Enhancing the Reactivity of Al/CuO Nanolaminates by Cu Incorporation at the Interfaces

Minor Copper-Doped Aluminum Alloy Enabling Long-Lifetime Organic Light-Emitting Diodes

Aluminum has been extensively used as a conductor material in numerous electronic devices, including solar cells, light-emitting diodes (LEDs), organic LEDs (OLEDs), and thin-film transistors. However, its spiking surface and easy electromigration have limited its performance. To overcome this, a trace amount of nonprecious copper dopant has been proven effective in enhancing device reliability. Nevertheless, a comprehensive investigation regarding the effect of copper doping on the morphology at the aluminum conductor-organic interface is yet to be done. We had hence fabricated a series of green OLED devices to probe how copper doping affected the aluminum conductor, morphologically and electrically, and the corresponding device's efficiency and lifetime performance. We found 4 wt % copper doping to be highly effective in enabling a spike-less and smoother aluminum interface, which in turn enabled the fabrication of devices with much higher efficiency and lifetime. Specifically, the corresponding power efficacy at 1000 cd/m² was increased from 32 to 42 lm/W and the lifetime increased from 75 to 263 h, an increment of 250%. Atomic force microscopy confirmed that the copper doping did help smooth out the conductor interface as deposited and reduce electromigration upon operation.

Influence of process parameters on energetic properties of sputter-deposited Al/CuO reactive multilayers

In this study, we demonstrate the effect of change of the sputtering power and the deposition pressure on the ignition and the combustion properties of Al/CuO reactive thin films. A reduced sputtering power of Al along with the deposition carried out at a higher-pressure result in a high-quality thin film showing a 200% improvement in the burn rate and a 50% drop in the ignition energy. This highlights the direct implication of the change of the process parameters on the responsivity and the reactivity of the reactive film while maintaining the Al and CuO thin-film integrity both crystallographically and chemically. Atomically resolved structural and chemical analyzes enabled us to qualitatively determine how the microstructural differences at the interface (thickness, stress level, delamination at high temperatures and intermixing) facilitate the Al and O migrations and impact the overall nano-thermite reactivity. We found that the deposition of CuO under low pressure produces well-defined and similar Al-CuO and CuO-Al interfaces with the least expected intermixing. Our investigations also showed that the magnitude of residual stress induced during the deposition plays a decisive role in influencing the overall nano-thermite reactivity. Higher is the magnitude of the tensile residual stress induced, stronger is the presence of gaseous oxygen at the interface. By contrast, high compressive interfacial stress aids in preserving the Al atoms for the main reaction while not getting expended in the interface thickening. Overall, this analysis helped in understanding the effect of change of deposition conditions on the reactivity of Al/CuO nanolaminates and several handles that may be pulled to optimize the process better by means of physical engineering of the interfaces.

Selecting Machine Learning Models to Support the Design of Al/CuO Nanothermites

Novel properties associated with nanothermites have attracted great interest for several applications, including lead-free primers and igniters. However, the prediction of quantitative structure-energetic performance relationships is still challenging. This study investigates machine learning methods as tools to surrogate complex physical models to design novel nanothermites with optimized burning rates chosen for energetic performance. The study focuses on Al/CuO nanolaminates, for which nine supervised regressors commonly used in ML applied to materials science are investigated. For each, an ML model is built using a database containing a set of 2700 Al/CuO nanolaminate systems, specifically generated for this study. We demonstrate the superiority of the multilayer perceptron algorithm to surrogate conventional physical-based models and predict the Al/CuO nanolaminate microstructure-burn rate relationship with good efficiency: the burn rate is estimated with less than 1% error (0.07 m·s^-1), which is very good for designing nano-engineered energetic materials, knowing that it typically varies from approximately 8-20 m·s^-1. In addition, the optimization of the Al/CuO nanolaminate structure for burn rate maximization through machine learning takes a few milliseconds, against several days to achieve this task using a physical model, and months experimentally.

Using a Thin ZnO Film as an Intermediate Layer to Tune the Performance of Mg-Based Nanolaminates: A First-Principles Study

Recently, an interface engineering method using a thin ZnO film as an intermediate layer was employed to tune the performance of nanothermites. The deposition-related surface chemistry of nanolaminates dominates the ignition and combustion performances of the nanothermites. We performed first-principles calculations and ab initio molecular dynamics simulations to study the chemical mechanisms of adsorption and penetration for Mg on the ZnO polar surface during the early stage of interface formation. The results show that the Mg adatom tends to be adsorbed on the fcc and hcp sites of the surface. The formation of an initial mixed interface is spontaneous at room temperature. The subsurface layer of Zn migrates above the surface, that is, the segregation of Zn on the ZnO surface. The thin ZnO film can act as a barrier layer to avoid the diffusion contact of Mg and Zn atoms with CuO. Our work provides some theoretical insights for tuning the performance of the nanolaminates through interface engineering at atomic and electronic levels.

Effect of the Ni and NiO Interface Layer on the Energy Performance of Core/Shell CuO/Al Systems

The interface layer is responsible for the outward migration of oxygen atoms, which subsequently leads to an adjustment in the energetic performance of nanothermite films. In this study, sandwich-structured CuO@Ni/Al and CuO@NiO/Al nanowire thermite films were successfully prepared to investigate the effects of the interface layer on the heat-release, ignition, and combustion performance. The effects of the Ni and NiO interface layers are extremely different on the heat-release performance and combustion properties of the CuO/Al nanowire thermite film. Herein, the introduced Ni layer decreased the heat release (1979.7 J/g), reactivity (E_a = 177.3 kJ/mol), and maximum pressure (2.32 MPa) compared with the CuO/Al composite. Al/Ni alloys can be formed at the interface to prevent oxygen from diffusing between CuO and Al. Moreover, the incorporation of the Ni interface layer into the CuO/Al systems results in a heat drop due to its heat-absorption capability as well as its blockage of heat transfer from the thermite reaction. The deposition of the NiO layer between CuO and Al leads to an increase in the heat release (3014.2 J/g) and a decrease in the activation energy (E_a = 178.6 kJ/mol). The NiO layer endows the CuO/Al system with a high energy-release rate and chemical reactivity. NiO can participate in a thermite reaction, which promotes the reaction of CuO/Al and induces the condensed phase.

Probing the reaction mechanism of Al/CuO nanocomposites doped with ammonium perchlorate

The oxide shell of Al nanoparticles (Al NPs) prevents further reaction of Al/CuO nanothermites which reduces Al utilization efficiency and the performance of the nanothermites. However, the performance of Al/CuO nanothermites can be improved by adding ammonium perchlorate (AP). In this work, in order to confirm and explain the enhancement mechanism of AP on Al/CuO nanothermites, Al/CuO/NC and Al/CuO/NC/AP composites were prepared using the electrospray method. The composites were characterized by differential scanning calorimetry/thermogravimetric, x-ray diffraction, scanning electron microscope and transmission electron microscopy. Meanwhile, the ignition temperature and the time-resolved analysis of the rapid pyrolysis chemistry of the composites were tested using T-jump and time-of-flight mass spectrometry, respectively. The results show that Al NPs of Al/CuO/NC/AP composite are hollow compared to Al/CuO/NC composite after reaction. Al NPs and CuO NPs reduce the decomposition temperature and facilitate the rapid decomposition of the AP, and the decomposition products of the AP can destroy the oxidation layer of Al NPs. This result facilitates the further conduct of the thermite reaction. A mutually reinforcing relationship exists between the Al/CuO/NC composites and AP.

Precisely Controlled Reactive Multilayer Films with Excellent Energy Release Property for Laser-Induced Ignition

Three types of reactive multilayer films (RMFs) were integrated to the energetic flyer plates (EFPs) by depositing TiO₂, MnO₂, and CuO onto aluminum films with different modulation periods using magnetron sputtering technology in this study. The effects of the laser ignition property and laser reflectivity on the RMFs and the thermal behavior of the RMFs were analyzed and compared with those of a single-layer Al film. A high-speed video, photonic Doppler velocimetry (PDV), and a thermal analysis were utilized to characterize the flame morphology, EFP velocity, and chemical thermal behavior, respectively. The surface reflectivities of the TiO₂/Al, MnO₂/Al, and CuO/Al layers were measured using laser reflectivity spectrometers. The results showed that RMFs with smaller modulation periods exhibited excellent laser ignition performances, and EFP with MnO₂/Al had the best performance. These RMFs achieved flame durations of 120-220 μs, maximum flame areas of 7.523-11.476 mm², and reaction areas of 0.153-0.434 mm² (laser-induced with 32.20 J/cm²). Flyer velocities of 3972-5522 m/s were obtained in the EFPs by changing the material and modulation period of the RMFs. Furthermore, the rate of the chemical reaction and laser energy utilization were also enhanced by reducing the modulation period and using different material. This behavior was consistent with a one-dimensional nanosecond-laser-induced plasma model. The RMFs of MnO₂/Al exhibited the highest level of energy release and promoted laser energy utilization, which could better improve the performance of laser ignition for practical application.

Energetic Al/Ni Superlattice as a Micro-Plasma Generator with Superb Performances

In this study, energetic Al/Ni superlattice was deposited by magnetron sputtering. A micro-plasma generator was fabricated using the energetic Al/Ni superlattice. The cross-sectional micro-structure of the energetic Al/Ni superlattice was scanned by transmission electron microscopy. Results show that the superlattice is composed of Al layer and Ni layers, and its periodic structure is clearly visible. Moreover, the bilayer thickness is about 25 nm, which consists of about 15 nm Al layer and 10 nm Ni layer. The micro initiator was stimulated using a 0.22 μF capacitor charged at 2900-4100 V. The electrical behaviors were investigated by testing the current-voltage waveform, and the plasma generation was explored by ultra-high-speed camera and photodiode. The integrated micro generator exhibited remarkable electrical exploding phenomenon, leading to plasma generations at a small timescale. The plasma outputs reflected by flyer velocities were superior to that with a much thicker bilayer of 500 nm Al/Ni multilayer. The higher flyer velocity combined with Gurney energy model confirmed the chemical reaction of the Al/Ni superlattice structure contributed to plasma production in comparison with the Al/Ni multilayers. Overall, the energetic Al/Ni superlattice was expected to pave a promising avenue to improve the initiator efficiency at a lower energy investment.

Highly Reactive Metastable Intermixed Composites (MICs): Preparation and Characterization

Highly reactive metastable intermixed composites (MICs) have attracted much attention in the past decades. The MIC family of materials mainly includes traditional metal-based nanothermites, novel core-shell-structured, 3D ordered macroporous-structured, and ternary nanocomposites. By applying special fabrication approaches, highly reactive MICs with uniformly dispersed reactants, "layer-by-layer" or "core-shell" structures, can be prepared. Thus, the combustion performance can be greatly improved, and the ignition characteristics and safety can be precisely controlled by using a certain preparation strategy. Here, the preparation and characterization of the MICs that have been developed during the past few decades are summarized. Traditional preparation methods for MICs generally include physical mixing, high-energy ball milling, sol-gel synthesis, and vapor deposition, while the novel methods include self-assembly, electrophoretic deposition, and electrospinning. Various preparation procedures and the ignition and combustion performance of different MIC reactive systems are compared and discussed. In particular, the advantages of novel structured MICs in terms of safety and combustion efficiency are clarified, based on which suggestions regarding the possible future research directions are proposed.

Enhanced Energetic Performances Based on Integration with the Al/PTFE Nanolaminates

Integrating energetic materials on a chip has received great attention for its widely potential applications in the microscale energy consumption system, including electric initiation device. In this article, reactive Al/PTFE nanolaminates with periodic layer structure are prepared by magnetron sputtering, which consists of fuel Al, oxidant PTFE, and inert layer Al-F compound in a metastable system. The as-deposited Al/PTFE nanolaminates exhibit a significantly high energy output, and the onset temperature and the heat of reaction are 410 °C and 3034 J/g, respectively. Based on these properties, an integrated film bridge is designed and fabricated via integrating Al/PTFE nanolaminates with a Cu exploding foil, which exhibits enhanced energetic performances with more violent explosion phenomenon, larger quantities of ejected product, and higher plasma temperature in comparison with the Cu film bridge. The kinetic energy of flyers derived from the expansion of the Cu film bridge is also increased around 29.9% via integration with the Al/PTFE nanolaminates. Overall, the energetic performances can be improved substantially through a combination of the chemical reaction of Al/PTFE nanolaminates with the electric explosion of the Cu film bridge.

Reactive B/Ti Nano-Multilayers with Superior Performance in Plasma Generation

In this study, reactive B/Ti nano-multilayers were fabricated by magnetron sputtering and the structure and chemical composition were confirmed by transmission electron microscopy and X-ray photoelectron spectroscopy analyses. The periodic multilayer structure can be clearly visible, and the multilayer material is composed of B layers (amorphous), Ti layers (nano-polycrystalline), and intermixed reactants in a metastable system. The as-deposited B/Ti nano-multilayers exhibit a significantly high heat release of 3722 J/g, with an onset reaction temperature of 449 °C. On the basis of these properties, an integrated microigniter was designed and prepared by integration of the B/Ti nano-multilayers with a TaN film bridge for potential applications in plasma generation, and the electric ignition processes were investigated with discharge voltages ranging from 25 to 40 V. The integrated microigniter exhibits improved and stable ignition performances with a short burst time, high plasma temperature, and violent explosion phenomenon in comparison with the TaN film igniter. Overall, the plasma generation of the microigniter can be enhanced substantially by integration with the B/Ti nano-multilayers.

Integration of the 3DOM Al/Co3O4 nanothermite film with a semiconductor bridge to realize a high-output micro-energetic igniter

Microigniters play an important role for the reliable initiation of micro explosive devices. However, the microigniter is still limited by the low out-put energy to realize high reliability and safety. Integration of energetic materials with microigniters is an effective method to enhance the ignition ability. In this work, a Al/Co₃O₄ nanothermite film with a three-dimensionally ordered macroporous structure was prepared by the deposition of nanoscale Al layers using magnetron sputtering on Co₃O₄ skeletons that are synthesized using an inverse template method. Both the uniform structure and nanoscale contact between the Al layers and the Co₃O₄ skeletons lead to an excellent exothermicity. In order to investigate the ignition properties, a micro-energetic igniter has been fabricated by the integration of the Al/Co₃O₄ nanothermite film with a semiconductor bridge microigniter. The thermite reactions between the nanoscale Al layer and the Co₃O₄ skeleton extensively promote the intensity of the spark, the length in duration and the size of the area, which greatly enhance the ignition reliability of the micro-energetic igniter. Moreover, this novel design enables the micro-energetic igniter to fire the pyrotechnic Zr/Pb₃O₄ in a gap of 3.7 mm by capacitor discharge stimulation and to keep the intrinsic instantaneity high and firing energy low. The realization of gap ignition will surely improve the safety level of initiating systems and have a significant impact on the design and application of explosive devices.

A micro-energetic igniter integrated with a 3DOM Al/Co₃O₄ nanothermite film is able to generate larger spark and realize gap ignition.

Performance Enhancement via Incorporation of ZnO Nanolayers in Energetic Al/CuO Multilayers

Al/CuO energetic structure are attractive materials due to their high thermal output and propensity to produce gas. They are widely used to bond components or as next generation of MEMS igniters. In such systems, the reaction process is largely dominated by the outward migration of oxygen atoms from the CuO matrix toward the aluminum layers, and many recent studies have already demonstrated that the interfacial nanolayer between the two reactive layers plays a major role in the material properties. Here we demonstrate that the ALD deposition of a thin ZnO layer on the CuO prior to Al deposition (by sputtering) leads to a substantial increase in the efficiency of the overall reaction. The CuO/ZnO/Al foils generate 98% of their theoretical enthalpy within a single reaction at 900 °C, whereas conventional ZnO-free CuO/Al foils produce only 78% of their theoretical enthalpy, distributed over two distinct reaction steps at 550 °C and 850 °C. Combining high-resolution transmission electron microscopy, X-ray diffraction, and differential scanning calorimetry, we characterized the successive formation of a thin zinc aluminate (ZnAl₂O₄) and zinc oxide interfacial layers, which act as an effective barrier layer against oxygen diffusion at low temperature.

Gas Suppression via Copper Interlayers in Magnetron Sputtered Al-Cu2O Multilayers

The use of thin-foil, self-propagating thermite reactions to bond components successfully depends on the ability to suppress gas generation and avoid pore formation during the exothermic production of brazes. To study the mechanisms of vapor production in diluted thermites, thin film multilayer Al-Cu-Cu₂O-Cu foils are produced via magnetron sputtering, where the Cu layer thickness is systematically increased from 0 to 100 nm in 25 nm increments. The excess Cu layers act as diffusion barriers, limiting the transport of oxygen from the oxide to the Al fuel, as determined by slow heating differential scanning calorimetry experiments. Furthermore, by adding excess Cu to the system, the temperature of the self-propagating thermite reactions drops below the boiling point of Cu, eliminating the metal vapor production. It is determined that Cu vapor production can be eliminated by increasing the Cu interlayer thickness above 50 nm. However, the porous nature of the final products suggests that only metal vapor production is suppressed via dilution. Gas generation via oxygen release is still capable of producing a porous reaction product.

Tuning the Ignition Performance of a Microchip Initiator by Integrating Various Al/MoO3 Reactive Multilayer Films on a Semiconductor Bridge

Reactive multilayer films (RMFs) can be integrated into semiconducting electronic structures with the use of microelectromechanical systems (MEMS) technology and represent potential applications in the advancement of microscale energy-demanding systems. In this study, aluminum/molybdenum trioxide (Al/MoO₃)-based RMFs with different modulation periods were integrated on a semiconductor bridge (SCB) using a combination of an image reversal lift-off process and magnetron sputtering technology. This produced an energetic semiconductor bridge (ESCB)-chip initiator with controlled ignition performance. The effects of the Al/MoO₃ RMFs with different modulation periods on ignition properties of the ESCB initiator were then systematically investigated in terms of flame duration, maximum flame area, and the reaction ratio of the RMFs. These microchip initiators achieved flame durations of 60-600 μs, maximum flame areas of 2.85-17.61 mm², and reaction ratios of ∼14-100% (discharged with 47 μF/30 V) by simply changing the modulation periods of the Al/MoO₃ RMFs. This behavior was also consistent with a one-dimensional diffusion reaction model. The microchip initiator exhibited a high level of integration and proved to have tuned ignition performance, which can potentially be used in civilian and military applications.

Self-Organized Al2Cu Nanocrystals at the Interface of Aluminum-Based Reactive Nanolaminates to Lower Reaction Onset Temperature

Nanoenergetic materials are beginning to play an important role in part because they are being considered as energetic components for materials, chemical, and biochemical communities (e.g., microthermal sources, microactuators, in situ welding and soldering, local enhancement of chemical reactions, nanosterilization, and controlled cell apoptosis) and because their fabrication/synthesis raises fundamental challenges that are pushing the engineering and scientific frontiers. One such challenge is the development of processes to control and enhance the reactivity of materials such as energetics of nanolaminates, and the understanding of associated mechanisms. We present here a new method to substantially decrease the reaction onset temperature and in consequence the reactivity of nanolaminates based on the incorporation of a Cu nanolayer at the interfaces of Al/CuO nanolaminates. We further demonstrate that control of its thickness allows accurate tuning of both the thermal transport and energetic properties of the system. Using high resolution transmission electron microscopy, X-ray diffraction, and differential scanning calorimetry to analyze the physical, chemical and thermal characteristics of the resulting Al/CuO + interfacial Cu nanolaminates, we find that the incorporation of 5 nm Cu at both Al/CuO and CuO/Al interfaces lowers the onset temperature from 550 to 475 °C because of the lower-temperature formation of Al-Cu intermetallic phases and alloying. Cu intermixing is different in the CuO/Cu/Al and Al/Cu/CuO interfaces and independent of total Cu thickness: Cu readily penetrates into Al grains upon annealing to 300 °C, leading to Al/Cu phase transformations, while Al does not penetrate into Cu. Importantly, θ-Al2Cu nanocrystals are created below 63% wt Cu/Al, and coexist with the Al solid solution phase. These well-defined θ-Al2Cu nanocrystals seem to act as embedded Al+CuO energetic reaction triggers that lower the onset temperature. We show that ∼10 nm thick Cu at Al/CuO interfaces constitutes the optimum amount to increase both reactivity and overall heat of reaction by a factor of ∼20%. Above this amount, there is a rapid decrease of the heat of reaction.

Density functional theory study of high-energy metal (Al, Mg, Ti, and Zr)/CuO composites

We investigated the geometric and electronic structures and stability of high-energy metal metastable intermolecular composites (Al, Mg, Ti, and Zr)/CuO(111) between metal layers and a CuO(111) substrate by density functional theory.

Al atom on MoO3(010) surface: adsorption and penetration using density functional theory

This study employs first-principle density functional theory to model Al/MoO₃ by placing an Al adatom onto a unit cell of a MoO₃(010) slab, and to probe the initiation of interfacial interactions of Al/MoO₃ nanothermite by tracking the adsorption and subsurface-penetration of the Al adatom.

Nanolaminated composite materials: structure, interface role and applications

Various kinds of the typical ultrathin 2D nanomaterials: a hot topic for intense scientific research and development of technological applications.

Nanoporous Silicon Combustion: Observation of Shock Wave and Flame Synthesis of Nanoparticle Silica

The persistent hydrogen termination present in nanoporous silicon (nPS) is unique compared to other forms of nanoscale silicon (Si) which typically readily form a silicon dioxide passivation layer. The hydrogen terminated surface combined with the extremely high surface area of nPS yields a material capable of powerful exothermic reactions when combined with strong oxidizers. Here, a galvanic etching mechanism is used to produce nPS both in bulk Si wafers as well as in patterned regions of Si wafers with microfabricated ignition wires. An explosive composite is generated by filling the pores with sodium perchlorate (NaClO4). Using high-speed video including Schlieren photography, a shock wave is observed to propagate through air at 1127 ± 116 m/s. Additionally, a fireball is observed above the region of nPS combustion which persists for nearly 3× as long when reacted in air compared to N2, indicating that highly reactive species are generated that can further combust with excess oxygen. Finally, reaction products from either nPS-NaClO4 composites or nPS alone combusted with only high pressure O2 (400 psig) gas as an oxidizer are captured in a calorimeter bomb. The products in both cases are similar and verified by transmission electron microscopy (TEM) to include nano- to micrometer scale SiOx particles. This work highlights the complex oxidation mechanism of nPS composites and demonstrates the ability to use a solid state reaction to create a secondary gas phase combustion.

Motional Resistance Evaluation of the Quartz Crystal Microbalance to Study the Formation of a Passive Layer in the Interfacial Region of a Copper|Diluted Sulfuric Solution

A hyphenated technique based on vis–NIR spectroscopy and electrochemical quartz crystal microbalance with motional resistance monitoring was employed to investigate the dissolution of copper in acid media. Changes in motional resistance, current, mass, and absorbance during copper dissolution allow the evolution of the interfacial region of copper|diluted sulfuric solution to be understood. In particular, motional resistance is presented in this work as a useful tool to observe the evolution of the passive layer at the interface. During the forced copper electrodissolution in sulfuric solution, SO4(2–) favors the formation of soluble [Cu(H2O)6]2+. On the contrary, OH– involves the formation of Cu(H2O)4(OH)2, which precipitates on the electrode surface. The high viscosity and density of Cu(H2O)4(OH)2 formed on surface causes an increase in motional resistance independently of resonance frequency changes. During the copper corrosion in a more natural acidic environment, the results of electrochemical impedance spectra at open circuit potential indicate that corrosion is controlled by the diffusion of copper to the solution at short experimental times. However, copper diffusion is hindered by the formation of a passive layer on the electrode surface at long experimental times. During the copper corrosion, motional resistance shows an oscillatory response because of an oscillatory formation/dissolution of the passive later. Vis–NIR spectroscopy and electrochemical quartz crystal microbalance with motional resistance monitoring give new perspectives for reaching a deep understanding of metal corrosion processes and, in a future, other interfacial processes such as the catalysis or adsorption of (bio)molecules.