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Nov 1970

Volume 7, Issue 6, pp. S5-613


Thermochemistry of Liquid Metal–Gas Crucible Reactions in Vacuum

Sven A. Jansson

J. Vac. Sci. Technol. 7, S5 (1970); http://dx.doi.org/10.1116/1.1315922 (9 pages) | Cited 3 times

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Thermochemical analyses are performed for the Ti–O–C, Fe–O–C, Al–O–C, Si–O–C, Mg–O–C, Be–O–C, Y–O–C, Cr–O–C, and U–O–C systems at 1800 K. The role of hydrogen, water vapor, and nitrogen in connection with these systems is exemplified. Log pMexOy vs log pO2 and log pC vs log pO2 diagrams are prepared to illustrate in a simple manner the relations between condensed phases and the equilibrium pressures of gaseous species over the different condensed phases. The diagrams are used to evaluate the correctness or applicability of available thermochemical data, and to predict or interpret reactions in or between the different systems, with particular reference to vacuum metallurgical processes.
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81.20.-n Methods of materials synthesis and materials processing
65.20.-w Thermal properties of liquids
65.40.gd Entropy

Solid Solution Effects in Thin Aluminum Films

G. A. Walker and C. C. Goldsmith

J. Vac. Sci. Technol. 7, 569 (1970); http://dx.doi.org/10.1116/1.1315878 (5 pages) | Cited 4 times

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The effect of a solid solution of hydrogen, oxygen, nitrogen, or water vapor in the lattice of thin films of Al was studied by x-ray diffraction. The lattice parameter shift due to solid solution effect independent of residual strain or faulting was observed. This method is applied to thin films to determine nondestructively whether there are low concentrations of impurities affecting the lattice of the films. It is also shown that large errors occur in the value of the residual stress measured by certain x-ray techniques or in that of the solid solution concentration if both of these effects are not taken into consideration during the subsequent calculations.
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68.55.Ln Defects and impurities: doping, implantation, distribution, concentration, etc.
68.60.Bs Mechanical and acoustical properties
61.05.cm X-ray reflectometry (surfaces, interfaces, films)
64.75.-g Phase equilibria

Composition Gradients in Ni–Fe Alloy Films Produced by Vapor Deposition from a Tungsten Boat

K. R. Carson and M. L. Rudee

J. Vac. Sci. Technol. 7, 573 (1970); http://dx.doi.org/10.1116/1.1315879 (4 pages) | Cited 1 time

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When an alloy film is produced by evaporation from a limited volume of material in a tungsten boat, differences in the vapor pressures of the constituents can produce different compositions through the thickness of the film. These composition changes can affect magnetic properties; e.g., it has been suggested that magnetization gradients produce anomalies in spin wave spectra. We have measured the variation of composition through the thickness of Ni–Fe films by moving a long substrate past a collimated source during deposition from a boat. It is observed that for a wide range of deposition temperatures and integrated thickness the results nearly coincide if all of the data are plotted as a function of normalized fractional thickness. For starting material of 80.89% Ni, evaporated to completion, the initial composition is 74% Ni and rises linearly to 81% Ni at 0.8 fractional thickness. A steeply rising exponential region follows. The origin of these regions will be discussed.
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68.55.Nq Composition and phase identification
81.15.-z Methods of deposition of films and coatings; film growth and epitaxy

Introduction of Water Vapor into Vacuum Systems and the Adsorption by the Walls

Victor R. Deitz and Noel H. Turner

J. Vac. Sci. Technol. 7, 577 (1970); http://dx.doi.org/10.1116/1.1315880 (4 pages)

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A technique is described whereby precise amounts of water vapor can be introduced into evacuated glass–Kovar stainless-steel systems. The adsorption of water vapor by the walls of a typical vacuum system maintained at 26.8°C is reported in the range 0.03–0.20 relative pressure. A continuous dynamic behavior was observed over time intervals up to 4000 min, where time zero corresponds to the initial contact of the walls with the water vapor. At a constant contact time, the pressure dependence of each isochrone followed a conventional Type II physical adsorption isotherm and a linear B.E.T. plot was observed in the range 0.04 and 0.18 relative pressures. It is quite feasible to follow the adsorption of water vapor volumetrically on a variety of solids at all pressures above an absolute pressure of 0.1 Torr due to the good reproducibility of the wall adsorption, provided the isochronal nature of the adsorption process is recognized.
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07.30.Bx Degasification, residual gas
68.03.Fg Evaporation and condensation of liquids
68.43.Mn Adsorption kinetics

Performance of a Modified Buried Collector Gauge

George A. Beitel and Charles M. Gosselin

J. Vac. Sci. Technol. 7, 580 (1970); http://dx.doi.org/10.1116/1.1315881 (6 pages)

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The performance of a modified buried collector gauge was determined over a (helium) pressure range 10−13–10−4 Torr. Optimum operating parameters were empirically chosen. With 5.0-mA emission current and 100-V grid to filament potential, the x-ray photoelectron current of the gauge was estimated to be 5.2×10−13 A. By subtracting the measured background current, linear response was obtained between 6×10−13 and 3×10−4 Torr (He) with a gauge sensitivity of 0.015 A∕Torr (He). Variations of gauge sensitivity as a function of filament geometry are discussed.
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07.30.Dz Vacuum gauges

Isothermal Effusion Sources for Vacuum Deposition of Solid Solutions

H. Holloway, D. K. Hohnke, R. L. Crawley, and E. Wilkes

J. Vac. Sci. Technol. 7, 586 (1970); http://dx.doi.org/10.1116/1.1315882 (3 pages) | Cited 2 times

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An effusion technique for vacuum deposition of solid solutions is described. The method uses a pair of effusion cells whose temperature fluctuations are arranged to occur in phase. This permits a considerable improvement in the compositional homogeneity of alloy films. The method has been applied to solid solutions of IV–VI compounds.
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81.15.-z Methods of deposition of films and coatings; film growth and epitaxy

Low TCR Kanthal Resistive Films for Hybrid IC's

N. G. Dhere, G. H. Sarma, and N. R. Parikh

J. Vac. Sci. Technol. 7, 588 (1970); http://dx.doi.org/10.1116/1.1315883 (5 pages)

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Investigations were carried out regarding the feasibility of Kanthal resistive films in hybrid integrated circuits. The technique for deposition was conventional evaporation from a multistrand tungsten filament onto substrates at 325 °C, in vacua better than 1×10−5 Torr. The filament source life was found to be long because of the absence of nickel in the alloy. The adhesion of films to glass and ceramic substrates and the compatibility with Al, Au thin films and thick-film Ag compositions used for conductors, were found to be good. Better substrate cleaning procedures and faster deposition rates resulted in lower TCR-value films. Fast evaporation of fresh charge invariably resulted in low TCR-value films. On the other hand the evaporation of the portion of the charge still remaining on the filament after the first evaporation resulted in high TCR-value films. To get low TCR-value films of given sheet resistances using fast evaporation and without the evaporation of the entire charge it was necessary to optimize the Kanthal charge on the filament. Low TCR films (∼10 ppm) were obtained in the range of sheet resistance 20 Ω∕sq–250 Ω∕sq. Because of simple evaporation technique, excellent adhesion to substrates, compatibility with conductor films, and low TCR values in a wide range of resistivities, Kanthal has been recommended for hybrid IC's.
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85.40.Xx Hybrid microelectronics; thick films
73.61.At Metal and metallic alloys
68.35.Gy Mechanical properties; surface strains

Theory for the Energy Distribution of Secondary Electrons

G. F. Amelio

J. Vac. Sci. Technol. 7, 593 (1970); http://dx.doi.org/10.1116/1.1315884 (12 pages) | Cited 14 times

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A theory in terms of the Boltzman transport equation is presented for the spectral distribution of excited (hot) electrons in solids. Solutions of the steady-state, field-free equations are obtained by a Green's function technique, which offers the advantage of separating the excitation mechanism from the scattering processes. For purposes of application the question of an electron beam normally striking the planar surfaces of copper and silicon is investigated. Scattering functions representing electron–electron and, most importantly, electron–plasmon interactions are developed from which the necessary Green's functions are derived. Secondary emission spectra are then predicted, using an excitation function based on a perturbation calculation and using an appropriate emission probability formulation. Inclusion of the plasmon scattering contribution leads to agreement with experiment within 10%–20%. Approximate closed-form solutions to the necessary integrals are also offered as well as a more empirical approach to obtaining the electron energy distributions.
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79.20.Hx Electron impact: secondary emission

An Economical and Demountable Diffusion-Pump Cold Trap

W. M. Ziniker

J. Vac. Sci. Technol. 7, 605 (1970); http://dx.doi.org/10.1116/1.1315885 (2 pages)

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Abstract Unavailable
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07.30.Cy Vacuum pumps
07.20.Mc Cryogenics; refrigerators, low-temperature detectors, and other low-temperature equipment

Sorption and Ion-Getter Pumping for a Sliding-Shaft Vacuum Lock

J. J. Stoffels

J. Vac. Sci. Technol. 7, 606 (1970); http://dx.doi.org/10.1116/1.1315886 (2 pages)

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Abstract Unavailable
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07.30.Cy Vacuum pumps

Apparatus for Ultrahigh-Vacuum In Situ Thin-Film Studies

Wayne R. Chase, Raymond A. Prell, and Franz X. Ruf

J. Vac. Sci. Technol. 7, 607 (1970); http://dx.doi.org/10.1116/1.1315887 (4 pages)

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Abstract Unavailable
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07.30.Kf Vacuum chambers, auxiliary apparatus, and materials
81.15.-z Methods of deposition of films and coatings; film growth and epitaxy

Leak Detection in Vacuum Systems by a Fluorescence Technique

Royce K. Winge

J. Vac. Sci. Technol. 7, 610 (1970); http://dx.doi.org/10.1116/1.1315888 (2 pages)

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Abstract Unavailable
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07.30.Hd Vacuum testing methods; leak detectors

Construction of Simple rf Vacuum Feedthrough

V. Brown, M. P. Rodgers, and F. C. Todd

J. Vac. Sci. Technol. 7, 611 (1970); http://dx.doi.org/10.1116/1.1315889 (2 pages)

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Abstract Unavailable
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07.30.Kf Vacuum chambers, auxiliary apparatus, and materials

Automatic Shutter Actuator for Ultrahigh-Vacuum Evaporator

R. W. Bertram

J. Vac. Sci. Technol. 7, 612 (1970); http://dx.doi.org/10.1116/1.1315890 (2 pages) | Cited 1 time

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Abstract Unavailable
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07.30.Kf Vacuum chambers, auxiliary apparatus, and materials
06.60.Sx Positioning and alignment; manipulating, remote handling

Degassing Kinetics of Molten Metals in Vacuum

Otto Winkler

J. Vac. Sci. Technol. 7, S14 (1970); http://dx.doi.org/10.1116/1.1315905 (8 pages)

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A brief review of the theoretical and experimental work on the kinetics of the vacuum degassing of liquid metals is given. This review is limited to the case usually encountered where the transport in the melt alone is rated determining, i.e., where desorption processes at the melt surface and the transport in the gas phase may be neglected. Different models describing the mass transfer from the interior of the melt to the interface are also discussed. The course of degassing of a melt pool without bubble formation, based on the mathematical treatments of Kraus (see Refs. 1 and 2) and Machlin (see Ref. 3) is described. In the model of Kraus—which may be applied, for instance, to ladle degassing—convection currents in the interior of the melt develop by density differences caused by the heat loss of the freely radiating melt surface. The calculations of Machlin refer to inductively stirred melts. Formulas for the mass transfer coefficients for these two cases are given. If layers of surface active elements or slags accumulate at a melt surface, the rate of degassing may be largely reduced. There is also an examination of how far the model of Kraus is applicable to degassing in electron-beam and vacuum-arc melting with consumable electrodes. Most technical degassing processes rely on the formation of bubbles, for only with them are the high rates required for economical degassing obtained. Also shown are the conditions under which bubble nuclei may exist and growth of the bubbles in a melt pool or in stream degassing is possible. Reference is made to the calculations of the gas pick-up of ascending CO bubbles in a steel melt made by Kraus (see Refs. 1 and 2), which also permit the calculation of the mass transfer coefficient if, in this case, a surplus of nuclei in the melt exists. If the gas content is too low for spontaneous bubble nucleation, the use of a neutral scavenging gas is advantageous. Computations of its purging effect have been made by Bradshaw and Richardson (see Ref. 4) as well as by Lange et al. (see Ref. 5). Stream degassing is not accessible to an exact mathematical treatment. However, an estimation of the degassing rates of droplets and experimental results show that the removal of hydrogen probably takes place mainly by diffusion from the external surfaces of metal droplets and bubbles, whereas nitrogen and oxygen removal depends more on the bubble formation in the metal stream and melt pool.
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81.20.Ym Purification
81.05.Bx Metals, semimetals, and alloys

Kinetics and Thermodynamics in Continuous Electron-Beam Evaporation of Binary Alloys

Teuvo Santala and C. M. Adams

J. Vac. Sci. Technol. 7, S22 (1970); http://dx.doi.org/10.1116/1.1315912 (8 pages) | Cited 1 time

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Continuous electron-beam evaporation of binary alloys was studied. Silver-copper wires with 5, 10, 20, and 30 at.% of silver were fed into an evaporation source which was heated by an electron beam. Beam powers up to 4.5 kW were used and evaporation temperatures from 1625–1960 K were obtained. Methods were developed to study mass and composition distribution of the vapor flux, the transient period, and the steady-state conditions. Prediction of the transient and the steady-state relationships among the compositions of the feed wire, the evaporant bath, and the vapor deposit, based on (a) published thermodynamic properties of silver-copper alloys, and (b) the assumption that the Langmuir equation correctly relates the evaporation rate of a particular component from solution to the equilibrium partial pressure of that component, agrees closely with experimental results. This means that transport within the liquid phase by diffusion or convection is not a significant rate-controlling factor.
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64.70.Hz Solid-vapor transitions
81.05.Bx Metals, semimetals, and alloys

Computer Simulation in Metals Research

W. Oldfield

J. Vac. Sci. Technol. 7, S30 (1970); http://dx.doi.org/10.1116/1.1315913 (6 pages)

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The role of computers in applied research is discussed. Computer simulation is considered as a new set of mathematical techniques which augments and goes beyond the older analytic techniques. The major challenge of simulation methods is scientific rather than computational in the selection of models to represent a physical process. Models are discussed in the context of the problems of applied science. The simulation approach differs from conventional methods in that several models are combined to represent the one physical process. The role of the computer is to fit the models together in an interactive ensemble. Simulation techniques are exemplified first by a simulation of the bending and fracture of a Charpy impact specimen. The simple simulation is shown to be a powerful technique for automatically analyzing the data output from an automated test system. Two applications of simulation techniques to solidification processes are next described. The first deals with dendrite growth. A computer simulation shows that models for heat (or solute) flow coupled with a model for the solid-liquid interface are adequate to account for the branching and growth velocity of dendrites. The second deals with a solidifying casting aud illustrates the way additional models can be added to allow the description given by the simulation to resolve finer details of behavior. The wide scope of simulation techniques is illustrated by reference to the simulation of transmission electron micrographs. In conclusion, the sequential approach to simulation is recommended. In this approach, the simplest possible simulation is developed first. Then, additional models are added to refine the original treatment and improve its resolution.
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07.05.Tp Computer modeling and simulation
81.10.Aj Theory and models of crystal growth; physics and chemistry of crystal growth, crystal morphology, and orientation
81.70.Bt Mechanical testing, impact tests, static and dynamic loads
68.37.Hk Scanning electron microscopy (SEM) (including EBIC)
68.37.Lp Transmission electron microscopy (TEM)

Vacuum Heat Treating Using Plasma EB

H. Takei and Y. Yoneda

J. Vac. Sci. Technol. 7, S36 (1970); http://dx.doi.org/10.1116/1.1315914 (3 pages)

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This paper describes a semicontinuous heat treatment equipment with some of its operating results for metal strips or foils. Work accelerated electron flux from a hot hollow cathode discharge is used for bombarding the strip. Use of hot hollow cathod discharge for annealing of a metal strip was briefly discussed by Morley in 1963. (see Ref. 1.) Smith, Jr. and Hunt reported in 1965 (Ref. 2) the use of high-voltage high-vacuum electron beam for continuous annealing of metal strips. Homogeneous thermal history, rapid heating cycle, and a very high temperature processing are obtainable by using an electron bombardment heating for running strips. Processing of metal strips while running will also be desirable for high temperature treatment where adhesion between layers of a roll may cause defects. The high-voltage high-vacuum EB is advantageous in obtaining higher energy density than the use of hot hollow cathode EB. The latter, however, operates at a low voltage and often more economically than the former. Less evaporation of a volatile component can be another factor to be considered for some alloys. Thus refractory alloys strip rolls that require high temperature contamination free environment, minimum vaporization of volatile component, and nonsticking between layers will be suitable for the plasma EB semicontinuous or continuous processing.
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81.40.Wx Radiation treatment (particle and electromagnetic)

Recent Developments in Hard and Soft Vacuum Electron-Beam Welding

H. A. James

J. Vac. Sci. Technol. 7, S39 (1970); http://dx.doi.org/10.1116/1.1315915 (1 page)

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Electron-beam welding at hard vacuum (10−6–10−3 Torr) has been a valued and increasingly widely used method of metal joining ever since its origination in the middle 1950's by Dr. J. A. Stohr. Extensive application of the process has been made by the aircraft and aerospace industry, in particular, for primary structural members. Means have been developed to permit the welding of such parts along straight or irregular paths over lengths of more than thirty feet. The increasing interest to apply electron-beam welding to an even broader range of industrial welding situations has led to development of high production, short pumpdown time machines that weld in the soft vacuum range of 0.001–1.0 Torr at rates of more than 1000 parts∕h. Some of the recently developed means to accomplish this in a particular case are described in detail. This paper also discusses the new developments which greatly simplify initial alignment of the electron beam and the workpiece, and make possible the guidance of the beam along the straight or irregular welding path. Some discussion of the special equipment facilities required for production of these weldments is included.
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81.20.Vj Joining; welding

New Applications of Electron-Beam Melting and Casting Techniques

H. Stephan and W. Dietrich

J. Vac. Sci. Technol. 7, S39 (1970); http://dx.doi.org/10.1116/1.1315916 (1 page)

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The advantages of electron-beam melting and casting compared to vacuum arc casting techniques will be discussed. The relations between fluidity, superheat, mold material, and mold temperature will be demonstrated using cast stars. Essential mechanical and chemical properties of cast rod samples will also be discussed. Process data of an electron-beam investment casting furnace such as beam power, casting production, and attainable superheat will be correlated. Results of a newly developed pelletizing process for titanium-scrap recycling and the purification of tungsten carbide particles illustrating the influence of pellet shape, gas content, and pellet weight will be discussed and compared to another, but different, recycling process for scrap consolidation by electron-beam melting. Use of the electron-beam continuous flow melting process for the production of long and thin titanium and steel castings will be demonstrated. The possibility of using scrap as starting material will be illustrated and compared with other types of starting stock.
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81.20.-n Methods of materials synthesis and materials processing

Vapor Deposition by Liquid Phase Sputtering

R. C. Krutenat and W. R. Gesick

J. Vac. Sci. Technol. 7, S40 (1970); http://dx.doi.org/10.1116/1.1315917 (5 pages) | Cited 3 times

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Liquid binary alloy targets have been sputtered at ion densities of up to 100 W∕cm2 providing deposition rates in excess of 10 mils∕h in a combined sputtering-evaporation mode. At high power densities a serf-sputtering mode has been demonstrated which allows deposition from 10−7 to 10−2 Torr. Comparison of sputtered deposit compositions of Pb-24 In, Fe-30 V and Fe-32 Ni with theoretical molar ratios predicted on the basis of thermal vaporization shows that alloy fractionation is substantially reduced. The composition of deposits from solid or liquid Pb-24 In targets had nearly the same Pb∕In ratio, 5.8(target ratio=1.75) although the predicted ratio for thermalized vapor was 1300. For Fe-30 V liquid targets where less than 0.5% vanadium is predicted from thermal vaporization alone, a sputtered deposit containing 10.3% vanadium was found, suggesting that the approximate sputtering∕evaporation ratio is 0.3. Liquid phase targets of Fe-32 Ni alloy had average molar ratios of Fe∕Ni close to 3 (target ratio was 2.2), whereas the predicted ratio from thermal vaporization was 5.8. There was only a slight increase in Fe∕Ni ratio in the self-sputtering mode at 10−6 Torr over that obtained with argon sputtering at 10−3 Torr.
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81.15.Cd Deposition by sputtering
79.20.Rf Atomic, molecular, and ion beam impact and interactions with surfaces

Superconducting Transition Temperatures of Vapor-Deposited Niobium Nitride

Gin-ichiro Oya and Yutaka Onodera

J. Vac. Sci. Technol. 7, S44 (1970); http://dx.doi.org/10.1116/1.1315918 (4 pages) | Cited 1 time

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Thin films of the superconducting compound niobium nitride were deposited at atmospheric pressure on fused silica substrates by reaction of gaseous niobium pentachloride with ammonia and hydrogen gases in a fused silica apparatus. Suitable conditions for the preparation of NbN were found by calculating the free energies of reaction for several possible reactions involving niobium chlorides, ammonia, and hydrogen. Niobium nitride films could be formed at substrate temperature ranging from 900°–1000°C. The deposition rate varied with the reaction conditions from 20 to 1500 Å∕sec, and deposits ranged from smooth films of polycrystals in which the individual crystal faces were 20 μ in length. The x-ray diffraction data for the NbN films deposited at 1000°C revealed face-centered cubic structure with cube edge of about 4.358 Å. Niobium nitride films prepared by this method had a wide range of resistivities, temperature coefficients of resistance, and superconducting transition temperatures depending on the deposition conditions. The maximum transition temperature obtained was 15.75 K for the films deposited at 900°C.
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74.62.Bf Effects of material synthesis, crystal structure, and chemical composition
74.78.-w Superconducting films and low-dimensional structures
73.61.-r Electrical properties of specific thin films
81.15.-z Methods of deposition of films and coatings; film growth and epitaxy

Metallurgical Characteristics of Titanium-Alloy Foil Prepared by Electron-Beam Evaporation

H. R. Smith, K. Kennedy, and F. S. Boericke

J. Vac. Sci. Technol. 7, S48 (1970); http://dx.doi.org/10.1116/1.1315919 (4 pages) | Cited 3 times

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The supersonic titanium aircraft has requirements for high-strength titanium-alloy foil for honeycomb structures. In conventional rolling of such alloys as titanium-6% aluminum-4% vanadium, multiple high-vacuum anneals are required to reach the thin-foil gages, from 0.001–0.004 in., used for honeycomb cores. The advantages of electron-beam evaporation and deposition in the desired thicknesses, and without rolling and multiple vacuum annealing, are studied. The present research program is designed to prove that foils of such alloys, produced by EB evaporation on a moving substrate, are equivalent to the rolled products. EB foils easily meet the chemical and mechanical property requirements of aerospace specifications. Bend tests are superior to the rolled foil. The metallurgical characteristics have been evaluated using optical micrography and electron micrography with replica, transmission, and scanning techniques. The deposits are fully dense and of grain sizes from 0.2–0.8 μ. Microprobe analyses indicate that the chemical composition is uniform and contains alpha and beta phases. All metallurgical characteristics of EB evaporated foils appear to be suitable for the intended end uses. Evaluations in the form of actual honeycomb structures are underway.
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81.05.Bx Metals, semimetals, and alloys
81.15.Jj Ion and electron beam-assisted deposition; ion plating

Vapor Generation and Deposition of Zinc at High Rates

J. F. Butler

J. Vac. Sci. Technol. 7, S52 (1970); http://dx.doi.org/10.1116/1.1315920 (5 pages)

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A system for zinc vapor generation and deposition onto a strip substrate at high rates is described. A resistance heated graphite crucible with a special design to suppress uncontrolled boiling is able to produce zinc vapor outputs as high as 150 lb∕h for the 300 in.2 hearth area utilized. An efficient system for nozzling the zinc vapor onto the strip substrate from an enclosed hood allows this maximum vaporization rate to be condensed uniformly at a thickness of 0.6 mils across a 12-in. width at a line speed of 100 ft∕min. Control of the vaporization rate is obtained through variation in the power input according to a heat flow model and also by means of a barometric liquid-zinc leg which is used to fill and empty the crucible and feed it continuously from outside the vacuum chamber. Other methods used to control the system are also discussed briefly as is the type of coating produced by deposition at these high rates.
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81.15.-z Methods of deposition of films and coatings; film growth and epitaxy

Formation of Superconducting Nb3Al and Nb3Al–Ge Films

A. Isao, T. Noguchi, Y. Uchida, and A. Kono

J. Vac. Sci. Technol. 7, S57 (1970); http://dx.doi.org/10.1116/1.1315921 (6 pages) | Cited 2 times

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The formation of Nb3Al or Nb3Al–Ge compounds on niobium substrates is described. The film formation was followed using optical microscopy and x-ray diffraction techniques. Electrical resistance measurements at cryogenic temperatures were obtained to determine critical transition temperature for superconductivity. The films wee prepared by three processes: (a) dipping the Nb substrate into an Al–Ge melt contained in a graphite crucible, holding for several seconds followed by a thermal diffusion treatment; (b) vacuum deposition of Al or Al–Ge on Nb followed by heat treatment similar to that in (a). The advantage of vacuum deposition is better control of the film thickness of Al or Al–Ge; (c) and simultaneous deposition of Nb and Al on Nb substrates in vacuum. The deposition rate of Nb and Al was controlled at a 3:1 atomic ratio. Germanium was simultaneously deposited with Al. The Nb3Al or Nb3(Al–Ge) films were formed at temperatures between 1350° and 1650°C for both the (a) and (b) processes with the critical superconductive transition temperature between 15 K and 17.5 K. The films prepared by simultaneous deposition of Al and Ge show that the superconducting behavior depends on the diffusion heat treatment. A heat treatment at 1000°C for 30 min resulted in a Nb3Al film having 3:1 atomic ratio. The critical superconducting temperature for the films produced by these processes was between 15 K and 16 K without an ordering heat treatment. A lowering of the heat treatment (diffusion) temperature for the simultaneously deposited films resulted in a critical superconducting temperature that is in agreement with values reported by Neugebauer for superconducting Nb3Sn. The lower heat treating temperatures of 1000° and 1200°C are expected to result in higher critical current densities.
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74.78.-w Superconducting films and low-dimensional structures
81.15.-z Methods of deposition of films and coatings; film growth and epitaxy

Vacuum Deposition of Thick Coatings and Free-Standing Parts Using Electron-Beam Evaporation

D. L. Chambers and W. K. Bower

J. Vac. Sci. Technol. 7, S62 (1970); http://dx.doi.org/10.1116/1.1315923 (1 page)

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Continued improvements in electron-beam evaporation technology have led to applications for vacuum deposition to apply thick coatings and to fabricate free-standing parts. The use of improved electron-beam guns, rod-type source feeders, high-capacity power supplies, and beam-sweep control components has permitted high-quality thick coatings and shapes to be continuously deposited in thicknesses from 0.010 in. to more than 0.100 in. The deposition of three materials using electron-beam heated sources is described. The materials are: magnesium, as a subliming material; gold, as an evaporating metallic element; and Type 304 stainless steel, as an alloy. Descriptions of the electron-beam equipment, the materials handling, the vacuum systems, the tooling, and rate monitors are presented, together with a discussion of the continuous-deposition process techniques. Evaporation–deposition parameters for the various materials and typical conditions for the film depositions are reported. Measurements were made to determine deposition rates at various electron-beam power levels for all of the deposited materials. The effects of the substrate temperature and the deposition rate on the deposited films were investigated and data are presented showing at several temperatures and rates. Metallographic analyses and mechanical property measurements are discussed showing the variation in coating characteristics as a function of the deposition conditions. A discussion of alloy deposition is included with a description of techniques used to deposit a specific alloy (Type 304 stainless steel) as an example of alloy deposition. A description is given of the equipment and process control used to deposit thick stainless-steel parts. Metallographic and chemical analyses of these deposits are reported, including the variations in alloy composition as a function of film thickness.
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81.15.Jj Ion and electron beam-assisted deposition; ion plating

Theory and Practice of Electroslag Melting

A. Mitchell

J. Vac. Sci. Technol. 7, S63 (1970); http://dx.doi.org/10.1116/1.1315924 (11 pages) | Cited 3 times

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The mechanisms of heat transfer and heat generation in an electroslag process are considered and related to operating characteristics of the process. It is concluded that the form of heat transfer in the slag∕mold wall region has a profound effect on the ingot surface. Also, it is noted that the presence of the slag layer has an over-all effect on the heat balance which accounts for the shallow ingot pool-profiles found in ESR ingots. The nature of chemical reactions in the electroslag process is briefly discussed in relation to the oxygen content of ESR ingots. Finally, the synergistic character of ESR process parameters is illustrated by considering the effect of power variations on the ingot solidification pattern.
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81.20.-n Methods of materials synthesis and materials processing

Purification of Vanadium by Vacuum Melting

W. E. Anable

J. Vac. Sci. Technol. 7, S74 (1970); http://dx.doi.org/10.1116/1.1315925 (8 pages)

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The Bureau of Mines compared the purification of two commercially available vanadium samples by three vacuum melting techniques: consumable-electrode arc melting in a conventional deep mold, consumable-electrode arc melting at the top of the mold, and conventional electron-beam melting. Top-of-the-mold (TOM) and electron-beam (EBF) melts were both conducted in the same vessel equipped with a bottom-withdrawal mechanism. Pressures during melting were in the range of 0.10–0.50 mTorr; the pressure in the deep mold could not be measured, but probably exceeded 100–300 mTorr during a typical melt. Arc melting was characterized by melting rates of 500–800 g∕min, but electron-beam melts were limited to rates of 20–30 g∕min. Forty-nine percent of the oxygen content was removed by double melting vanadium sponge at the top of the mold, and 42% of the oxygen content was removed from electrorefined vanadium treated in the same manner; however, the carbon and nitrogen increased. The purity of samples melted at the TOM approached the purity of samples prepared in the EBF. In some instances, a further decrease in the oxygen and metallic impurity content resulted from remelting selected materials in the electron-beam furnace. Little or no purification resulted from melting vanadium in the conventional deep mold. Purification proceeded faster and more completely on melting vanadium with small additions of yttrium, carbon, or aluminum; aluminum was largely removed on double melting, but carbon and yttrium were retained in the products. Metal or carbon additions tended to stabilize the arc and improve metal recovery from 85 to greater than 90% during a consumable-electrode arc melt. Typical metal hardness ranged from Rhn B-20 to B-30. Mass-spectrometric studies conducted in conjunction with the purification work demonstrated that CO, CO2, Al2O, and AlO were the principal oxides, while Al, Fe, Ti, Mn, Ni, V, Cr, Ca, and Cu were the principal metallics evolved when heating and melting vanadium. The volatilization of VO was slow and incomplete; therefore, sacrificial dissociation was of minor importance in the purification of vanadium.
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81.20.Ym Purification
81.05.Bx Metals, semimetals, and alloys

Power Supplies for Electroslag Furnaces: A Preliminary Comparison

R. J. Roberts

J. Vac. Sci. Technol. 7, S81 (1970); http://dx.doi.org/10.1116/1.1315926 (1 page)

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This paper reviews the relative merits of the five main types of power supplies that can be used for electroslag melting. These are: ac single-phase line frequency, ac three-phase line frequency, dc electrode positive, dc electrode negative, and ac low frequency. The comparisons are based mainly on operating experience with furnaces producing industrial-sized ingots [over 12 in. (30.5 cm) in diameter] in a wide variety of ferrous and nickel-based alloys. The power supplies are compared on the basis of the following 14 industrially important indices: power cost per ton, power supply capital cost, electrode costs, total furnace capital cost, melt setup cost, desulphurization in ferrous alloys, molten metal pool depth, absence of inherent stirring, applicability to slab melting, molten slag starting, melt mode flexibility, supply line balance, supply line flicker, and power supply reliability. In general, the survey shows each of the possible melt modes their advantages, disadvantages, and the fact that none of them can be recommended as a universal solution for all applications. It is, however, apparent from the comparisons that ac single-phase line frequency has the broadest potential application.
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81.20.-n Methods of materials synthesis and materials processing
07.20.Hy Furnaces; heaters

Application of Static Metallic Adhesion Data to Friction

R. G. Aldrich and D. V. Keller

J. Vac. Sci. Technol. 7, S82 (1970); http://dx.doi.org/10.1116/1.1315927 (8 pages)

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The significance of metallic adhesion phenomena are reviewed relative to the sliding friction behavior of metals and alloys. A model is presented for the analysis of sliding friction based upon contact resistance measurements and experimental data presented for the materials combinations ultra-pure iron vs ultra-pure iron, iron 65-ppm carbon vs iron 65-ppm carbon, and 440 C stainless steel vs 440 C stainless steel. It is shown that the behavior observed for these materials combinations under conditions of sliding friction can be predicted from normal force adhesion experiments using a four wire contact resistance bridge circuit. The effects of environment as well as compressive load, sliding frequency, time, and specimen geometry are discussed. It is further shown that significant data are generated by the adhesion technique for the definition of the mechanical properties of the true load bearing area.
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81.40.Pq Friction, lubrication, and wear
81.05.Bx Metals, semimetals, and alloys
68.35.Gy Mechanical properties; surface strains

Behavior of Refractory Metal Surfaces in Ultrahigh Vacuum as Observed by Low-Energy Electron Diffraction (LEED) and Auger Electron Spectroscopy

George J. Dooley and T. W. Haas

J. Vac. Sci. Technol. 7, S90 (1970); http://dx.doi.org/10.1116/1.1315928 (11 pages) | Cited 3 times

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Surface phenomena of both refractory metal single crystals and polycrystalline foils in ultrahigh vacuum environments (1×10−9–2×10−11 Torr) are discussed. Some of the more common refractory metals which have been studied are Ti, V, Cr, Fe, Zr, Nb, Mo, Rh, Hf, Ta, W, Re, and Au. Surface studies are initiated once the sample has been placed in the ultrahigh vacuum chamber, and the entire system has been baked out for several hours around 250°C. The first technique employed is Auger electron spectroscopy which involves measuring the energies of certain inelastically (secondary) emitted electrons by means of any one of several available energy analyzing devices. In our case, the low-energy electron diffraction (LEED) optics of a standard Varian unit were modified to serve as the required retarding potential energy analyzers. This technique enables the composition of the sample surface to be monitored during the procedures necessary to produce the clean metal surface. Specifically, some of the cleaning procedures are high temperature anneals (to near the melting point), reaction with H or O, and Ar ion bombardment. Some of the various contaminants which segregate on several refractory metal surfaces during cleaning procedures will be identified and techniques for their removal discussed. The sample surface is considered clean when its Auger spectrum corresponds very closely to published spectra taken from surfaces thought to be clean to the limit of present detection techniques. Once clean and in the 10−10–10−11 Torr range, the surface of the sample will remain clean for extended periods of time. If the clean specimen is then exposed to somewhat higher pressures (10−6–10−8 Torr) of common gases such as O2, H2, N2, and CO, the LEED pattern will in most instances change from that characteristic of the clean surface to another pattern due to the particular structure and species of adsorbed gas. One or more coverage states may exist for the same gas being chemisorbed onto the same single crystal metal surface. In most cases, a new coverage state will give rise to a different LEED pattern. And, except for H, the particular adsorbed species can again be identified using Auger spectroscopy. Specific cases to be discussed will be the adsorption of H, O, and CO on the three most densely packed planes of Mo, namely the (110), (100), and (112) planes, the adsorption of O on the Re (0001) plane, and other selected results on W, Ta, Hf, and Zr.
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68.35.-p Solid surfaces and solid-solid interfaces: structure and energetics
61.05.jh Low-energy electron diffraction (LEED) and reflection high-energy electron diffraction (RHEED)
81.70.Jb Chemical composition analysis, chemical depth and dopant profiling

Gas-Metal Reactions of Refractory Metals at High Temperature in High Vacuum

E. Fromm

J. Vac. Sci. Technol. 7, S100 (1970); http://dx.doi.org/10.1116/1.1315891 (6 pages) | Cited 2 times

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The reactions of Nb, Ta, Mo, and W with the gases H2, N2, O2, H2O, CH4, and CO at high temperatures are discussed. Quantitative relations are compiled for the estimation of the minimum gas content attainable in vacuum metallurgical processes of both the degassing time and the metal loss due to oxide evaporation.
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73.20.Mf Collective excitations (including excitons, polarons, plasmons and other charge-density excitations)
81.20.-n Methods of materials synthesis and materials processing

Electron-Beam Float Zone and Vacuum Purification of Vanadium

R. E. Reed

J. Vac. Sci. Technol. 7, S105 (1970); http://dx.doi.org/10.1116/1.1315892 (8 pages) | Cited 2 times

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Electron-beam float zone melting vanadium three passes at 3.9 in.∕h in 4×10−10 Torr vacuum resulted in resistance ratios of about 700 and a total impurity content of 50 wt ppm. The zoning reduced both carbon and oxygen content. However, while carbon removal was always accompanied by a lowering of the oxygen content, the reverse was not true. The removal of oxygen was probably accomplished by the formation and volatilization of VO. The mechanism for carbon removal was not clearly resolved. Nitrogen was not appreciably affected by electron-beam float zone melting. All metallic impurities, with the exception of Ta and W and possibly Si, were effectively volatilized. No evidence was found for zone refining action on any impurity. Vacuum outgassing further reduced the carbon and oxygen level. However, the oxygen removal was far more effective than the carbon. The nitrogen content increased, particularly on the specimens that lost about 40% in weight due to vanadium evaporation. However, the effect of vacuum outgassing was less on the highest purity as-zoned specimens. The same purification mechanisms apparently operated.
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81.10.Fq Growth from melts; zone melting and refining

Creep–Rupture Properties of C-129Y in Vacuum

R. L. Stephenson

J. Vac. Sci. Technol. 7, S112 (1970); http://dx.doi.org/10.1116/1.1315893 (4 pages)

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Creep-rupture properties for C-129Y (Nb–10% W–10% Hf–0.1% Y) to 1000 h are presented at 980°, 1095°, and 1205°C. Improvements in strength at 980° and 1205°C can be achieved by pretest annealing at higher temperatures. These improvements are achieved only at the expense of a significant loss in ductility.
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81.40.Lm Deformation, plasticity, and creep
81.05.Bx Metals, semimetals, and alloys

Outgassing of Nuclear Rocket Fuel Elements

D. S. Easton and R. E. Clausing

J. Vac. Sci. Technol. 7, S116 (1970); http://dx.doi.org/10.1116/1.1315894 (8 pages)

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In order to predict the gaseous environment in a nuclear rocket engine before and after operation in space, an apparatus has been developed for measuring the type, quantity, and outgassing rates of gases that are released from graphite fuel elements at various temperatures in vacuum. Data readout from a quadrupole residual gas analyzer (QRGA) and nude Bayard-Alpert type ion gages permit analysis of up to 12 gases simultaneously. The data are processed by a computer program which first calculates the partial pressures of the various gases from a least square fit to a set of 18 simultaneous equations (one for each spectrometer peak) with 12 unknowns (12 separate gases). The coefficients of the unknowns are obtained from the cracking patterns of individual gases. The program then calculates and tabulates the outgassing rate of each gas for each sampling time and produces plots of the outgassing as functions of time or temperature. The computer program also: (a) fits the outgassing rates to an analytical expression, prints out the constants for the equation, and draws the best curve of the specified form through the data points; (b) extrapolates the data to long outgassing times and prints out the outgassing rates and total quantity of each gas at selected times; (c) compiles the data from a number of runs and plots the outgassing rates at preselected times as a function of temperature; and (d) prints out control data such as cracking patterns, calibration constants, and various checks and comparisons to aid in the evaluation of the instrumentation. The experiment not only produces accurate and detailed outgassing data, but also makes possible a more accurate extrapolation of data to long times and other temperatures. The detailed results will also aid in understanding the mechanisms controlling outgassing behavior.
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28.41.Bm Fuel elements, preparation, reloading, and reprocessing
28.50.Ky Propulsion reactors

Application of Auger Electron Spectroscopy to Reactor Materials Research

R. E. Clausing

J. Vac. Sci. Technol. 7, S124 (1970); http://dx.doi.org/10.1116/1.1315895 (1 page)

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The analysis of minute quantities of material on a surface is frequently essential in understanding the behavior of materials relative to the systems of which they are a part. Auger electron spectroscopy offers a unique method for studying the first few atomic layers of a surface. The elemental composition of the surface can be determined provided that the surface is dominated by only a few elements. Also, in favorable circumstances, information on the oxidation state of the surface elements may be obtained. In reactor systems thin films of fission fragments and∕or corrosion products may be important not only from the standpoint of the usual materials problems of corrosion or mechanical properties, but also for reasons related to neutron economy, fission-product control, maintenance, and the removal of afterheat due to radioactive decay when a reactor is shut down. Auger analysis is being used to determine the elemental composition of thin film deposits on graphite from the Oak Ridge National Laboratory Molten-Salt Reactor Experiment. This paper considers four main problem areas related to the application of Auger electron spectroscopy to nuclear reactor materials. First, the materials to be studied are radioactive which makes handling them hazardous. While this may necessitate special shielding and safety precautions, it is primarily an inconvenience and except in cases involving unusually intense beta emission the radioactivity of the sample need not interfere with the measurement of Auger spectra. Second, the relative merits of using a retarding potential electron energy analyzer as opposed to cylindrical or spherical sector electron spectrometers are discussed. The retarding potential electron energy analyzers are physically simpler and more readily available, but the spectrometers have important advantages in resolution, in sensitivity, and in discriminating against beta radiation, as well as the background of secondary electrons. Third, the problems encountered during the analysis of the spectra are illustrated. In fission product analysis, chemical shifts, and the overlap of Auger spectra of elements (especially those adjacent to each other in the fourth and higher periods) can become bothersome. If a large number of elements are present on the same surface, the large width of the most prominent Auger peaks is a very significant complicating factor. Fourth, extreme care must be taken to ensure that the surface examined is not contaminated or altered to an unknown extent during sample acquisition or preparation. If contamination cannot be avoided, cleaning techniques which do not destroy the surface of interest must be devised. Thermal treatments, electron bombardment, ion bombardment, or chemical means may be helpful depending on circumstances.
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28.41.Qb Structural and shielding materials
82.80.Pv Electron spectroscopy (X-ray photoelectron (XPS), Auger electron spectroscopy (AES), etc.)

Aluminum Ion Plating of Uranium–Molybdenum Alloy Fast-Burst Reactor Elements

R. T. Bell

J. Vac. Sci. Technol. 7, S125 (1970); http://dx.doi.org/10.1116/1.1315896 (1 page)

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Ion plating of thin (<0.002 in.) aluminum coatings on fast-burst reactor parts fabricated from uranium–10% molybdenum alloy was evaluated as a method of protecting the alloy from oxidation and as a means of containing the fission products. A number of core rings were plated with nickel while other rings were ion-plated with aluminum so that a comparison between the two coatings could be made. During the ion plating of aluminum and subsequent heat treatment, certain uranium–aluminum intermetallic compounds (UAl2, UAl3, and UAl4) were formed. During the process of testing to destruction, these rings encountered fissions in excess of 1017 and temperatures in excess of 700°C during which the nickel plating spalled severely while the aluminum and the uranium–aluminum intermetallics remained adherent to the alloy.
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28.41.Bm Fuel elements, preparation, reloading, and reprocessing
81.15.Jj Ion and electron beam-assisted deposition; ion plating

An Investigation of Heat Flow in Unidirectional Solidification of Vacuum-Cast Airfoils

B. G. Monteith and T. S. Piwonka

J. Vac. Sci. Technol. 7, S126 (1970); http://dx.doi.org/10.1116/1.1315897 (6 pages)

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In order to better understand the thermal events occurring during the unidirectional solidification of Mar M-200 (proprietary alloy of Martin-Marietta, Inc.) alloy turbine blades, an analytical thermal model was developed which permitted simulation of the solidification process. A representative turbine blade was divided into isothermal nodes, and an electrical analog thermal model was constructed and solved using a digital computer. The technique was verified by comparing calculated and measured external mold surface temperatures during solidification. The analytical thermal model showed that thermal gradients in the liquid–solid growth zone are high near the chill, and decrease as the distance from the chill increases. Temperature profiles were converted into solidification profiles from experimental data which showed the percent solid as a function of temperature in the solidification zone. The curves permit a qualitative explanation of the occasional occurrence of segregation and hot cracking in this alloy, and indicate that precautions must be taken in the solidification process to avoid these phenomena.
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81.10.Aj Theory and models of crystal growth; physics and chemistry of crystal growth, crystal morphology, and orientation

Vacuum Heat Treatment of Tool Steels

R. W. Reynoldson and K. C. Harris

J. Vac. Sci. Technol. 7, S131 (1970); http://dx.doi.org/10.1116/1.1315898 (1 page)

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The heat treatment of tools and dies in vacuum furnaces is discussed, together with the major problems of dimensional changes in tool steels, and methods of controlling such changes in the equipment available today.
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81.40.Gh Other heat and thermomechanical treatments

Quench Atomization of Iron-Base Alloys into Metal Powders

Pradip Rao, Richard Grandzol, Norbert Schulz, and John Tallmadge

J. Vac. Sci. Technol. 7, S132 (1970); http://dx.doi.org/10.1116/1.1315899 (5 pages)

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Quench atomization is discussed as a powder formation step used in the production of structural shapes by powder metallurgy. Emphasis is placed on the continuing study of atomization of liquid metals by the two-fluid nozzle method. The influence of atomization control variables on powder properties is considered, where the important characteristics include particle size, chemistry, grain size, and particle shape. Results from a 3–20 kg pilot unit are reported for the case of nitrogen atomization with an annular nozzle. Size, shape, and other powder properties are compared for the case of low and high carbon iron alloys. Some of the interrelationships between atomization and concurrent parts of the powder metallurgy study include fundamental mechanisms and process optimization as well as powder production and experimental studies.
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81.20.Ev Powder processing: powder metallurgy, compaction, sintering, mechanical alloying, and granulation
81.05.Bx Metals, semimetals, and alloys

Refining and Decarburizing Steel-Degassing Process in the Melting Practice of Alloy Steels

H. Bauer, H. J. Fleischer, and J. Otto

J. Vac. Sci. Technol. 7, S137 (1970); http://dx.doi.org/10.1116/1.1315900 (6 pages)

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Reduction of the oxygen content of low to medium alloy steels by the C–O reaction under low pressure is discussed. Avoidance of disturbing reactions with the ladle refractory is accomplished by using basic lined teeming ladles with sliding stoppers. The exothermic vacuum refining of high chromium content alloyed steels is accomplished with gaseous oxygen. The importance of this new process should be considered when planning for the construction of steel plants in the future.
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81.20.-n Methods of materials synthesis and materials processing
81.05.Bx Metals, semimetals, and alloys

The Importance of Vacuum and Remelting Practices in a Modern Specialty Steel Plant. Part I: Metallurgical Problems and Their Solution

H. J. Mueller-Aue, H. Spitzer, K. Tesche, and G. Zingel

J. Vac. Sci. Technol. 7, S143 (1970); http://dx.doi.org/10.1116/1.1315901 (1 page)

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In the production of specialty steels, a number of merallurgical problems are encountered that affect the ultimate quality and cost. To name a few, there are high-cost charging materials, long melting times, inadequate alloy recovery, the need for compliance with extremely close compositional analysis, costly desulfurization, slow precipitation of deoxidizing products, high hydrogen contents, oxygen, nitrogen, and hydrogen pick-up during tapping, and segregation during solidification. Various degassing methods developed, with and without agitation, washed and non-washed baths, are all applied in vacuum decarburizing, deoxidizing, and complemental alloying. It is possible to keep these operations separate from the actual melting plant and adopt a two-stage technique made up of the “melting furnace” and “plant for treatment.” This separation increases capacity substantially and reduces costs. Larger, economical vacuum-induction furnaces permit melting, decarburizing, deoxidizing, alloying, evaporation, and pouring under vacuum or inert gas. Two remelting practices using vacuum and slag have been developed to very high technological standards which permit the application of additional refining and ensure a practically segregation-free solidification.
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81.20.-n Methods of materials synthesis and materials processing
81.05.Bx Metals, semimetals, and alloys

The Importance of Vacuum and Remelting Practices in a Modern Specialty Steel Plant. Part II: The Production of Different Specialty Steels

H. J. Mueller-Aue, H. Spitzer, K. Tesche, and G. Zingel

J. Vac. Sci. Technol. 7, S143 (1970); http://dx.doi.org/10.1116/1.1315902 (1 page)

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The various groups of specialty steels require different melting techniques, treatments, pouring methods, and remelting processes. Depending on their composition and application, quality and cost are significant factors governing the decision for a specific procedure. For example, the two-stage technique—UHP electric furnace or BOF-vacuum plant—is successful in the production of anti-friction bearing steel, in that it reduces the oxide content and produces a more consistent product. In the production of alloyed engineering steels, as used by the automotive industry, excellent results are obtained with this same two-step method. This method reduces melting times with gains in purity and closer control of alloying content and grain size. For special requirements such as aircraft engines, the steel is vacuum-melted and vacuum-remelted. Precision forgings require degassing treatments and with unusual specifications for purity and freedom from segregation vacuum-arc or electro-slag remelting. Special purity tool steels are initially melted in the arc furnace or oxygen converter and then treated under vacuum. Widespread use is made of the possible variations in the two-stage arrangement, “melting furnace-vacuum plant”, in the production of stainless steels. As opposed to the traditional methods of producing this type of steel, appropriate combinations result in significant cost and quality advantages. High purity stainless steels, particularly in the form of flat shapes, are commonly VAR- or ESR-remelted. However, the most pronounced effects in melting, vacuum treatment, and remelting are found in the field of high-temperature materials.
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81.20.-n Methods of materials synthesis and materials processing
81.05.Bx Metals, semimetals, and alloys

Deoxidation of Stainless Steel by Carbon in Laboratory-Scale Vacuum Induction Melting

Tetsuya Watanabe

J. Vac. Sci. Technol. 7, S144 (1970); http://dx.doi.org/10.1116/1.1315903 (5 pages)

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This paper describes an investigation of deoxidation of stainless steels by carbon during laboratory-scale vacuum induction melting. Chemical kinetic processes occurring during deoxidation by carbon, final equilibrium pressure of CO, deoxidation limit, and the effect of SiO2 in refractory materials on deoxidation efficiency, are explained.
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81.20.-n Methods of materials synthesis and materials processing
81.05.Bx Metals, semimetals, and alloys
82.20.-w Chemical kinetics and dynamics

Vacuum–Carbon Deoxidation of Iron Melts in a 70% Alumina Brick Crucible

K. R. Olen

J. Vac. Sci. Technol. 7, S149 (1970); http://dx.doi.org/10.1116/1.1315904 (5 pages)

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A series of 0.20 and 1.00% C-Fe melts was processed under various reduced pressures of carbon monoxide at 1600°C in a 70% alumina crucible made from commercial quality refractory brick. The bath aluminum and oxygen contents were found to be a nonlinear function of treatment pressure, whereas the bath silicon content was found to be pressure independent. The results support a previously proposed model in which melt-refractory interactions limit oxygen removal during vacuum processing.
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81.20.-n Methods of materials synthesis and materials processing
81.05.Bx Metals, semimetals, and alloys

Vacuum Stream Degassing of Molten Aluminum

S. J. Hellier and G. H. J. Bennett

J. Vac. Sci. Technol. 7, S154 (1970); http://dx.doi.org/10.1116/1.1315906 (4 pages)

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The design and operation of a small-scale stream degassing facility for removing solute hydrogen from molten aluminum are described. It is shown that an aluminum melt may be successfully degassed by passing it through a vacuum in the form of a thin continuous cylindrical stream. Solute hydrogen removal is improved by increasing the specific surface area of the stream and also by increasing the height of fall of the stream up to an optimum value. Increasing the height of fall beyond the optimum does not result in a further improvement in hydrogen removal, and can in fact lead to poorer degassing than that obtained using shorter streams. This is associated with fracture of the longest streams during fall. The rate of hydrogen removal increases as the stream temperature is reduced. Using a 1.6- mm-diam orifice and 57-cm height of fall, 2 kg melts of 99.99% pure aluminum at 750°C, containing up to and over 0.5 Ncm3∕100 g of hydrogen, were stream degassed in a vacuum of 1 Torr to levels near 0.1 Ncm3∕100 g. Hydrogen removal from the unbroken streams appears to follow second-order kinetics.
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81.20.Ym Purification
81.05.Bx Metals, semimetals, and alloys

Removal of Hydrogen by Pouring Molten Steel in Vacuum

M. Fukumoto and K. Taniguchi

J. Vac. Sci. Technol. 7, S158 (1970); http://dx.doi.org/10.1116/1.1315907 (4 pages)

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An investigation was made into the removal of hydrogen from the melt of medium carbon steel on 10 heat practices of vacuum, pouring under a pressure of 8–12 mmHg. The degassing process can be divided into three steps according to observation from high-speed photography. By vacuum degassing, hydrogen, nitrogen, and oxygen are reduced from an average of 3.5 to 1.7 ppm, from 70 to 60 ppm, and from 60 to 35 ppm, respectively. With the composition and the volume of purge gas which comes out of the steel in the vacuum tank, hydrogen, nitrogen, and oxygen in the melt should decrease by about 2, 9, and 15 ppm, respectively. The removal of hydrogen depends upon the formation and the growth of gas bubbles. In this case, the amount of oxygen has a large affect upon the removal of hydrogen. In other practices, it is recognized that a lower pressure such as 1–3 mmHg is more favorable for the removal of hydrogen than 8–12 mmHg from the view point of growth and formation of gas bubbles.
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81.20.Ym Purification
81.05.Bx Metals, semimetals, and alloys

Theory, Design, and Selection of Vacuum Metallurgical Processing Equipment

John H. Durant

J. Vac. Sci. Technol. 7, S162 (1970); http://dx.doi.org/10.1116/1.1315908 (1 page)

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Process advantages of vacuum are compared with conventional and inert gas atmospheres with respect to purity, repeatability, and operating cost. Recognition of vapor pressures of workloads, containers, and furnace hot zone parts is essential to predicting system performance parameters, maintenance schedules, and pumping equipment selection. Cooling requirements of batch equipment are evaluated with respect to quench characteristics, equipment turn-around time, and work-piece surface quality. Design features of system details are evaluated for such factors as heat removal (jacketing vs traced cooling); safety (one-piece electrode design); integrity at full vacuum and partial pressure operation. Typical systems are examined for conformity to design criteria established.
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81.20.-n Methods of materials synthesis and materials processing
07.30.Kf Vacuum chambers, auxiliary apparatus, and materials

Design and Operation of a One-Chamber Vacuum Furnace for Dewax, Presinter, and Sinter of Cemented Carbide

Walter M. McCain

J. Vac. Sci. Technol. 7, S162 (1970); http://dx.doi.org/10.1116/1.1315909 (6 pages)

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Cemented carbide production is via normal powder metallurgy processes. Cobalt is the most common “cement” and commercial paraffin is the most common pressing lubricant. Production furnaces for processing cemented carbide have evolved from simple hydrogen atmosphere furnaces to complex, specialized, multi-chamber vacuum furnaces. The workhorse of the industry today is semi-batch equipment, carousel-like, in which loads are lowered from a loading chamber onto an indexing table in a large cylindrical vacuum tank, and successively rotated and raised into a dewax furnace, then a sinter furnace, and into cooling, before being finally unloaded from the initial loading chamber. While having excellent capacity per investment dollar or per labor dollar, such equipment lacks process flexibility, and loss of a single component can stop the whole process. In 1964 a single chamber design was conceived, inherently more simple, with good flexibility, and lower incremental investment. A prototype was built and tested in 1965, and by 1966 the first two production furnaces were in operation. Many such furnaces are now in operation, and more are currently being installed. The removal of the pressing lubricant from the reaction zone is critical to the maintenance of the carbon balance required. While its removal is relatively easy in a hydrogen furnace, it is physically more difficult in vacuum. Reference to a Cox chart will permit design of a reasonably efficient system. Each of the seven major chemical and physical reactions which occur in converting the powder metal compact to a fully dense “hard metal” part, must be taken into account in the design of production equipment. Liquid phase sintering consists of densification, homogenization, and controlled grain growth. Equations have been developed expressing grain growth as a time-temperature function. Time-temperature profile surveys have been used to determine isotherms, and isograin growth lines, to provide closely controlled sintering.
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81.20.Ev Powder processing: powder metallurgy, compaction, sintering, mechanical alloying, and granulation
07.20.Hy Furnaces; heaters

Effect of Atomization Media and Consolidation Techniques upon Physical Properties of a P∕M Cobalt-Base Alloy

S. B. Brandstedt

J. Vac. Sci. Technol. 7, S167 (1970); http://dx.doi.org/10.1116/1.1315910 (1 page)

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Inert gas produces a powder with less surface area and lower gas content than water atomization. Nitrogen as an atomization medium results ia approximately five times the nitrogen content compared to powders atomized with argon. Oxygen is present principally in the form of surface oxide, and to a minor extent as adsorbed gas on the surface of the powder particles. The latter can be removed by a vacuum treatment which also partially removes the oxide film. Results from Coldstream processing with air as the fluid for comminution is compared with inert gas processing. Coldpressing and sintering, hot extrusion, and hot forging are compared as alternative methods to consolidate powder of type X-40 into high density bodies. Densities of 92% of theoretical were obtained by coldpressing and sintering in dry hydrogen or vacuum. Both hot forging and hot extrusion using the canning-evacuation method produce full density compacts. Room temperature properties for X-40 and two other Co-base alloys were determined for these consolidation methods. Metallographic evaluation of P∕M products vs conventionally-cast material reveals differences believed to produce improved reproducibility and higher reliability of the P∕M product. Alloys earlier known as “nonforgeable” can be given a high degree of forgeability by starting with a prealloyed powder as the raw material. Examples of such applications are presented.
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81.20.Ev Powder processing: powder metallurgy, compaction, sintering, mechanical alloying, and granulation
81.05.Bx Metals, semimetals, and alloys

Use of the Photoemission Electron Microscope as a High-Vacuum Hot-Stage Microscope for Temperatures up to 2000°C

H.-D. Dannöhl and L. Wegmann

J. Vac. Sci. Technol. 7, S168 (1970); http://dx.doi.org/10.1116/1.1315911 (1 page)

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When studying vacuum-treated materials at high temperatures, the specimen must be kept at a low pressure, which is at least of the same magnitude as that used during the metallurgical treatment, to avoid contamination by gases. The pressure obtainable in most commercial hot-stage microscopes is not low enough, resolution at the higher temperatures is poor, and contamination of the optics often affects longtime studies. Progress has been made with the emission electron microscope using kinetic and thermionic emission; however, electron emission at low temperatures was possible only with kinetic emission or by coating the specimen with thin films to lower the work function. Surface conditions were then uncontrollably altered. These disadvantages are not present in the photoemission electron microscope. Using powerful vacuum pumps, continuous observations at gas pressures within the normal working range of 5×10−7 Torr and 10−3 Torr are possible. With liquid helium cryopumping, pressures of 10−8 Torr are obtainable. Gas treatments at higher pressure are possible, but without simultaneous observation of the specimen. In the temperature range up to the onset of thermionic emission, a resolution of 150 Å can be obtained from polished samples. When thermionic emission occurs, contrast is not altered and the limit of resolution is unaltered. This type of microscope is now available for studying materials in excellent vacuum with high resolution in the range from room temperature to 2000 °C. Special devices prevent contamination of the sample so that long-term studies can be made over several hours or days with continuous observation. Several accessories attached to the preparation chamber, which is directly connected to the observation chamber and pumped with the same vacuum pumps, allow different treatments such as specimen coating, quenching, cleaning by ion-bombardment, and ion etching. A comparison of the photoemission electron microscope and the scanning electron microscope is made on flat specimens. The results show that only the photoemission electron microscope works at all temperatures with excellent contrast and resolution. Several examples are used to illustrate the potential application of the photoemission electron microscope in the fields of recrystallization, diffusion, precipitation, and transformation studies.
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68.37.Xy Scanning Auger microscopy, photoelectron microscopy
07.78.+s Electron, positron, and ion microscopes; electron diffractometers
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