U.S. patent application number 15/782785 was filed with the patent office on 2018-02-08 for apparatus for containment of molten aluminum using non-wetting materials.
This patent application is currently assigned to The Government of the United States of America, as represented by the Secretary of the Navy. The applicant listed for this patent is The Government of the United States of America, as represented by the Secretary of the Navy, The Government of the United States of America, as represented by the Secretary of the Navy. Invention is credited to Robel Y. Bekele, Jesse A. Frantz, Jason D. Myers, Bryan Sadowski, Jasbinder S. Sanghera, Guillermo R. Villalobos.
Application Number | 20180037985 15/782785 |
Document ID | / |
Family ID | 51387339 |
Filed Date | 2018-02-08 |
United States Patent
Application |
20180037985 |
Kind Code |
A1 |
Myers; Jason D. ; et
al. |
February 8, 2018 |
Apparatus for Containment of Molten Aluminum Using Non-Wetting
Materials
Abstract
An apparatus for containment of a molten substance using
non-wetting materials comprising a crucible, and a layer of a
non-wetting material deposited onto the crucible, wherein said
layer of non-wetting material is deposited near the rim of the
crucible and wherein the non-wetting material is deposited onto the
crucible by one selected from the group consisting of RF magnetron
sputtering, chemical vapor deposition, thermal spray, thermal
evaporation, dip coating of precursors followed by thermal
treatment, and spray coating of precursors followed by thermal
treatment.
Inventors: |
Myers; Jason D.;
(Alexandria, VA) ; Frantz; Jesse A.; (Landover,
MD) ; Villalobos; Guillermo R.; (Springfield, VA)
; Sanghera; Jasbinder S.; (Ashburn, VA) ;
Sadowski; Bryan; (Falls Church, VA) ; Bekele; Robel
Y.; (Washington, DC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Government of the United States of America, as represented by
the Secretary of the Navy |
Washington |
DC |
US |
|
|
Assignee: |
The Government of the United States
of America, as represented by the Secretary of the Navy
Washington
DC
|
Family ID: |
51387339 |
Appl. No.: |
15/782785 |
Filed: |
October 12, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14951178 |
Nov 24, 2015 |
9822442 |
|
|
15782785 |
|
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|
14075239 |
Nov 8, 2013 |
9227242 |
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14951178 |
|
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|
61770742 |
Feb 28, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C23C 14/0641 20130101;
F27B 14/10 20130101; C23C 14/081 20130101; C23C 14/0635 20130101;
C23C 14/08 20130101; C23C 14/35 20130101; F27B 2014/104 20130101;
C23C 14/0647 20130101; B22D 41/02 20130101 |
International
Class: |
C23C 14/35 20060101
C23C014/35; C23C 14/06 20060101 C23C014/06; B22D 41/02 20060101
B22D041/02; C23C 14/08 20060101 C23C014/08; F27B 14/10 20060101
F27B014/10 |
Claims
1. An apparatus for containment of a molten substance using
non-wetting materials comprising: a crucible; a layer of a
non-wetting material deposited onto the crucible; wherein said
layer of non-wetting material is deposited near the rim of the
crucible; wherein the non-wetting material is deposited onto the
crucible by one selected from the group consisting of RF magnetron
sputtering, chemical vapor deposition, thermal spray, thermal
evaporation, dip coating of precursors followed by thermal
treatment, and spray coating of precursors followed by thermal
treatment; and wherein the crucible has an estimated non-wetting
material film thickness of 500-1000 nm.
2. The apparatus for containment of a molten substance using
non-wetting materials of claim 2 wherein the layer of non-wetting
material is one selected from the group consisting of
MgAl.sub.2O.sub.4, oxides, Al.sub.2O.sub.3, nitrides, AlN, BN,
carbides, and SiC.
3. An apparatus for containment of a molten substance using
non-wetting materials comprising: a crucible; a layer of a
non-wetting material deposited onto the crucible; wherein said
layer of non-wetting material is deposited near the rim of the
crucible; and wherein the step of depositing the non-wetting
material onto the crucible was via RF magnetron sputtering and
wherein the RF magnetron sputtering was at an energy density of
.about.9 W/cm.sup.2 and a pressure of 1-10 mT and wherein the
crucible was held at room temperature for an estimated non-wetting
material film thickness of 500-1000 nm; and wherein the non-wetting
material stops a molten substance at an edge of the non-wetting
material and wherein the molten substance will not advance
further.
4. The apparatus for containment of molten aluminum using
non-wetting materials of claim 3 wherein the non-wetting material
is one selected from the group consisting of MgAl.sub.2O.sub.4,
oxides, Al.sub.2O.sub.3, nitrides, AlN, BN, carbides, and SiC.
5. The apparatus for containment of molten aluminum using
non-wetting materials of claim 4 wherein the non-wetting material
has a surface energy that results in a contact angle of about
90.degree. or greater when in contact with the molten
substance.
6. A containment-of-molten-aluminum crucible as a product of the
process comprising the steps of: masking off a crucible using a
mask to confine any deposition to the rim of the crucible;
depositing a non-wetting material onto the crucible; and rotating
the crucible during deposition; wherein the step of depositing the
non-wetting material onto the crucible was via RF magnetron
sputtering and wherein the RF magnetron sputtering was at an energy
density of .about.9 W/cm.sup.2 and a pressure of 1-10 mT and
wherein the crucible was held at room temperature for an estimated
non-wetting material film thickness of 500-1000 nm.
Description
REFERENCE TO RELATED APPLICATION
[0001] This application is a non-provisional of, and claims
priority to and the benefits of, U.S. Provisional Patent
Application No. 61/770,742 filed on Feb. 28, 2013, and U.S. patent
application Ser. No. 14/075,239 filed on Nov. 8, 2013, and U.S.
patent application Ser. No. 14/951,178 filed on Nov. 24, 2015, the
entireties of each are hereby incorporated by reference.
BACKGROUND
[0002] This disclosure pertains to a method and apparatus of
containing molten aluminum using a barrier layer of a non-wetting
material.
[0003] Thermal evaporation is a very common method of depositing
thin films of aluminum. In this technique, aluminum shot is placed
into a crucible that is typically made of graphite, a refractory
metal, or an oxide, and heated using either an electron beam or
resistive coils. Unfortunately, molten aluminum has a strong
propensity to wet most crucible materials and is highly corrosive
to refractory metals, such as tungsten and molybdenum. As the
molten aluminum creeps during the deposition, it can wet out onto
other system elements, solidify on the backside of the crucible and
cause thermal shock and cracking, corrode resistive heating
elements, and change the thermal conduction properties of the
crucible. This problem is typically managed by frequently replacing
crucibles, leading to excess cost and material waste.
SUMMARY OF DISCLOSURE
Description
[0004] This disclosure pertains to a method and apparatus of
containing molten aluminum using a barrier layer of a non-wetting
material.
DESCRIPTION OF THE DRAWINGS
[0005] The following description and drawings set forth certain
illustrative implementations of the disclosure in detail, which are
indicative of several exemplary ways in which the various
principles of the disclosure may be carried out. The illustrated
examples, however, are not exhaustive of the many possible
embodiments of the disclosure. Other objects, advantages and novel
features of the disclosure will be set forth in the following
detailed description when considered in conjunction with the
drawings.
[0006] FIG. 1: Illustration of a used Fabmate crucible with
spinel-coated rims. Fabmate crucible with alternating bare and
spinel-coated regions around the rim after one aluminum deposition.
Note the straight lines of aluminum at the edge of the spinel film,
indicating non-wetting behavior.
[0007] FIG. 2: Illustration of a used Fabmate crucible without
spinel-coated rims. Fabmate crucible without spinel coating after
one aluminum deposition. The rim is entirely coated with aluminum,
and it is beginning to creep out of the crucible in one region.
DETAILED DESCRIPTION OF THE INVENTION
[0008] We discuss here a method to contain molten aluminum within a
crucible using non-wetting barrier layers.
[0009] The non-wetting material is chosen to have a surface energy
that results in a large contact angle (i.e. 90.degree.) when in
contact with molten aluminum.
[0010] The non-wetting material can be deposited using a variety of
methods.
[0011] As the molten aluminum wets out its container, the material
is stopped at the edge of the deposited material and will not
advance further, prolonging crucible lifetime and reducing source
material waste.
[0012] Additionally, while this initial disclosure references
laboratory-scale containment, the technique is applicable to
containers of any size and shape. This disclosure solves a real
practical problem which affects the commercial market.
EXAMPLE 1
[0013] MgAl.sub.2O.sub.4 (spinel) was deposited using RF magnetron
sputtering onto two Fabmate (densified graphite) crucibles with an
energy density of .about.9 W/cm.sup.2 and a pressure of 1-10 mT
with the crucibles held at room temperature for an estimated spinel
film thickness of 500-1000 nm.
[0014] The crucibles were rotated at .about.10 rpm during
deposition.
[0015] The crucibles were masked off using polyimide adhesive tape
to confine the deposited spinel to the rim of the crucible.
[0016] After deposition, the polyimide tape was removed and the
crucibles were wiped clean using solvents.
[0017] Aluminum shot is added to the crucible, which is
subsequently installed in a high vacuum electron beam evaporation
chamber. The electron beam is rastered in a Lissajous pattern to
heat the aluminum, with care taken to avoid direct heating of the
rim.
[0018] The crucible is heated to .about.1200.degree. C., at which
point aluminum reaches the desired deposition rate.
[0019] We have found the method and apparatus as discussed herein
extends the lifetime of crucibles.
[0020] Another advantage includes reduced waste from discarded
source material.
[0021] Furthermore, the method and apparatus as discussed herein
reduces damage potential from aluminum creep onto system
components.
[0022] These advantages are demonstrated in the figures. FIG. 2
illustrates a used Fabmate crucible without spinel-coated rims. The
Fabmate crucible shown is without spinel coating after one aluminum
deposition.
[0023] Note the rim is entirely coated with aluminum, and it is
beginning to creep out of the crucible in one region.
[0024] This is in contrast to FIG. 1 which illustrates a used
Fabmate crucible with spinel-coated rims. This Fabmate crucible has
alternating bare and spinel-coated regions around the rim after one
aluminum deposition.
[0025] Note the straight lines of aluminum at the edge of the
spinel film, indicating non-wetting behavior.
[0026] Instead of MgAl.sub.2O.sub.4, a variety of other materials
can be used, including but not limited to oxides, such as
Al.sub.2O.sub.3, or nitrides, such as AlN and BN, or carbides, such
as SiC.
[0027] Instead of sputter deposition, other deposition methods can
be used, such as chemical vapor deposition, thermal spray, or
thermal evaporation, as well as dip coating or spray coating of
precursors followed by thermal treatment.
[0028] Furthermore, suitable coatings can also be used to prevent
wetting by other metals and alloys.
[0029] The above examples are merely illustrative of several
possible embodiments of various aspects of the present disclosure,
wherein equivalent alterations and/or modifications will occur to
others skilled in the art upon reading and understanding this
specification and the annexed drawings. In addition, although a
particular feature of the disclosure may have been illustrated
and/or described with respect to only one of several
implementations, such feature may be combined with one or more
other features of the other implementations as may be desired and
advantageous for any given or particular application. Also, to the
extent that the terms "including", "includes", "having", "has",
"with", or variants thereof are used in the detailed description
and/or in the claims, such terms are intended to be inclusive in a
manner similar to the term "comprising".
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