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Organisationseinheit der BAM
- 1 Analytische Chemie; Referenzmaterialien (6)
- 8 Zerstörungsfreie Prüfung (4)
- 1.2 Biophotonik (3)
- 1.7 Organische Spuren- und Lebensmittelanalytik (3)
- 6 Materialchemie (3)
- 8.0 Abteilungsleitung und andere (3)
- 6.2 Material- und Oberflächentechnologien (1)
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- 6.5 Synthese und Streuverfahren nanostrukturierter Materialien (1)
- 8.1 Sensorik, mess- und prüftechnische Verfahren (1)
Paper des Monats
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Great complexity characterizes Additive Manufacturing (AM) of metallic components via laser powder bed fusion (PBF-LB/M). Due to this, defects in the printed components (like cracks and pores) are still common. Monitoring methods are commercially used, but the relationship between process data and defect formation is not well understood yet. Furthermore, defects and deformations might develop with a temporal delay to the laser energy input. The component’s actual quality is consequently only determinable after the finished process.
To overcome this drawback, thermographic in-situ testing is introduced. The defocused process laser is utilized for nondestructive testing performed layer by layer throughout the build process. The results of the defect detection via infrared cameras are shown for a research PBF-LB/M machine.
This creates the basis for a shift from in-situ monitoring towards in-situ testing during the AM process. Defects are detected immediately inside the process chamber, and the actual component quality is determined.
Till now application of printed magnetoelectronics is hindered by lack of large area exchange coupled metallic multilayers required to produce printable magneto-sensory inks. Large-scale roll-to-roll (R2R) fabrication process is an attractive approach owing to its capabilities for high volume, high throughput, and large area manufacturing. Precise and high performance R2R sputtering technology is developed to fabricate large area giant magnetoresistive (GMR) thin-films stacks that contain 30 metallic bilayers prepared by continuous R2R sputtering of Co and Cu sequential on a hundred meters long polyethylene terephthalate (PET) web. The R2R sputtered Co/Cu multilayer on a 0.2 × 100 m2 PET web exhibits a GMR ratio of ≈40% achieving the largest area exchange coupled room temperature magneto-sensitive system demonstrated to date. The prepared GMR thin-film is converted to magnetosensitive ink that enables printing of magnetic sensors with high performance in a cost-efficient way, which promotes integration with printed electronics. An average GMR ratio of ≈18% is obtained for 370 printed magnetic sensors. The realized precise R2R sputtering approach can also be extended to a wide range of hybrid thin-film material systems opening up a path for new functional inks applied with printing technologies.
Die zerstörungsfreie Prüfung von metallischen Bauteilen hergestellt mit additiver Fertigung (Additive Manufacturing - AM) gewinnt zunehmend an industrieller Bedeutung. Grund dafür ist die Feststellung von Qualität, Reproduzierbarkeit und damit auch Sicherheit für Bauteile, die mittels AM gefertigt wurden. Jedoch wird noch immer ex-situ geprüft, wobei Defekte (z.B. Poren, Risse etc.) erst nach Prozessabschluss entdeckt werden. Übersteigen Anzahl und/oder Abmessung die vorgegebenen Grenzwerte für diese Defekte, so kommt es zu Ausschuss, was angesichts sehr langer Bauprozessdauern äußerst unrentabel ist. Eine Schwierigkeit ist dabei, dass manche Defekte sich erst zeitverzögert zum eigentlichen Materialauftrag bilden, z.B. durch thermische Spannungen oder Schmelzbadaktivitäten. Dementsprechend sind reine Monitoringansätze zur Detektion ggf. nicht ausreichend.
Daher wird in dieser Arbeit ein Verfahren zur aktiven Thermografie an dem AM-Prozess Laser Powder Bed Fusion (L-PBF) untersucht. Das Bauteil wird mit Hilfe des defokussierten Prozesslasers bei geringer Laserleistung zwischen den einzelnen gefertigten Lagen unabhängig vom eigentlichen Bauprozess erwärmt. Die entstehende Wärmesignatur wird ort- und zeitaufgelöst durch eine Infrarotkamera erfasst. Durch diese der Lagenfertigung nachgelagerte Prüfung werden auch zum Bauprozess zeitversetzte Defektbildungen nachweisbar.
In dieser Arbeit finden die Untersuchungen als Proof-of-Concept, losgelöst vom AM-Prozess, an einem typischen metallischen Testkörper statt. Dieser besitzt eine Nut als oberflächlichen Defekt. Die durchgeführten Messungen finden an einer eigens entwickelten L-PBF-Forschungsanlage innerhalb der Prozesskammer statt. Damit wird ein neuartiger Ansatz zur aktiven Thermografie für L-PBF erforscht, der eine größere Bandbreite an Defektarten auffindbar macht. Der Ansatz wird validiert und Genauigkeit sowie Auflösungsvermögen geprüft. Eine Anwendung am AM-Prozess wird damit direkt forciert und die dafür benötigten Zusammenhänge werden präsentiert.
In-situ monitoring of the Laser Powder Bed Fusion build process via bi- chromatic optical tomography
(2022)
As metal additive manufacturing (AM) is entering industrial serial production of safety relevant components, the need for reliable process qualification is growing continuously. Especially in strictly regulated industries, such as aviation, the use of AM is strongly dependent on ensuring consistent quality of components. Because of its numerous influencing factors, up to now, the metal AM process is not fully controllable. Today, expensive part qualification processes for each single component are common in industry.
This contribution focusses on bi-chromatic optical tomography as a new approach for AM in-situ quality control. In contrast to classical optical tomography, the emitted process radiation is monitored simultaneously with two temperature calibrated cameras at two separate wavelength bands. This approach allows one to estimate the local maximum temperatures during the manufacturing process, thus increases the comparability of monitoring data of different processes. A new process information level at low investment cost is reachable, compared to, e.g., infrared thermography.
Photon upconversion upon 1550 nm excitation is of high relevance for applications in the third biological excitation window, for photovoltaics beyond current limitations, and enables appealing options in the field of glass Fiber telecommunications. Trivalent doped erbium ions (Er3+) are the material of choice for 1550 nm excited upconversion, however, they suffer from a low absorption cross-section and a low brightness. Therefore, the ability of Silicon metasurfaces to provide greatly enhanced electrical near-fields is employed to enable efficient photon upconversion even at low external Illumination conditions. Hexagonally shaped β-NaYF4:Er3+ nanoparticles are placed on large-area silicon metasurfaces designed to convert near-infrared (1550 nm) to visible light. More than 2400-fold enhanced photon upconversion luminescence is achieved by using this metasurface instead of a planar substrate.
With the aid of optical simulations based on the finite-element method, this result is attributed to the coupling of the excitation source with metasurface resonances at appropriate incident angles. Analysis of the excitation power density dependence of upconversion luminescence and red-to-green-emission ratios enables the estimation of nanoscale near-field enhancement on the metasurface. The findings permit the significant reduction of required external excitation intensities for photon upconversion of 1550 nm light, opening perspectives in biophotonics, telecommunication, and photovoltaics.
Enhanced photon upconversion using erbium-doped nanoparticles interacting with silicon metasurfaces
(2021)
Photon upconversion (UC) using trivalent erbium (Er+3) doped crystals is a promising concept to harness near infrared photons of the solar spectrum which cannot be directly absorbed by silicon solar cells. However, their UC efficiency at low-intensity 1 sun illumination is not relevant on device level so far. Exploiting giant near-field enhancement effects on metasurfaces is an appealing approach to enable efficient UC at low irradiance conditions. Here, we report on more than 1000-fold enhanced photon UC of NaYF4:Er+3 nanoparticles interacting with the near-fields supported by a silicon metasurface under 1550 nm excitation.
The hexapeptide hIAPP22–27 (NFGAIL) is known as a crucial amyloid core sequence of the human islet amyloid polypeptide (hIAPP) whose aggregates can be used to better understand the wild‐type hIAPP′s toxicity to β‐cell death. In amyloid research, the role of hydrophobic and aromatic‐aromatic interactions as potential driving forces during the aggregation process is controversially discussed not only in case of NFGAIL, but also for amyloidogenic peptides in general. We have used halogenation of the aromatic residue as a strategy to modulate hydrophobic and aromatic‐aromatic interactions and prepared a library of NFGAIL variants containing fluorinated and iodinated phenylalanine analogues. We used thioflavin T staining, transmission electron microscopy (TEM) and small‐angle X‐ray scattering (SAXS) to study the impact of side‐chain halogenation on NFGAIL amyloid formation kinetics. Our data revealed a synergy between aggregation behavior and hydrophobicity of the phenylalanine residue. This study introduces systematic fluorination as a toolbox to further investigate the nature of the amyloid self‐assembly process.
Large-scale nanoimprinted metasurfaces based on silicon photonic crystal slabs were produced and coated with a NaYF4:Yb3+/Er3+ upconversion nanoparticle (UCNP) layer. UCNPs on these metasurfaces yield a more than 500-fold enhanced upconversion emission compared to UCNPs on planar surfaces. It is also demonstrated how the optical response of the UCNPs can be used to estimate the local field energy in the coating layer. Optical simulations using the finite element method validate the experimental results and the calculated spatial three-dimensional field Energy distribution helps us to understand the emission enhancement mechanism of the UCNPs closely attached to the metasurface. In addition, we analyzed the spectral shifts of the resonances for uncoated and coated metasurfaces and metasurfaces submerged in water to enable a prediction of the optimum layer thicknesses for different excitation wavelengths, paving the way to applications such as electromagnetic field sensors or bioassays.
Mechanochemistry has become a valuable method for the synthesis of new materials and molecules, with a particular strength for screening and preparing multicomponent crystals. In this work, two novel cocrystals of pyrazinamide (PZA) with pimelic acid (PA) were prepared mechanochemically. Their formation was monitored in real time by in situ synchrotron powder X-ray diffraction. Control over the polymorphic form was obtained through the selective choice of liquid additive via liquid assisted grinding. Slurry experiments and dispersion-corrected density functional theory calculations suggest that Form I is the thermodynamically stable form under ambient conditions. Upon aging, Form II converts to Form I. The stability of Form II upon aging was found to depend strongly on the milling duration, intensity, and material of the milling vessels. Longer or higher energy milling drastically increased the lifetime of the Form II product. For the first time, this work also demonstrates that the choice of milling jar can have a decisive effect on the aging stability of a bulk polymorphic powder. In contrast to material prepared in steel milling vessels, the preparation of Form II in Perspex (PMMA) vessels increased its lifetime 3-fold. These findings offer a new dimension to garnering control over mechanochemical cocrystallization and demonstrate the critical importance of the careful and timely ex situ screening of ball mill grinding reactions. This will be of importance for potential industrial applications of mechanochemical cocrystallization where understanding polymorph longevity is crucial for the development of a robust preparative protocol.
The coherent exchange of optical near fields between two neighbouring dipoles plays an essential role in the optical properties, quantum dynamics and thus the function of many naturally occurring and artificial nanosystems. These interactions are challenging to quantify experimentally. They extend over only a few nanometres and depend sensitively on the detuning, dephasing and relative orientation (that is, the vectorial properties) of the coupled dipoles. Here, we introduce plasmonic nanofocusing spectroscopy to record coherent light scattering spectra with 5 nm spatial resolution from the apex of a conical gold nanotaper.
The apex is excited solely by evanescent fields and coupled to plasmon resonances in a single gold nanorod. We resolve resonance energy shifts and line broadenings as a function of dipole distance and relative orientation. We demonstrate how These phenomena arise from mode couplings between different vectorial components of the interacting optical near fields, specifically from the coupling of the nanorod to both transverse and longitudinal polarizabilities of the taper apex.