Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

NIST invents fleet and fast test for nanomanufacturing quality control

07.03.2016

Manufacturers may soon have a speedy and nondestructive way to test a wide array of materials under real-world conditions, thanks to an advance that researchers at the National Institute of Standards and Technology (NIST) have made in roll-to-roll measurements. Roll-to-roll measurements are typically optical measurements for roll-to-roll manufacturing, any method that uses conveyor belts for continuous processing of items, from tires to nanotechnology components.

In order for new materials such as carbon nanotubes and graphene to play an increasingly important role in electronic devices, high-tech composites and other applications, manufacturers will need quality-control tests to ensure that products have desired characteristics, and lack flaws.


Measurements of electrical properties of a plastic tape (yellow), taken using a specially designed microwave cavity (the white cylinder at center) and accompanying electrical circuit, change quickly and consistently in response to changes in the tape's thickness. The setup is inspired by high-volume roll-to-roll manufacturing devices used to mass-produce nanomaterials. The changes in the tape's thickness spell NIST in Morse code.

Credit: NIST/Nathan Orloff

Current test procedures often require cutting, scratching or otherwise touching a product, which slows the manufacturing process and can damage or even destroy the sample being tested.

To add to existing testing non-contact methods, NIST physicists Nathan Orloff, Christian Long and Jan Obrzut measured properties of films by passing them through a specially designed metal box known as a microwave cavity. Electromagnetic waves build up inside the cavity at a specific "resonance" frequency determined by the box's size and shape, similar to how a guitar string vibrates at a specific pitch depending on its length and tension.

When an object is placed inside the cavity, the resonance frequency changes in a way that depends on the object's size, electrical resistance and dielectric constant, a measure of an object's ability to store energy in an electric field. The frequency change is reminiscent of how shortening or tightening a guitar string makes it resonate at a higher pitch, says Orloff.

The researchers also built an electrical circuit to measure these changes. They first tested their device by running a strip of plastic tape known as polyimide through the cavity, using a roll-to-roll setup resembling high-volume roll-to-roll manufacturing devices used to mass-produce nanomaterials. (See video.)

As the tape's thickness increased and decreased--the researchers made the changes in tape thickness spell "NIST" in Morse code--the cavity's resonant frequency changed in tandem. So did another parameter called the "quality factor," which is the ratio of the energy stored in the cavity to the energy lost per frequency cycle. Because polyimide's electrical properties are well known, a manufacturer could use the cavity measurements to monitor whether tape is coming off the production line at a consistent thickness--and even feeding back information from the measurements to control the thickness.

Alternatively, a manufacturer could use the new method to monitor the electrical properties of a less well-characterized material of known dimensions. Orloff and Long demonstrated this by passing 12- and 15-centimeter-long films of carbon nanotubes deposited on sheets of plastic through the cavity and measuring the films' electrical resistance. The entire process took "less than a second," says Orloff. He added that with industry-standard equipment, the measurements could be taken at speeds beyond 10 meters per second, more than enough for many present-day manufacturing operations.

The new method has several advantages for a thin-film manufacturer, says Orloff. One, "You can measure the entire thing, not just a small sample," he said. Such real-time measurements could be used to tune the manufacturing process without shutting it down, or to discard a faulty batch of product before it gets out the factory door. "This method could significantly boost prospects of not making a faulty batch in the first place," Long noted.

And because the method is nondestructive, Orloff added, "If a batch passes the test, manufacturers can sell it."

Films of carbon nanotubes and graphene are just starting to be manufactured in bulk for potential applications such as composite airplane materials, smartphone screens and wearable electronic devices.

Orloff, Long and Obrzut submitted a patent application for this technique in December 2015.

A producer of such materials has already expressed interest in the new method, said Orloff. "They're really excited about it." He added that the method is not specific to nanomanufacturing, and with a properly designed cavity, could also help with quality control of many other kinds of products, including tires, pharmaceuticals and even beer.

Media Contact

Ben Stein
bstein@nist.gov
301-975-2763

 @usnistgov

http://www.nist.gov 

Ben Stein | EurekAlert!

More articles from Power and Electrical Engineering:

nachricht Did you know that the wrapping of Easter eggs benefits from specialty light sources?
13.04.2017 | Heraeus Noblelight GmbH

nachricht To e-, or not to e-, the question for the exotic 'Si-III' phase of silicon
05.04.2017 | Carnegie Institution for Science

All articles from Power and Electrical Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Making lightweight construction suitable for series production

More and more automobile companies are focusing on body parts made of carbon fiber reinforced plastics (CFRP). However, manufacturing and repair costs must be further reduced in order to make CFRP more economical in use. Together with the Volkswagen AG and five other partners in the project HolQueSt 3D, the Laser Zentrum Hannover e.V. (LZH) has developed laser processes for the automatic trimming, drilling and repair of three-dimensional components.

Automated manufacturing processes are the basis for ultimately establishing the series production of CFRP components. In the project HolQueSt 3D, the LZH has...

Im Focus: Wonder material? Novel nanotube structure strengthens thin films for flexible electronics

Reflecting the structure of composites found in nature and the ancient world, researchers at the University of Illinois at Urbana-Champaign have synthesized thin carbon nanotube (CNT) textiles that exhibit both high electrical conductivity and a level of toughness that is about fifty times higher than copper films, currently used in electronics.

"The structural robustness of thin metal films has significant importance for the reliable operation of smart skin and flexible electronics including...

Im Focus: Deep inside Galaxy M87

The nearby, giant radio galaxy M87 hosts a supermassive black hole (BH) and is well-known for its bright jet dominating the spectrum over ten orders of magnitude in frequency. Due to its proximity, jet prominence, and the large black hole mass, M87 is the best laboratory for investigating the formation, acceleration, and collimation of relativistic jets. A research team led by Silke Britzen from the Max Planck Institute for Radio Astronomy in Bonn, Germany, has found strong indication for turbulent processes connecting the accretion disk and the jet of that galaxy providing insights into the longstanding problem of the origin of astrophysical jets.

Supermassive black holes form some of the most enigmatic phenomena in astrophysics. Their enormous energy output is supposed to be generated by the...

Im Focus: A Quantum Low Pass for Photons

Physicists in Garching observe novel quantum effect that limits the number of emitted photons.

The probability to find a certain number of photons inside a laser pulse usually corresponds to a classical distribution of independent events, the so-called...

Im Focus: Microprocessors based on a layer of just three atoms

Microprocessors based on atomically thin materials hold the promise of the evolution of traditional processors as well as new applications in the field of flexible electronics. Now, a TU Wien research team led by Thomas Müller has made a breakthrough in this field as part of an ongoing research project.

Two-dimensional materials, or 2D materials for short, are extremely versatile, although – or often more precisely because – they are made up of just one or a...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Expert meeting “Health Business Connect” will connect international medical technology companies

20.04.2017 | Event News

Wenn der Computer das Gehirn austrickst

18.04.2017 | Event News

7th International Conference on Crystalline Silicon Photovoltaics in Freiburg on April 3-5, 2017

03.04.2017 | Event News

 
Latest News

Bare bones: Making bones transparent

27.04.2017 | Life Sciences

Study offers new theoretical approach to describing non-equilibrium phase transitions

27.04.2017 | Physics and Astronomy

From volcano's slope, NASA instrument looks sky high and to the future

27.04.2017 | Earth Sciences

VideoLinks
B2B-VideoLinks
More VideoLinks >>>