Patterning of multi crystalline silicon Solar cell is prepared with photolithography etching. Electroless plating is used to get metallization of Nickel contacts. SEM analysis of Nickel deposition and measurement of contact resistance for series and shunt resistance is done. To increase the fill factor, the screen printed electrodes are subjected to different firing temperatures there by increasing the efficiency of solar cell. Nickel-silicide formation at the interface between the Silicon and Nickel enhances stability and reduces the contact resistance, resulting in higher energy conversion efficiency.

Novel fabrication technologies for high performance electrical and optical chip-to-substrate input/output (I/O) interconnections were developed. This research is driven by the long term performance and integration requirements of high performance chip-to-substrate I/Os, as well as the package reliability demands from semiconductor manufacturing. An electroless copper plating and annealing process was developed to join copper structures to achieve chip-to-substrate assembly by all copper pillar interconnects. The developed copper pillar interconnects provide much higher current carrying capability for chip-to-substrate power/ground input/output distributions and have low electrical parasitic characteristics for high frequency electrical signal communications. This copper bonding process also demonstrates the capability to compensate for misalignments and height variations of bonded structures. A finite element generalized plane deformation model was employed to design fully compliant copper pillars to eliminate the need of underfill. Electrical parasitics of copper pillar chip-to-substrate interconnects were studied by the derived formulas for low parasitic requirements. An optimized dimension space for all the criteria was provided on the pillar dimension chart. A novel nanoimprint lithography was developed to combine with photolithography in one process to create high quality features on a macrostructure for chip-to-substrate optical I/O applications. This fabrication process also demonstrated the capability to produce off-angle complex structures.

This dissertation describes the fabrication and operation of porous silicon gas sensors. The first chapter describes the motivation behind gas sensor research and provides the reader with background knowledge of gas sensors including the terminology and a review of various gas sensors. The following two chapters describe both how the porous silicon gas sensors are created and how they have been tested in the laboratory. Chapter 4 describes the steps required to create arrays of gas sensors to provide for a selective device through the application of patented selective coatings. Chapter 5 proposes a physical model that leads to a numerical solution for predicting the operation of the gas sensor. The next chapter builds from this model to analyze and optimize the experimental methods that are used to test both this and other gas sensors. The final chapter of this dissertation describes the prototype gas sensor system that has most recently been created, the company that was formed to further the development of that system, and the future applications of the porous silicon gas sensor.

L'ABS est un copolymère de Acrylonitrile-Butadiène-Styrène utilisé industriellement et dont la surface peut être recouverte para un dépôt métallique. Le processus traditionnel pour déposer des films métalliques de manière auto catalytique est connu comme " Electroless ". Cependant, ce processus utilise un mélange sulfochromique dans l'étape de traitement préliminaire de la surface, contenant du Cr (VI), qui est dans la liste des contaminants toxiques qui doivent être substitués. Il est donc primordial de développer de nouveaux procédés de modification de surface de faible impact sur l'environnement. Dans ce travail de thèse, nous avons développé trois nouvelles techniques de modifications de la surface d'ABS. Les deux premières permettent une modification générale de la surface et la troisième une modification spécifique. La première méthode, par voie sèche basée sur l'application en alternance de décharges Corona et radiations ultra-violet, est appelée " Traitement Optophysique ". La deuxième méthode appelée " Traitement Photocatalytique " correspond à l'application des propriétés photocatalytiques de nanoparticules de TiO2 (30nm) en suspension sur la surface du polymère et soumis à une radiation ultra-violet. La troisième méthode appelée " Traitement Optothermique " permettant une modification sélective, est réalisée par ablation thermique laser" à partir d'une sensibilisation de la surface avec des nanoparticules de Palladium et des particules d'Argent. Postérieur à l'étape de traitement " Traitement Optophysique " ou " Traitement Photocatalytique ", les substrats ont été pré-métallisés soit par le procédé " Electroless ", soit par le procédé de "Dépôt Chimique Dynamique " (DCP). A différence du procédé " Electroless ", le procédé " DCP " ne nécessite pas d'une étape antérieure d'activation de sites superficielles avec des ions palladium. Le dépôt métallique final est réalisé par voie électrolytique conventionnelle. Les surfaces prétraitées ont été analysées par des Mesures d'Angle de Contact et les techniques de spectroscopie FT-IR et XPS. La présence de charges superficielles a été évaluée par la Mesure de Potentielle de Surface et de Radiométrie des Photoporteurs. La morphologie des surfaces a été observée et mesurée par les techniques de SEM, AFM et AFAM. Les analyses de rugosité ont été faites par Senseur Mécanique, par Optique Interférentielle et par AFM. L'adhérence des dépôts métalliques a été mesurée par la méthode de la Bande Adhésive sur Coupe Croisée (ASTM D-3359), les essais Pull Off. (ASTM D4541-02) et Peel Off (ASTM B533 A). Les dépôts les plus adhérents ont été obtenus avec un prétraitement " Optophysique " et une pré-métallisation par " DCP ". Les valeurs d'adhérence obtenues sont supérieures à celle des dépôts obtenus para le procédé traditionnelle " Electroless ". Le " Traitement Optothermique " a permis une gravure sélective de la surface de l'ABS en utilisant des lasers de faible puissance.

Magister Scientiae - MSc / South Africa s coal and platinum mineral resources are crucial resources towards creating an alternative and environmentally sustainable energy system. The beneficiation of these natural resources can help to enhance a sustainable and effective clean energy base infrastructure and further promote their exploration and exportation for economics gains. By diversification of these resources, coal and the platinum group metals (PGMs) especially palladium market can be further harnessed in the foreseeable future hence SA energy security can be guaranteed from the technological point of view. The South Africa power industry is a critical sector, and has served as a major platform in the South African socio-economic development. This sector has also been identified as a route towards an independent energy base, with global relevance through the development of membrane technologies to effectively and economically separate and purify hydrogen from the gas mixtures released during coal gasification. The South Africa power industry is a critical sector, and has served as a major platform in the SA's socio-economic development. This sector has also been identified as a route towards an independent energy base, with global relevance through the development of membrane technologies to effectively and economically separate and purify hydrogen from the gas mixtures released during coal gasification. Coal gasification is considered as a source of hydrogen gas and the effluent gases released during this process include hydrogen sulphide, oxides of carbon and nitrogen, hydrogen and other particulates. In developing an alternative hydrogen gas separating method, composite membrane based on organic-inorganic system is being considered since the other available methods of hydrogen separation are relatively expensive. The scientific approach of this study involves the use of palladium modified polyimide composite membrane. Palladium metal serves as hydrogen sorption material, deposited on polyimide substrates (composite film) by electroless technique. Polyimide is a class of polymer with excellent physico-chemical properties such as good mechanical strength, superior thermal stability and high resistance to chemical attack. In this study, a composite polymer-palladium membrane was developed and investigated to determine the prospect of using this membrane as a cheap, accessible, reliable and efficient system to separate and purify hydrogen gas. Prior to the palladium metal plating, the challenge of metal adhesion on glassy polymer such as polyimide film was addressed by chemical etching and unirradiated and irradiated polyimide film surface using NaOH, NaOCl and a mixture of NaOH/NaOCl solutions. The time of etching was varied and the overall effect of this surface treatment was deeply investigated using Fourier transform infrared (FTIR) spectroscopy. The FTIR study focused on the structural deformation of the polyimide functional group units and the emergence of ‘active sites’ along the polyimide backbone structures that have been identified to allow the Pd metal exchange on the functionalised polyimide film. The detailed use of FTIR spectroscopic technique in this study on the etched unirradiated and irradiated polyimide film was to understand the chemical interaction between the polyimide functional group units and the chemical etchants. The surface morphology of unirradiated and irradiated polyimide samples was studied using SEM, the depth profile (penetration) of palladium particles after electroless deposition on the polyimide matrix was investigated by SEM and TEM analysis. As for the alkaline etched irradiated polyimide, pore distribution, shape and size depended on the etching time and solution. In the XRD analysis, the palladium modified unirradiated polyimide film indicated the diffraction peaks of palladium metal in the (1,1,1), (2,2,0) and (2,0,0) planes present in the polyimide surface, and the peel test showed that the strength of adhesion of palladium on unirradiated surface was low compared to the palladium modified irradiated polyimide. The NaOH solution showed the best etchant at 20 minutes for the unirradiated palladium modified polyimide. The hallmark of this study was the design, fabrication and assemblage of home-built hydrogen diffusion reactor unit used to measure rate of hydrogen diffusion property of unirradiated and irradiated polyimide films from 25 °C to 325 °C. The rate of hydrogen diffusion was observed to depend on the etching time of polyimide surface before and after the polyimide surface irradiation treatment. / South Africa

Transition metals complexes have been involved in various catalytic, biomedical and industrial applications, but only lately they have been associated with nanomaterials to produce innovative and well-defined new hybrid systems. The introduction of transition metals into nanomaterials is important to bear the advantages of metals to nanoscale and also to raise the stability of nanomaterials. In this dissertation, we study two approaches of associating transition metals into nanomaterials. The first approach is via spontaneous self-organization based assembly of small molecule amphiphiles and bulky hydrophilic polymers to produce organic-inorganic hybrid materials that have nanoscale features and can be precisely controlled depending on the experimental conditions used. These hybrid materials can successfully act as templates to design new porous material with interesting architecture. The second approach studied is via electroless reduction of transition metals on the surface of nanocarbons (nanotubes and nanodiamonds) without using any reducing agents or catalysts. The synthesis of these systems is highly efficient and facile resulting in stable and mechanically robust new materials with promising applications in catalysis.

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Ferroelectric-reinforced metal matrix composites (FR-MMCs) show promise as high damping materials for structural applications. Most structural materials are valued based on their stiffness and strength; however, stiff materials typically have limited inherent ability to dampen mechanical or acoustic vibrations. The addition of ferroelectric ceramic particles may also augment the strength of the matrix, creating a multifunctional composite. In this work, the damping behavior of FR-MMCs created by the addition of barium titanate (BaTiO3) discontinuous reinforcement in a bearing bronze (Cu-10w%Sn) matrix has been studied. It has been shown that even when combined with other traditional composite mechanisms, added damping ability has been achieved due to the ferroelectric nature of the reinforcement. FR-MMCs currently represent a material system capable of exhibiting increased damping ability, as compared to the structural metal matrix alone. / Master of Science

Additive manufacturing introduces a new design paradigm that allows the fabrication of geometrically complex parts that cannot be produced by traditional manufacturing and assembly methods. Using a cellular heat exchanger as a motivational example, this thesis investigates the creation of a hybrid manufacturing approach that combines selective laser sintering with an electroforming process to produce complex, hollow, metal geometries. The developed process uses electroless nickel plating on laser sintered parts that then undergo a flash burnout procedure to remove the polymer, leaving a complex, hollow, metal part. The resulting geometries cannot be produced directly with other additive manufacturing systems. Copper electroplating and electroless nickel plating are investigated as metal coating methods. Several parametric parts are tested while developing a manufacturing process. Copper electroplating is determined to be too dependent on the geometry of the part, with large changes in plate thickness between the exterior and interior of the tested parts. Even in relatively basic cellular structures, electroplating does not plate the interior of the part. Two phases of electroless nickel plating combined with a flash burnout procedure produce the desired geometry. The tested part has a density of 3.16g/cm3 and withstands pressures up to 25MPa. The cellular part produced has a nickel plate thickness of 800µm and consists of 35% nickel and 65% air (empty space). Detailed procedures are included for the electroplating and electroless plating processes developed. / Master of Science