling problems in semiconductor
manufacturing. Moreover, lot release policies are commonly used in
this manufacturing setting to further improve the performance of such
systems and reduce its inherent variability. In this work, simulation is
used in the scheduling of re-entrant flow shop manufacturing systems
with an application in semiconductor wafer fabrication; where, a
simulation model has been developed for the Intel Five-Machine Six
Step Mini-Fab using the ExtendTM simulation environment. The
Mini-Fab has been selected as it captures the challenges involved in
scheduling the highly re-entrant semiconductor manufacturing lines.
A number of scenarios have been developed and have been used to
evaluate the effect of different dispatching rules and lot release
policies on the selected performance measures. Results of simulation
showed that the performance of the Mini-Fab can be drastically
improved using a combination of dispatching rules and lot release
policy.
Abstract: The electrolyte stirring method of anodization etching
process for manufacturing porous silicon (PS) is reported in this work.
Two experimental setups of nature air stirring (PS-ASM) and
electrolyte stirring (PS-ESM) are employed to clarify the influence of
stirring mechanisms on electrochemical etching process. Compared to
traditional fabrication without any stirring apparatus (PS-TM), a large
plateau region of PS surface structure is obtained from samples with
both stirring methods by the 3D-profiler measurement. Moreover, the
light emission response is also improved by both proposed electrolyte
stirring methods due to the cycling force in electrolyte could
effectively enhance etch-carrier distribution while the electrochemical
etching process is made. According to the analysis of statistical
calculation of photoluminescence (PL) intensity, lower standard
deviations are obtained from PS-samples with studied stirring methods,
i.e. the uniformity of PL-intensity is effectively improved. The
calculated deviations of PL-intensity are 93.2, 74.5 and 64,
respectively, for PS-TM, PS-ASM and PS-ESM.
Abstract: Among all mechanical joining processes, welding has
been employed for its advantage in design flexibility, cost saving,
reduced overall weight and enhanced structural performance.
However, for structures made of relatively thin components, welding
can introduce significant buckling distortion which causes loss of
dimensional control, structural integrity and increased fabrication
costs. Different parameters can affect buckling behavior of welded
thin structures such as, heat input, welding sequence, dimension of
structure. In this work, a 3-D thermo elastic-viscoplastic finite
element analysis technique is applied to evaluate the effect of shell
dimensions on buckling behavior and entropy generation of welded
thin shells. Also, in the present work, the approximated longitudinal
transient stresses which produced in each time step, is applied to the
3D-eigenvalue analysis to ratify predicted buckling time and
corresponding eigenmode. Besides, the possibility of buckling
prediction by entropy generation at each time is investigated and it is
found that one can predict time of buckling with drawing entropy
generation versus out of plane deformation. The results of finite
element analysis show that the length, span and thickness of welded
thin shells affect the number of local buckling, mode shape of global
buckling and post-buckling behavior of welded thin shells.
Abstract: The fabrication of porous NiTi shape memory alloys (SMAs) from elemental powder compacts was conducted by selfpropagating high temperature synthesis (SHS). Effects of the preheating temperature and the chamber pressure on the combustion characteristics as well as the final morphology and the composition of products were studied. The samples with porosity between 56.4 and 59.0% under preheating temperature in the range of 200-300°C and Ar-gas chamber pressure of 138 and 201 kPa were obtained. The pore structures were found to be dissimilar only in the samples processed with different preheating temperature. The major phase in the porous product is NiTi with small amounts of secondary phases, NiTi2 and Ni4Ti3. The preheating temperature and the chamber pressure have very little effect on the phase constituent. While the combustion temperature of the sample was notably increased by increasing the preheating temperature, they were slightly changed by varying the chamber pressure.
Abstract: This research presents the development of simulation
modeling for WIP management in semiconductor fabrication.
Manufacturing simulation modeling is needed for productivity
optimization analysis due to the complex process flows involved
more than 35 percent re-entrance processing steps more than 15 times
at same equipment. Furthermore, semiconductor fabrication required
to produce high product mixed with total processing steps varies from
300 to 800 steps and cycle time between 30 to 70 days. Besides the
complexity, expansive wafer cost that potentially impact the
company profits margin once miss due date is another motivation to
explore options to experiment any analysis using simulation
modeling. In this paper, the simulation model is developed using
existing commercial software platform AutoSched AP, with
customized integration with Manufacturing Execution Systems
(MES) and Advanced Productivity Family (APF) for data collections
used to configure the model parameters and data source. Model
parameters such as processing steps cycle time, equipment
performance, handling time, efficiency of operator are collected
through this customization. Once the parameters are validated, few
customizations are made to ensure the prior model is executed. The
accuracy for the simulation model is validated with the actual output
per day for all equipments. The comparison analysis from result of
the simulation model compared to actual for achieved 95 percent
accuracy for 30 days. This model later was used to perform various
what if analysis to understand impacts on cycle time and overall
output. By using this simulation model, complex manufacturing
environment like semiconductor fabrication (fab) now have
alternative source of validation for any new requirements impact
analysis.
Abstract: This paper presents the design, fabrication and
evaluation of magneto-rheological damper. Semi-active control
devices have received significant attention in recent years because
they offer the adaptability of active control devices without requiring
the associated large power sources. Magneto-Rheological (MR)
dampers are semi- active control devices that use MR fluids to
produce controllable dampers. They potentially offer highly reliable
operation and can be viewed as fail-safe in that they become passive
dampers if the control hardware malfunction. The advantage of MR
dampers over conventional dampers are that they are simple in
construction, compromise between high frequency isolation and
natural frequency isolation, they offer semi-active control, use very
little power, have very quick response, has few moving parts, have a
relax tolerances and direct interfacing with electronics. Magneto-
Rheological (MR) fluids are Controllable fluids belonging to the
class of active materials that have the unique ability to change
dynamic yield stress when acted upon by an electric or magnetic
field, while maintaining viscosity relatively constant. This property
can be utilized in MR damper where the damping force is changed by
changing the rheological properties of the fluid magnetically. MR
fluids have a dynamic yield stress over Electro-Rheological fluids
(ER) and a broader operational temperature range. The objective of
this papert was to study the application of an MR damper to vibration
control, design the vibration damper using MR fluids, test and
evaluate its performance. In this paper the Rheology and the theory
behind MR fluids and their use on vibration control were studied.
Then a MR vibration damper suitable for vehicle suspension was
designed and fabricated using the MR fluid. The MR damper was
tested using a dynamic test rig and the results were obtained in the
form of force vs velocity and the force vs displacement plots. The
results were encouraging and greatly inspire further research on the
topic.
Abstract: In metal cutting industries, mathematical/statistical
models are typically used to predict tool replacement time. These
off-line methods usually result in less than optimum replacement
time thereby either wasting resources or causing quality problems.
The few online real-time methods proposed use indirect measurement
techniques and are prone to similar errors. Our idea is based on
identifying the optimal replacement time using an electronic nose to
detect the airborne compounds released when the tool wear reaches
to a chemical substrate doped into tool material during the
fabrication. The study investigates the feasibility of the idea, possible
doping materials and methods along with data stream mining
techniques for detection and monitoring different phases of tool
wear.
Abstract: This paper reports on an effort to address the issue of
inequality in girls- and women-s access to science, engineering and
technology (SET) education and careers through raising awareness on
SET among secondary school girls in South Africa. Girls participated
in hands-on high-tech rapid prototyping environment of a fabrication
laboratory that was aimed at stimulating creativity and innovation as
part of a Fab Kids initiative. The Fab Kids intervention is about
creating a SET pipeline as part of the Young Engineers and Scientists
of Africa Initiative.The methodology was based on a real world
situation and a hands-on approach. In the process, participants
acquired a number of skills including computer-aided design,
research skills, communication skills, teamwork skills, technical
drawing skills, writing skills and problem-solving skills. Exposure to
technology enhanced the girls- confidence in being able to handle
technology-related tasks.
Abstract: Nanostructured materials have attracted many
researchers due to their outstanding mechanical and physical
properties. For example, carbon nanotubes (CNTs) or carbon
nanofibres (CNFs) are considered to be attractive reinforcement
materials for light weight and high strength metal matrix composites.
These composites are being projected for use in structural
applications for their high specific strength as well as functional
materials for their exciting thermal and electrical characteristics. The
critical issues of CNT-reinforced MMCs include processing
techniques, nanotube dispersion, interface, strengthening mechanisms
and mechanical properties. One of the major obstacles to the effective
use of carbon nanotubes as reinforcements in metal matrix
composites is their agglomeration and poor distribution/dispersion
within the metallic matrix. In order to tap into the advantages of the
properties of CNTs (or CNFs) in composites, the high dispersion of
CNTs (or CNFs) and strong interfacial bonding are the key issues
which are still challenging. Processing techniques used for synthesis
of the composites have been studied with an objective to achieve
homogeneous distribution of carbon nanotubes in the matrix.
Modified mechanical alloying (ball milling) techniques have emerged
as promising routes for the fabrication of carbon nanotube (CNT)
reinforced metal matrix composites. In order to obtain a
homogeneous product, good control of the milling process, in
particular control of the ball movement, is essential. The control of
the ball motion during the milling leads to a reduction in grinding
energy and a more homogeneous product. Also, the critical inner
diameter of the milling container at a particular rotational speed can
be calculated. In the present work, we use conventional and modified
mechanical alloying to generate a homogenous distribution of 2 wt.
% CNT within Al powders. 99% purity Aluminium powder (Acros,
200mesh) was used along with two different types of multiwall
carbon nanotube (MWCNTs) having different aspect ratios to
produce Al-CNT composites. The composite powders were processed
into bulk material by compaction, and sintering using a cylindrical
compaction and tube furnace. Field Emission Scanning electron
microscopy (FESEM), X-Ray diffraction (XRD), Raman
spectroscopy and Vickers macro hardness tester were used to
evaluate CNT dispersion, powder morphology, CNT damage, phase
analysis, mechanical properties and crystal size determination.
Despite the success of ball milling in dispersing CNTs in Al powder,
it is often accompanied with considerable strain hardening of the Al
powder, which may have implications on the final properties of the
composite. The results show that particle size and morphology vary
with milling time. Also, by using the mixing process and sonication
before mechanical alloying and modified ball mill, dispersion of the
CNTs in Al matrix improves.
Abstract: The exhaustive quality control is becoming more and
more important when commercializing competitive products in the
world's globalized market. Taken this affirmation as an undeniable
truth, it becomes critical in certain sector markets that need to offer
the highest restrictions in quality terms. One of these examples is the
percussion cap mass production, a critical element assembled in
firearm ammunition. These elements, built in great quantities at a
very high speed, must achieve a minimum tolerance deviation in
their fabrication, due to their vital importance in firing the piece of
ammunition where they are built in. This paper outlines a machine
vision development for the 100% inspection of percussion caps
obtaining data from 2D and 3D simultaneous images. The acquisition
speed and precision of these images from a metallic reflective piece
as a percussion cap, the accuracy of the measures taken from these
images and the multiple fabrication errors detected make the main
findings of this work.
Abstract: Chemical and physical functionalization of multiwalled
carbon nanotubes (MWCNT) has been commonly practiced to
achieve better dispersion of carbon nanotubes (CNTs) in polymer
matrix. This work describes various functionalization methods (acidtreatment,
non-ionic surfactant treatment with TritonX-100),
fabrication of MWCNT/PP nanocomposites via melt blending and
characterization of mechanical properties. Microscopy analysis
(FESEM, TEM, XPS) showed effective purification of MWCNTs
under acid treatment, and better dispersion under both chemical and
physical functionalization techniques combined, in their respective
order. Tensile tests showed increase in tensile strength for the
nanocomposites that contain MWCNTs up to 2 wt%. A decrease in
tensile strength was seen in samples that contain 4 wt% of MWCNTs
for both raw and Triton X-100 functionalized, signifying MWCNT
degradation/rebundling at composition with higher content of
MWCNTs. For the acid-treated MWCNTs, however, the tensile
results showed slight improvement even at 4wt%, indicating effective
dispersion of MWCNTs.
Abstract: A novel direction-of-arrival (DOA) estimation technique, which uses a conventional multiple signal classification (MUSIC) algorithm with periodic signals, is applied to a single RF-port parasitic array antenna for direction finding. Simulation results show that the proposed method gives high resolution (1 degree) DOA estimation in an uncorrelated signal environment. The novelty lies in that the MUSIC algorithm is applied to a simplified antenna configuration. Only one RF port and one analogue-to-digital converter (ADC) are used in this antenna, which features low DC power consumption, low cost, and ease of fabrication. Modifications to the conventional MUSIC algorithm do not bring much additional complexity. The proposed technique is also free from the negative influence by the mutual coupling between elements. Therefore, the technique has great potential to be implemented into the existing wireless mobile communications systems, especially at the power consumption limited mobile terminals, to provide additional position location (PL) services.
Abstract: Traditionally, wind tunnel models are made of metal
and are very expensive. In these years, everyone is looking for ways
to do more with less. Under the right test conditions, a rapid
prototype part could be tested in a wind tunnel. Using rapid prototype
manufacturing techniques and materials in this way significantly
reduces time and cost of production of wind tunnel models. This
study was done of fused deposition modeling (FDM) and their ability
to make components for wind tunnel models in a timely and cost
effective manner. This paper discusses the application of wind tunnel
model configuration constructed using FDM for transonic wind
tunnel testing. A study was undertaken comparing a rapid
prototyping model constructed of FDM Technologies using
polycarbonate to that of a standard machined steel model. Testing
covered the Mach range of Mach 0.3 to Mach 0.75 at an angle-ofattack
range of - 2° to +12°. Results from this study show relatively
good agreement between the two models and rapid prototyping
Method reduces time and cost of production of wind tunnel models.
It can be concluded from this study that wind tunnel models
constructed using rapid prototyping method and materials can be
used in wind tunnel testing for initial baseline aerodynamic database
development.
Abstract: In this paper, design, fabrication and coupled
multifield analysis of hollow out-of-plane silicon microneedle array
with piezoelectrically actuated microfluidic device for transdermal
drug delivery (TDD) applications is presented. The fabrication
process of silicon microneedle array is first done by series of
combined isotropic and anisotropic etching processes using
inductively coupled plasma (ICP) etching technology. Then coupled
multifield analysis of MEMS based piezoelectrically actuated device
with integrated 2×2 silicon microneedle array is presented. To predict
the stress distribution and model fluid flow in coupled field analysis,
finite element (FE) and computational fluid dynamic (CFD) analysis
using ANSYS rather than analytical systems has been performed.
Static analysis and transient CFD analysis were performed to predict
the fluid flow through the microneedle array. The inlet pressure from
10 kPa to 150 kPa was considered for static CFD analysis. In the
lumen region fluid flow rate 3.2946 μL/min is obtained at 150 V for
2×2 microneedle array. In the present study the authors have
performed simulation of structural, piezoelectric and CFD analysis
on three dimensional model of the piezoelectrically actuated
mcirofluidic device integrated with 2×2 microneedle array.
Abstract: The ferroelectric behavior of barium strontium
titanate (BST) in thin film form has been investigated in order to
study the possibility of using BST for ferroelectric gate-field effect
transistor (FeFET) for memory devices application. BST thin films
have been fabricated as Al/BST/Pt/SiO2/Si-gate configuration. The
variation of the dielectric constant (ε) and tan δ with frequency have
been studied to ensure the dielectric quality of the material. The
results show that at low frequencies, ε increases as the Ba content
increases, whereas at high frequencies, it shows the opposite
variation, which is attributed to the dipole dynamics. tan δ shows low
values with a peak at the mid-frequency range. The ferroelectric
behavior of the Al/BST/Pt/SiO2/Si has been investigated using C-V
characteristics. The results show that the strength of the ferroelectric
hysteresis loop increases as the Ba content increases; this is attributed
to the grain size and dipole dynamics effect.
Abstract: This paper presents a novel CMOS four-transistor
SRAM cell for very high density and low power embedded SRAM
applications as well as for stand-alone SRAM applications. This cell
retains its data with leakage current and positive feedback without
refresh cycle. The new cell size is 20% smaller than a conventional
six-transistor cell using same design rules. Also proposed cell uses
two word-lines and one pair bit-line. Read operation perform from
one side of cell, and write operation perform from another side of
cell, and swing voltage reduced on word-lines thus dynamic power
during read/write operation reduced. The fabrication process is fully
compatible with high-performance CMOS logic technologies,
because there is no need to integrate a poly-Si resistor or a TFT load.
HSPICE simulation in standard 0.25μm CMOS technology confirms
all results obtained from this paper.
Abstract: Metallic micro parts are playing an important role in micro-fabrication industry. Recently, we have demonstrated a new deformation mechanism for micro-formability of polycrystalline materials. Different depressed micro-features smaller than the grain size have been successfully fabricated on 6061 aluminum alloy (AA6061) substrates with good fidelity. To further verify this proposed deformation mechanism that grain size is not a limiting factor, we demonstrate here that in addition of depressed features, protruded micro-features on a polycrystalline substrate can similarly be fabricated.
Abstract: The use of hard and brittle material has become
increasingly more extensive in recent years. Therefore processing of
these materials for the parts fabrication has become a challenging
problem. However, it is time-consuming to machine the hard brittle
materials with the traditional metal-cutting technique that uses
abrasive wheels. In addition, the tool would suffer excessive wear as
well. However, if ultrasonic energy is applied to the machining
process and coupled with the use of hard abrasive grits, hard and
brittle materials can be effectively machined. Ultrasonic machining
process is mostly used for the brittle materials. The present research
work has developed models using finite element approach to predict
the mechanical stresses sand strains produced in the tool during
ultrasonic machining process. Also the flow behavior of abrasive
slurry coming out of the nozzle has been studied for simulation using
ANSYS CFX module. The different abrasives of different grit sizes
have been used for the experimentation work.