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This presentation is an overview of the following, Spalling on 211 oriented wafers produces flat surface without faceting: 1) Demonstrated spall on entire 2" wafer; 2) GaAs and GaInP grown on 211 wafers by HVPE; and 3) Promising cell with VOC=1.02 V and IQE-1. Next steps: 1) Grow cell on spalled wafer and 2) Growth studies to improve material and cell on 211 substrates.
We analyze the effect of growth on non-(100) surfaces resulting from incomplete planarization of spalled GaAs wafers on the defect structure of GaAs solar cell layers grown by hydride vapor phase epitaxy (HVPE). Controlled spalling of (100)-oriented GaAs has the potential to reduce substrate costs for III-V epitaxy; however, it creates regularly faceted surfaces that may complicate the growth of high-quality III-V optoelectronic devices. We leverage the anisotropic growth rate of HVPE to planarize these faceted GaAs substrates, reducing the surface roughness and degree of faceting. We observe degraded solar cell performance and material quality in sample areas where facets are not completely removed. We used dark lock-in thermography and photoluminescence to identify recombination in areas that were not fully planarized. We used cathodoluminescence to identify the presence of extended defects in these regions, which are correlated with bandgap fluctuations in the material. We hypothesize that these defects were created by strain from compositional fluctuations in ternary alloys grown on the faceted surfaces. This work elucidates the potential issues of solar cells grown on faceted surfaces and builds understanding toward realizing high performance III-V photovoltaics with the cost-reduction potential of controlled spalling.
Successful wafer-scale layer transfer from high-quality 2-in. diameter bulk gallium nitride substrates was demonstrated using the Controlled Spalling technique. The crystal quality of both the as-fractured bulk substrate and the spalled GaN film was assessed using transmission electron microscopy analysis, and the defect density was below the detection limit (mid 107 cm−2) for both samples. By using the experimentally determined critical conditions for tensile stress and thickness of the Ni stressor layer, an effective fracture toughness KIC of 1.7 MPa m could be calculated for [0001] fracture using the Suo and Hutchinson mechanical model. The resulting in-plane contraction of the GaN film after spalling permitted a novel method for measuring film strain without knowledge of the elastic properties of the material. This was used to measure the Raman E2(high) peak shift coefficient of Δω(cm−1) = 1411ε which, when converted to a stress coefficient (2.95 cm−1/GPa), was in agreement with only one other literature value.
There has been a challenge for many decades to understand how heterogeneities influence the behavior of materials under shock loading, eventually leading to spall formation and failure. Experimental, analytical, and computational techniques have matured to the point where systematic studies of materials with complex microstructures under shock loading and the associated failure mechanisms are feasible. This is enabled by more accurate diagnostics as well as characterization methods. As interest in complex materials grows, understanding and predicting the role of heterogeneities in determining the dynamic behavior becomes crucial. Early computational studies, hydrocodes, in particular, historically preclude any irregularities in the form of defects and impurities in the material microstructure for the sake of simplification and to retain the hydrodynamic conservation equations. Contemporary computational methods, notably molecular dynamics simulations, can overcome this limitation by incorporating inhomogeneities albeit at a much lower length and time scale. This review discusses literature that has focused on investigating the role of various imperfections in the shock and spall behavior, emphasizing mainly heterogeneities such as second-phase particles, inclusions, and voids under both shock compression and release. Pre-existing defects are found in most engineering materials, ranging from thermodynamically necessary vacancies, to interstitial and dislocation, to microstructural features such as inclusions, second phase particles, voids, grain boundaries, and triple junctions. This literature review explores the interaction of these heterogeneities under shock loading during compression and release. Systematic characterization of material heterogeneities before and after shock loading, along with direct measurements of Hugoniot elastic limit and spall strength, allows for more generalized theories to be formulated. Further, continuous improvement toward time-resolved, in situ experimental data strengthens the ability to elucidate upon results gathered from simulations and analytical models, thus improving the overall ability to understand and predict how materials behave under dynamic loading.
This report presents the infrasound data recorded as part of the Source Physics Experiment - Phase 2, Dry Alluvium Geology. This experiment, also known colloquially as DAG, consisted of four underground chemical explosions at the Nevada National Security Site. We focus our analysis on only the fourth explosion (DAG-4) as we determined that this was the only event that produced clear source-generated infrasound energy as recorded by the DAG sensors. We analyze the data using two inversion methods. The first method is designed to estimate the point-source seismoacoustic source time functions, and the second inversion method is designed to estimate the first-order characteristics (e.g. horizontal dimensions and maximum amplitude) of the actual spall surface. For both analysis methods, we are able to fit the data reasonably well, with various assumptions of the source model. The estimated seismoacoustic source appears to be a combination of a buried, isotropic explosion with a maximum amplitude of ~2 x 10 9 Nm and a vertically oriented force, applied to the Earth's surface with a maximum amplitude of 4 x 10 7 N. We use the vertically oriented force to simulate surface spall. The estimated spall surface has an approximate radius of ~40 m with a maximum acceleration magnitude in the range of 0.8 to 1.5 m/s/s. These estimates are approximately similar to the measured surface acceleration at the site.
Additive manufactured Ti-5Al-5V-5Mo-3Cr (Ti-5553) is being considered as an AM repair material for engineering applications because of its superior strength properties compared to other titanium alloys. Here, we describe the failure mechanisms observed through computed tomography, electron backscatter diffraction (EBSD), and scanning electron microscopy (SEM) of spall damage as a result of tensile failure in as-built and annealed Ti-5553. We also investigate the phase stability in native powder, as-built and annealed Ti-5553 through diamond anvil cell (DAC) and ramp compression experiments. We then explore the effect of tensile loading on a sample containing an interface between a Ti-6Al-V4 (Ti-64) baseplate and additively manufactured Ti-5553 layer. Post-mortem materials characterization showed spallation occurred in regions of initial porosity and the interface provides a nucleation site for spall damage below the spall strength of Ti-5553. Preliminary peridynamics modeling of the dynamic experiments is described. Finally, we discuss further development of Stochastic Parallel PARticle Kinteic Simulator (SPPARKS) Monte Carlo (MC) capabilities to include the integration of alpha (α)-phase and microstructural simulations for this multiphase titanium alloy.
In evaluating the state-of-the-art spalling techniques, the key factor that is missing is the control of crack propagation, which is responsible for low quality wafers due to high surface roughness and Total Thickness Variation, TTV. This project has shown that acoustic waves can alter the conditions at the crack tip during thermal spalling, modifying the propagation speed and the stress field around it (stress intensity factor, K). Both factors are directly related to the roughness of the spalled surface, so as we control speed and stress, we can fine-tune the surface roughness through the entire wafer as suggested by Arakawa.
The results of a two year study of the mechanisms of spall failure in the HPOTP bearings are described. The objective was to build a foundation for detailed analyses of the contact life in terms of: cyclic plasticity, contact mechanics, spall nucleation, and spall growth. Since the laboratory rolling contact testing is carried out in the 3 ball/rod contact fatigue testing machine, the analysis of the contacts and contact lives produced in this machine received attention. The results from the experimentally observed growth lives are compared with calculated predictions derived from the fracture mechanics calculations.
A cyclic oxidation interfacial spalling model has been developed in Part 1. The governing equations have been simplified here by substituting a new algebraic expression for the series (Good-Smialek approximation). This produced a direct relationship between cyclic oxidation weight change and model input parameters. It also allowed for the mathematical derivation of various descriptive parameters as a function of the inputs. It is shown that the maximum in weight change varies directly with the parabolic rate constant and cycle duration and inversely with the spall fraction, all to the 1/2 power. The number of cycles to reach maximum and zero weight change vary inversely with the spall fraction, and the ratio of these cycles is exactly 1:3 for most oxides. By suitably normalizing the weight change and cycle number, it is shown that all cyclic oxidation weight change model curves can be represented by one universal expression for a given oxide scale.
This study demonstrates the potential of sonic lift-off (SLO) technology for repeatable substrate reuse in gallium arsenide (GaAs)–based photovoltaics (PVs), offering a pathway toward cost effective production for terrestrial PV applications. Single-junction GaAs solar cells fabricated on acoustically spalled substrates achieved performance metrics comparable with those grown on standard commercial substrates, exhibiting short-circuit current densities (J sc ) of approximately 26.2–26.4 mA/cm 2 , open-circuit voltages (V oc ) around 1001 mV, fill factors (FFs) of 84%, and AM1.5G efficiencies near 22%. These results confirm that one reuse cycle can be realized without a performance penalty, offering a direct pathway to reducing substrate cost in fabrication. Furthermore, subsequent reuse of the substrates highlighted critical challenges, as devices fabricated from reused substrates showed significant degradation in performance (J sc of 15.5 mA/cm 2 , V oc of 748 mV, FF of 72%, and efficiency of 8%), primarily due to degradation of the epitaxial structure resulting from repeated spalling cycles.
In this study, we experimentally investigate the high stain rate and spall behavior of Cantor high-entropy alloy (HEA), CoCrFeMnNi. First, the Hugoniot equations of state (EOS) for the samples are determined using laser-driven CoCrFeMnNi flyers launched into known Lithium Fluoride (LiF) windows. Photon Doppler Velocimetry (PDV) recordings of the velocity profiles find the EOS coefficients using an impedance mismatch technique. Following this set of measurements, laser-driven aluminum flyer plates are accelerated to velocities of 0.5–1.0 km/s using a high-energy pulse laser. Upon impact with CoCrFeMnNi samples, the shock response is found through PDV measurements of the free surface velocities. From this second set of measurements, the spall strength of the alloy is found for pressures up to 5 GPa and strain rates in excess of 106 s−1. Further analysis of the failure mechanisms behind the spallation is conducted using fractography revealing the occurrence of ductile fracture at voids presumed to be caused by chromium oxide deposits created during the manufacturing process.
In this work, we apply the morphology control of hydride vapor phase epitaxial (HVPE) growth to planarize faceted, non-planar substrates. Controlled spalling is a promising high-throughput substrate reuse technology that could reduce substrate costs for III-V devices; however, the spalling fracture for (100)-oriented GaAs substrates produces a regularly corrugated surface of facets that are 5-20 um in height. We discuss how to planarize these surfaces using only a few minutes of HVPE growth and how to minimize the impact on throughput when integrating faceted wafers into a potential manufacturing process at scale.
We investigate deformation and damage of a Zr-based bulk metallic glass (BMG) and its Ta particle-reinforced composite (MGMC) under impact loading, as well as quasi-static tension for comparison. Yield strength, spall strength, and damage accumulation rate are obtained from free-surface velocity histories, and MGMC appears to be more damage-resistant. Scanning electron microscopy, electron back scattering diffraction and x-ray computed tomography, are utilized for characterizing microstructures, which show features consistent with macroscopic measurements. Different damage and fracture modes are observed for BMG and MGMC. Multiple well-defined spall planes are observed in BMG, while isolated and scattered cracking around reinforced particles dominates fracture of MGMC. Particle–matrix interface serves as the source and barrier to crack nucleation and propagation under both quasi-static and impact loading. Finally, deformation twinning and grain refinement play a key role in plastic deformation during shock loading but not in quasi-static loading. In addition, 3D cup-cone structures are resolved in BMG, but not in MGMC due to its heterogeneous stress field.
The spall strength and dynamic yield stress of polycrystalline hafnium have been measured in a series of plane-wave shock loading experiments using flat sample–transparent window composite targets, with the transparent windows representing polymethyl methacrylate or lithium fluoride plates arranged on the rear side of a hafnium sample. The front side of the target was subjected to shock impact of a copper striker, the rear surface velocity was measured, and the sample was recovered for subsequent metallographic examination. The results were also used for evaluation of the accuracy of spall strength measurements and the analysis of features of high-rate deformation of hafnium.
Presentation includes slides on Surface Science used to probe LEU-10Mo Spall; Auger highlights graphitic-like inclusions and Mo-deficient oxide on base metal; Higher C concentration detected within spall area Images Courtesy; Depth profiling reveals thick oxide; Mo concentration nears nominal only at depths ~400 nm; and lastly Key Findings.
Discussion of the microimpact-crater morphology observed by scanning electron microscopy on a glass bead (nearly 580 microns in maximum diameter) recovered from zone A of the Luna 16 sample. The microcrater has a diameter of approximately 200 microns and a centrally located melted region or pit that is slightly elevated above the surrounding area. Around the pit is a radial fracture zone half of which has spalled off. The spall zone is more than half again as large as the radial fracture zone.
Proposed solutions to the problems of sputter erosion and sputtered material spalling in the discharge chamber of small mercury ion thrusters are presented. The accelerated life test evaluated three such proposed solutions: (1) the use of tantalum as a single low sputter yield material for the exposed surfaces of the discharge chamber components subject to sputtering, (2) the use of a severely roughened anode surface to improve the adhesion of the sputter-deposited coating, and (3) the use of a wire cloth anode surface in order to limit the size of any coating flakes which might spall from it. Because of the promising results obtained in the accelerated life test with anode surfaces roughened by grit-blasting, experiments were carried out to optimize the grit-blasting procedure. The experimental results and an optimal grit-blasting procedure are presented.
Tantalum and molybdenum sputtered from discharge chamber components during operation of a 5 centimeter diameter mercury ion thruster adhered much more strongly to coarsely grit blasted anode surfaces than to standard surfaces. Spalling of the sputtered coating did occur from a coarse screen anode surface but only in flakes less than a mesh unit long. The results were obtained in a 200 hour accelerated life test conducted at an elevated discharge potential of 64.6 volts. The test approximately reproduced the major sputter erosion and deposition effects that occur under normal operation but at approximately 75 times the normal rate. No discharge chamber component suffered sufficient erosion in the test to threaten its structural integrity or further serviceability. The test indicated that the use of tantalum-surfaced discharge chamber components in conjunction with a fine wire screen anode surface should cure the problems of sputter erosion and sputtered deposits spalling in long term operation of small mercury ion thrusters.