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Growth of continuous silicon dendritic web that is up to 5 cm wide instead on only 1.3 cm is formed by freezing of supercooled liquid silicon between two needlelike dendritic crystals. Growth takes place in a work chamber filled with argon gas. As web grows, it is drawn out of chamber through a duct and guided to a storage reel.
Proposed control system for dendritic-web growth of silicon ribbons varies ribbon speed according to melt temperature. System prevents too fast or too slow withdrawal of silicon web, which cause pullout of web or excessive web thickness, respectively. System also enables semiautomatic startup of web growth by automatically increasing web speed from zero to optimum value.
We report progress in three areas of investigation related to dendritic crystal growth. Those items include: 1. Selection of tip features dendritic crystal growth; 2) Investigation of nonlinear evolution for two-sided model; and 3) Rigorous mathematical justification.
Abstract not provided.
The distribution of slip dislocations in silicon dendritic web ribbons due to plastic deformation during the cooling phase of the growth was studied. The results show the existence of two distinguishable stress regions across the ribbon formed during the plastic deformation stage, namely, shear stress at the ribbon edges and tensile stress at the middle. In addition, slip dislocations caused by shear stress near the edges appear to originate at the twin plane.
Broadly speaking, our efforts have been concentrated in two aspects of directional solidification: (A) a more complete theoretical understanding of convection effects in a Bridgman apparatus; and (B) a clear understanding of scalings of various features of dendritic crystal growth in the sensitive limit of small capillary effects. For studies that fall within class A, the principal objectives are as follows: (A1) Derive analytical formulas for segregation, interfacial shape and fluid velocities in mathematically amenable asymptotic limits. (A2) Numerically verify and extend asymptotic results to other ranges of parameter space with a view to a broader physical understanding of the general trends. With respect to studies that fall within class B, the principal objectives include answering the following questions about dendritic crystal growth: (B1) Are there unsteady dendrite solutions in 2-D to the completely nonlinear time evolving equations in the small surface tension limit with only a locally steady tip region with well defined tip radius and velocity? Is anisotropy in surface tension necessary for the existence of such solutions as it is for a true steady state needle crystal? How does the size of such a local region depend on capillary effects, anisotropy and undercooling? (B2) How do the different control parameters affect the nonlinear amplification of tip noise and dendritic side branch coarsening?
The main focus is on solidification occurring in highly supercooled melts. Solidification rates in such melts are extremely high, an attractive feature from a commercial standpoint. Thus, the reported growth velocities for pure Ni and Co dendrites at a supercooling of 175 K are in excess of 180 km/hr. Rapidly quenched crystalline alloys produced by various atomization processes (e.g., centrifugal atomization or inert gas atomization) or melt spinning are examples of solidification processes, currently being intensively explored commercially, wherein extremely high solidification rates are achieved. Estimated dendrite tip growth rates are about 2 km/hr in a binary Al-4.5 wt % alloy, with a heat transfer coefficient of 6.4x10 sub 5 w/sq cm K or 15 cal/cu cm sK. In the limit, when the solidification rate exceeds a critical value, a glassy microstructure is obtained even in highly alloyed melts, which under normal conditions would solidity to form one or more crystalline phases. Glassy metals, also called metallic glasses, are candidate materials for distribution transformers because of their very low energy losses and are also being used in brazing and soldering applications.
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A quantitative calculation of growth rates and tip radii is presented for dendrites growing in undercooled dilute solutions. Included in the calculations are the capillary corrections to the steady-state Ivantsov needle-crystal solutions. The results show good agreement with available experimental data and support the validity of the marginal-stability theory of dendritic growth.
Single-crystal material grown under precise control. New furnace permits sustained growth of single-crystal silicon ribbon by dendritic-web growth process. Furnace brings together mechanisms necessary for continuous automatic operation.
Epitaxial columnar grain growth is a prevalent microstructural feature in the additive manufacturing (AM) of metal components such as Inconel, with cubic unit cell crystal lattice structure (face centered cubic (FCC) or body centered cubic (BCC)). These columnar grains evolve from the partly molten grains in the substrate or the solidified metal. This work proposes an efficient model to simulate the competitive growth of epitaxial columnar dendritic grains. The proposed model tracks the dynamic changes in the dendrites emanating from discrete points along the solid/liquid interface of a quasi-steady melt pool (MP). These dynamic changes include convergence and divergence of growing dendrites. The model is extended to predict the microstructure of large 3D parts and experimentally validated by comparing the simulation results for laser powder bed fusion (L-PBF) and wire-arc additive manufacturing (WAAM) processes. The microstructure and pole figures are predicted for Inconel 718 samples produced by L-PBF and Inconel 740H samples produced by WAAM processes. Finally, the model predictions compare well with the observed microstructure and pole figures results for both the L-PBF and WAAM processes.
Replacing the liquid electrolyte in lithium batteries with solid-state ion conductor is promising for next-generation energy storage that is safe and has high energy density. In this work, nanometer-resolution ionic and electronic transport imaging of Li 3 PS 4 (LPS), a solid-state electrolyte (SSE), is reported. This nm resolution is achieved by using a logarithm-scale current amplifier that enhances the current sensitivity to the fA range. Large fluctuations of ion current—one to two orders of magnitude on the LPS and on the LPS region of a polymer/LPS bulk hybrid SSE—that must be mitigated to eliminate Li dendrite formation and growth, are found. This ion current fluctuation is understood in terms of highly anisotropic transport kinetic barriers along the different crystalline axes due to different grain orientations in the polycrystalline and glass ceramic materials. The results on the bulk hybrid SSE show a sharp transition of ionic and electronic transport at the LPS/polymer boundary and decreases in average ionic current with decreasing polyimine particle size and with extensive cycling. The results elucidate the mechanism of polyimine extension into interparticles to prevent Li dendrite growth. This work opens up novel characterization of charge transport, which relates to Li plating and stripping for solid-state-batteries.
A simple model for 'constrained' growth of an 'array' of cells or dendrites in a binary alloy melt, in the presence of a positive temperature gradient in the liquid ahead of the tips, is presented. The cell or dendrite tip radius is calculated by adopting both the 'ad hoc' assumption of minimum undercooling at the tips as well as the more recently proposed hypothesis of dendritic growth under conditions of 'marginal stability'. Theoretical predictions of the model have been compared with experimental data in binary succinonitrile-acetone alloys. It has been shown that, according to the present model, the 'marginally stable' state may be virtually indistinguishable from the 'minimum undercooled' state, under the usual conditions of dendritic growth.
More than a dozen methods have been applied to the growth of silicon ribbons, beginning as early as 1963. The ribbon geometry has been particularly intriguing for photovoltaic applications, because it might provide large area, damage free, nearly continuous substrates without the material loss or cost of ingot wafering. In general, the efficiency of silicon ribbon solar cells has been lower than that of ingot cells. The status of some ribbon growth techniques that have achieved laboratory efficiencies greater than 13.5% are reviewed, i.e., edge-defined, film-fed growth (EFG), edge-supported pulling (ESP), ribbon against a drop (RAD), and dendritic web growth (web).
The quiescent Microgravity environment can be quite dynamic. Thermocapillary flow about "large" static bubbles on the order of 1mm in diameter was easily observed by following smaller tracer bubbles. The bubble induced flow was seen to disrupt a large dendritic array, effectively distributing free branches about the solid-liquid interface. "Small" dynamic bubbles were observed to travel at fast velocities through the mushy zone with the implication of bringing/detaching/redistributing dendrite arm fragments at the solid-liquid interface. Large and small bubbles effectively re-orient/re-distribute dendrite branches/arms/fragments at the solid liquid interface. Subsequent initiation of controlled directional solidification results in growth of dendrites having random orientations which significantly compromises the desired science.
Dopant incorporated feed pellets to maintain required concentration. Technique of continuous replenishment of dopant in silicon melt helps ensure correct resistivity in solid silicon grown from melt. Technique used in dendritic-web growth process in which ribbon of silicon continously pulled from molten material. Providing uniform doping and resistivity in ribbon technique enables production of high-quality silicon ribbon at high yields for use in semiconductor devices.
A barrier crucible design which consistently maintains melt stability over long periods of time was successfully tested and used in long growth runs. The pellet feeder for melt replenishment was operated continuously for growth runs of up to 17 hours. The liquid level sensor comprising a laser/sensor system was operated, performed well, and meets the requirements for maintaining liquid level height during growth and melt replenishment. An automated feedback loop connecting the feed mechanism and the liquid level sensing system was designed and constructed and operated successfully for 3.5 hours demonstrating the feasibility of semi-automated dendritic web growth. The sensitivity of the cost of sheet, to variations in capital equipment cost and recycling dendrites was calculated and it was shown that these factors have relatively little impact on sheet cost. Dendrites from web which had gone all the way through the solar cell fabrication process, when melted and grown into web, produce crystals which show no degradation in cell efficiency. Material quality remains high and cells made from web grown at the start, during, and the end of a run from a replenished melt show comparable efficiencies.