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京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第18987号 / 工博第4029号 / 新制||工||1620(附属図書館) / 31938 / 京都大学大学院工学研究科材料工学専攻 / (主査)教授 辻 伸泰, 教授 白井 泰治, 教授 松原 英一郎 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

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A novel concept of on-chip bondwire inductors and transformers with ferrite epoxy glob coating is proposed, offering a cost effective approach to realize power systems on chip (PSoC) or System-in-Package (PSiP). The concept has been investigated both experimentally and with finite element modeling. Improvement in total inductance is demonstrated for multi-turn bondwire inductors over single bondwire inductors. The inductance and Q factor can be further boosted with coupled multi-turn inductor concept. Transformer parameters including self- and mutual inductance, and coupling factors are extracted from both modeled and measured S-parameters. More importantly, the bondwire magnetic components can be easily integrated into SoC manufacturing processes with minimal changes to the layout, and open enormous possibilities for realizing cost-effective, high current, high efficiency PSoC's or PSiP's. The design guidelines for single bondwire inductors as well as multi-turn inductors are discussed step by step in several chapters. Not only is the innovated concept for bondwire inductor with ferrite ink presented, but also the practical implementation and design rules are given. With all the well defined steps, people who want to use these bondwire inductors with ferrite ink in their PSoC research or products will find it as simple as using commercial inductors. Last but not least, the PSoC concept using a bondwire inductor is demonstrated by building the prototype of dc-dc buck converter IC as well as the whole package. IC and the whole function block are tested and presented in this work.

Reducing the size of bulky magnetic components (inductors and transformers) in power converters can be achieved by increasing switching frequency and applying innovative designs of magnetic components. Ferrite is the most suitable bulk magnetic material for working at high frequencies but it is difficult to fabricate novel designs of ferrite magnetic components because of the limitations of conventional fabrication methods. Additive manufacturing (AM) has the potential to make customize ferrite magnetic components. One big challenge in 3D printing ferrite magnetic components is the lack of compatible and functional ferrite materials as printers' feedstock. This work focuses on developing ferrite feedstock for 3D printing ferrite magnetic components and providing a guideline for formulating ferrite feedstock by studying the effects of materials and processing parameters on major properties of the ferrite feedstock. The ferrite feedstock should not only be processable by a 3D printer but also make functional ferrite material that can work in power converters. To meet the requirements, the following four aspects of the feedstock are considered in this study: 1. the feedstock should be sinterable to achieve high enough magnetic permeability; 2. magnetic permeability of the feedstock can be easily tailored; 3. rheological properties of the feedstock should ensure reasonable printing resolution; 4. the feedstock can print high aspect ratio structures without slumping. Based on the four major considerations and the desired properties, materials were selected for formulating the ferrite feedstock. The effects of materials and processing variables on the major properties of the ferrite feedstock need to be studied to develop a formulation guidance of the feedstock. The effects of materials fractions and the post-printing peak sintering temperature of the feedstock on maximizing magnetic permeability were studied. The peak sintering temperature had a significant impact on permeability and solid loading (SL) and solid loading excluding diluent (SLED) had smaller impacts. Densities and microstructures of the sintered ferrite cores were characterized to illustrate how the variables affect magnetic permeability. Adding sintering additives to the feedstock was selected as an easy and effective way to tailor the permeability of the ferrite feedstock. The effect of the fractions of two types of additives, SiO2 and Co3O4, on permeability of ferrite were studied. Both SiO2 and Co3O4 can effectively reduce the permeability of the ferrite. A novel multi-permeability toroid core design was 3D-printed with ferrite feedstocks having different fractions of SiO2 to demonstrate the feasibility of fabricating special designs of ferrite magnetics using feedstocks with additives. Core-loss densities of ferrite cores fabricated with feedstocks having different fractions of the two additives were also characterized since it is another important property of ferrite cores in high-frequency converters. Adding SiO2 significantly increases the core-loss density of ferrite cores while adding proper fractions of Co3O4 decreased core-loss density at low magnetic flux densities. The mechanisms of how Co3O4 affect permeability and core-loss density were discussed. The effect of the solid loading (SL) on print-line width resolution was studied by conducting line printing tests. The experiment results showed the best print-line width resolution was achieved using the feedstock with an intermediate SL. The is, which considered both viscosity of the feedstock and coagulation in the feedstock suspension, were discussed. The effect of solid loading excluding diluent (SLED) and UV illumination time on the achievable aspect ratio of printed feedstock was studied. Yield shear strength (y) of feedstocks composition versus UV-curing time were characterized. We evaluated various phenomenological models reported in the literature for predicting the critical yield shear strength (y*) required to obtain a paste structure for a certain aspect ratio. Knowing y* would help to determine the shortest time needed for UV illumination. Applying the model that best fitted to our experimental results, we developed a processing guideline that from specified magnetic permeability and dimensions of a ferrite core, would prescribe the needed SLED and the minimal UV curing time for printing. The guideline was demonstrated by the successful fabrication of tall ferrite inductor cores commonly found in power converters. The main contributions of this study are listed below: 1. Designed, formulated, and characterized ferrite feedstock that not only has functionality for power electronics applications but is also compatible with a direct extrusion type 3D printer. The feedstock can be made into ferrite cores with relative permeability ranging from 10 to 500 which are much higher than those of soft ferrite feedstocks currently reported elsewhere. The packing densities of 950℃ sintered ferrite cores made from the feedstock can be as high as 95%. With the Hyrel 30M 3D-printer, the smallest nozzle orifice diameter that the feedstock can be extruded from is 0.42 mm. We demonstrated printing of the feedstock into a cylinders with a height of 18 mm and an aspect ratio of 3 without slumping issue. 2. Identified the effects of materials and processing variales on 4 major considerations of the ferrite feedstock including maximizing sintered packing density, tailoring permeability, print-line resolution, and achievable dimensions of the printed feedstock without slumping. A deeper understanding of the mechanisms of how the variables affect main properties of the feedstock was provided. 3. Provided a preparation guideline of the ferrite feedstock that prescribe feedstock formulation and UV illumination time per print-layer from the target relative permeability and dimension of a ferrite core. / Doctor of Philosophy / To reduce the size of power electronic devices, applying novel designs of ferrite magnetic components (inductors and transformers) is a promising method. While conventional fabrication methods cannot fabricate novel designs of ferrite magnetic components that have odd or intricate geometries, additive manufacturing (AM) has the potential. One big challenge in 3D printing ferrite magnetic components is the lack of compatible and functional ferrite materials as printers' feedstock. This work focuses on developing ferrite feedstock for 3D printing ferrite magnetic components and providing a guideline for formulating ferrite feedstock by studying the effects of materials and processing parameters on major properties of the ferrite feedstock. The ferrite feedstock should not only have the desired functionalities but also be suitable for printing. Major considerations and desired properties of the feedstock were discussed. Materials were selected to formulate the feedstock based on the desired properties. To develop a formulation guidance for the feedstock, the effects of materials and processing variables on the major properties of ferrite feedstock were studied. The studies included the following 4 aspects: 1. the effects of materials fractions in the feedstock and the post-printing sintering temperature of the feedstock on maximizing magnetic permeability; 2. the effect of additives in the feedstock on tailoring permeability; 3. the effect of feedstock rheology on print-line resolution; 4. the effect of materials fraction and ultraviolet light illumination time on achievable aspect ratio of printed feedstock.

<p> The Fe-C-Mn phase diagram has been calculated from thermodynamic data. Experimentally determined tie-lines are in good agreement with the calculated diagram. </p> <p> It has been shown that the assumption that the austenite-ferrite interface is in a local equilibrium condition during the late stages of the transformation in highly supersaturated alloys and at all times in alloys in an area of low supersaturation is justified. The approximate solution to the diffusion equations correctly predicts the experimentally determined manganese concentration profiles. </p> <p> Hillert's concept of paraequilibrium has been examined and explicitly defined. The concentration given by a paraequilibrium calculation correctly predicts the experimentally observed growth rates of Kinsman and Aaronson (1967) for very highly supersaturated alloys. </p> <p> A convolution technique for use in the interpretation of strongly localized concentration changes determined by electron beam microanalysis has been developed. </p> / Thesis / Doctor of Philosophy (PhD)

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The development of high strength hot rolled steels is an important area for improving vehicle fuel efficiency. In collaboration with ArcelorMittal, this project focussed on developing a hot rolled steel with 980 MPa ultimate tensile strength, 800 MPa yield strength and 50% hole expansion ratio. To achieve the target mechanical properties, four different chemistries were trialled which varied the carbon, niobium and vanadium contents. Six combinations of finishing, coiling and intermediate temperatures were trialled for each chemistry. The effects of thermomechanical processing parameters and alloying contents on the mechanical properties were determined through tensile and hole expansion testing. Microstructural analysis was completed to correlate the mechanical properties to the microstructural characteristics. Microscopy techniques performed included optical microscopy, scanning electron microscopy, transmission electron microscopy and atom probe tomography. The phase transformations which occur during thermomechanical processing were investigated using dilatometry testing. Microstructural characterization was used to determine the breakdown of strengthening contributions from intrinsic, solid solution, grain boundary, precipitation and dislocation strengthening. Trials varying the processing parameters and steel chemistry led to an understanding of how thermomechanical processing and alloying influence the microstructural features and corresponding mechanical properties in hot rolled microalloyed steels. / Thesis / Master of Applied Science (MASc)