Polymer powder bed fusion (PBF/P) is one of many additive manufacturing (AM) processes utilized for producing polymer parts from digital 3D models. AM is preferred over traditional manufacturing methods in many applications due to advantages including tool-less manufacturing, high geometric complexity, short lead times, and reduced material waste. However, many industries that stand to benefit the most from AM are limited in their ability to use AM parts in large part due to low confidence in AM part quality. Among the polymer AM processes, PBF/P processes show significant promise for these applications due to their comparatively high isotropy and mechanical properties. Due to the many process variables present in PBF/P, printing conditions can vary from print to print resulting in poor repeatability of physical properties in printed parts. Many approaches have been studied for addressing this issue such as modeling of print dynamics, print parameter optimization, and process control. However, PBF/P remains largely unutilized in applications where quality control and assurance are high priorities. This work presents a novel approach for in-situ process monitoring and control in PBF/P and is demonstrated for the large area projection sintering (LAPS) process. The method proposed in this study monitors the powder bed surface via visible light cameras and identifies critical steps in the melting process defined as optical melting states (OMSs). The relationship between print parameters, process signatures, and resulting physical properties are studied. This thesis shows that during melting, the changing surface geometry and optical properties of the powder bed can be effectively monitored with optical cameras and are strongly correlated with the final density and ultimate tensile strength (UTS) of the printed part. By implementing closed-loop OMS control, consistent physical properties can be obtained despite different processing conditions. While established methods of identifying the property plateau for other PBF/P processes are not effective for the LAPS process, such as energy density methods, OMS control has been shown to effectively achieve full density and UTS in LAPS parts while optimizing print time. However, OMS methods are limited in their ability to evaluate ductility and percent crystallinity.

Silver sintering technology has received considerable attention in recent years because it has the potential to be a suitable interconnection material for high-temperature power electronic packaging, such as high melting temperature, high electrical/thermal conductivity, and excellent mechanical reliability. It should be noted, however, that pressure (usually between three to five MPa) was added during the sintering stage for attaching power chips with area larger than 100 mm2. This extra pressure increased the complexity of the sintering process. The maximum chip size processed by pressure-free sintering, in the published resources, was 6 x 6 mm2. One objective of this work was to achieve chip-attachment with area of 13.5 x 13.5 mm2 (a chip size of one kind of commercial IGBT) by pressure-free sintering of nano-silver paste. Another objective was to fabricate high-power (1200 V and 150 A) multi-chip module by pressure-free sintering. In each module (half-bridge), two IGBT dies (13.5 x 13.5 mm2) and two diode dies (10 x 10 mm2) were attached to a DBC substrate. Modules with solder joints (SN100C) and pressure-sintered silver joints were also fabricated as the control group. The peak temperature in the process of of pressure-free sintering of silver was around 260oC, whereas 270oC for vacuum reflowing of solder, and 280oC under three MPa for pressure-sintering of silver. The process for wire bonding, lead-frame attachment, and thermocouple attachment are also recorded. Modules with the above three kinds of joints were first characterized by electrical methods. All of them could block 1200 V DC voltage after packaging, which is the voltage rating of bare dies. Modules were also tested up to the rated current (150 A) and half of the rated voltage (600 V), which were the test conditions in the datasheet for commercial modules with the same voltage and current ratings. I-V characteristics of packaged devices were similar (on-resistance less than 0.5 mohm). All switching waveforms at transient stage (both turn-on and turn-off) were clean. Six switching parameters (turn-on delay, rise time, turn-off delay, fall time, turn-on loss, and turn-off loss) were measured, which were also similar (<9%) among different kinds of modules. The results from electrical characterizations showed that both static characterizations and double-pulse test cannot be used for evaluating the differences among chip-attach layers. All modules were also characterized by their thermal performances. Transient thermal impedances were measured by gate-emitter signals. Two setups for thermal impedance measurement were used. In one setup, the bottoms of modules were left in the air, and in the other setup, bottoms of modules were attached to a chiller (liquid cooling and temperature controlled at 25oC) with thermal grease. Thermal impedances of three kinds of modules still increased after 40 seconds for the testing without chiller, since the thermal resistance of heat convection from bottom copper to the air was included , which was much larger than the sum of the previous layers (from IGBT junction, through the chip-attach layer, to the bottom of DBC substrate). In contrast, thermal impedances became almost stable (less than 3%) after 15 seconds for all modules when the chiller was used. Among these three kinds of modules, the module with pressure sintered joints had the lowest thermal impedance and the thermal resistance (tested with the chiller) around 0.609oK/W, In contrast, the thermal resistance was around 964oK /W for the soldered module, and 2.30oK /W for pressure-free sintered module. In summary, pressure-free large-area sintered joints were achieved and passed the fabrication process for IGBT half-bridge module with wiring bonding. Packaged devices with these kinds of joints were verified with good electrical performance. However, thermal performances of pressure-free joints were worse than solder joints and pressure-sintered joints. / Master of Science

The fifth and sixth generations of mobile communications and the internet of things (IoT) demand high-performance electronic devices made at low cost over a large area. Unlike the conventional Si-based electronics, the emerging large-area electronics (LAE) require flexible, stretchable, and lightweight devices that are printable and able to mass manufacture without compromising the performance of state-of-the-art electronic devices. Hence, there is a quest to find alternative fabrication routes and conventional photolithography. In this research work, we explored the adhesion lithography (a-Lith) to further simplify the process steps by adapting bi-layer metals to induce intrinsic stress in the bi-layer and hence facilitate the self-peeling of metal layers which results in more uniform and smaller nanogap between two metals than the previously established a-Lith fabricated nanogaps. The nanogap metal electrodes are further used to fabricate radio frequency (RF) Schottky diodes made using a printable metal oxide semiconductor and flashlight annealing over wafer-scale and demonstrate the operation frequencies above 100 GHz/47 GHz (intrinsic/extrinsic). Notably, for the first time, photonic annealing on such an ultra-small (< 20 nm) nanoscale channel was demonstrated, and the rapid manufacturing of RF diodes from the solution route was achieved. On the other hand, for the first time, organic diodes made using a-Lith fabricated nanogap metal electrodes, and high mobility polymer semiconductors with molecular dopants showed an extrinsic cut-off frequency well above 14 GHz. Finally, the nanogap metal electrodes were explored as a mold and shadow mask to fabricate nano-feature soft stamp and nano-fluidic channels (NFC), respectively. The soft stamp can replicate the high aspect ratio nanoscale features on any arbitrary substrates using available soft lithography routes, and the NFC is further envisioned for bio-molecules detection and sensing applications.

Touch (or tactile) sensors are gaining renewed interest as the level of sophistication in the application of minimally invasive surgery and humanoid robots increases. The spatial resolution of current large-area tactile sensors (greater than 1 cm2) lag human fingers by over an order of magnitude. Using metal and semiconducting nanoparticles, a ~100 nm thick, large area thin-film device working on the principles of electron tunneling is self-assembled, such that the change in current density through the film and the electroluminescence light intensity are linearly proportional to the local stress. By pressing a United States 1 cent coin (and also a copper grid) on the device a well resolved stress image by focusing the electroluminescence light directly on CCD is obtained. Both the lateral and height resolution of texture are comparable to human finger at similar stress levels of ~10 KPa. The fabrication of the film is based on self-assembly of polyelectrolytes, and metal and semiconducting nanoparticles in a layered architecture. The polyelectrolyte layer functions as the dielectric tunneling barrier and the nanoparticles function as the base for tunneling electrons. The assembly of the device can be simplified by incorporating the functionality of the polyelectrolyte and the nanoparticles in a single composite medium. A non-micellar mineralization process for the synthesis of multifunctional nanocomposite materials is also reported as a possible building block for the assembly of tactile sensor. The non-micellar method results in the synthesis of monodisperse semi-conducting nanoparticles templated on polymer chains dissolved in solution at high yield. The monodispersity is achieved due to the beaded necklace morphology of the polyelectrolyte chains in solution where the beads are nanometer-scale nodules in the polymer chain and the nanoparticles are confined to the beads. The resultant structure is a nanoparticle studded necklace where the particles are imbedded in the beads. Multiple cycles of the synthesis on the polymer template yield nanoparticles of identical size, resulting in a nanocomposite with high particle fraction. The resultant nanocomposite has beaded-fibrilar morphology with imbedded nanoparticles, and can be solution cast to make electroluminescent thin film devices. The concept is further modified for synthesis of metal nanoparticles on polyelectrolyte templates with isolated beaded morphology. / Ph. D.

Currently, there are two major driving forces for considering alternative materials to lead- based products, specifically interconnections, in electronics applications, including the impending legislation or regulations which may tax, restrict, or eliminate the use of lead and the trend toward advanced interconnection technology, which may challenge the limits of present soldering technology. The reliability of solder joints is a concern because fracture failures in solder joints accounts for 70% of failures in electronic components. Lead-free solders are being investigated as replacements for lead solders currently used in electronics. Thermo-mechanical properties describe the stresses accumulated due to thermal fatigue as a result of CTE mismatch within the system. By understanding the failure mechanisms related to lead-free solders, the application of lead- free solders could be more strategically designed for specific applications. The objective of this thesis is to observe microstructural change in large-area solder joints caused by thermal cycling and relate these changes to reliability issues in large-area lead and lead-free solder constructed semiconductor power devices. This study focused on the microstructural changes within the solder alloy of a large-area solder joint under thermal cycling conditions. Two major primary observations were made from this research, they are: 1) due to a combination of testing conditions and material properties, the lead-free solders, Sn/3.5Ag and Sn/Ag/0.7Cu, sustained the most severe damage as compared to Sn/37Pb, and 2) due to elevated stresses at the solder/substrate interface in a simulated power semiconductor device sample damage was found to be most severe. / Master of Science

Dédié à l'étude du ciel en rayons gamma, le satellite Fermi comporte à son bord le Large Area Telescope (LAT), sensible au rayonnement gamma de 20 MeV à 300 GeV. Les données recueillies par le LAT depuis son lancement en 2008 ont permis de multiplier par 10 le nombre de noyaux actifs de galaxie (NAG) détectés dans le domaine du GeV. Les rayons gamma observés dans les NAGs proviennent de processus énergétiques faisant intervenir des particules chargées de très haute énergie. Ces particules sont confinées dans un jet de plasma magnétisé qui prend sa source dans une région proche du trou noir supermassif habitant la zone centrale de la galaxie hôte. Ce jet s’éloigne à des vitesses aussi élevées que 0.9999c, formant dans de nombreux cas des lobes radio sur des échelles du kiloparsec voire du mégaparsec. Les NAGs dont le jet fait un angle faible avec la ligne de visée sont appelés blazars. La combinaison de cette très faible inclinaison du jet par rapport à la ligne de visée et de vitesses d’éjection relativistes donne lieu à des effets relativistes : mouvements apparents superluminiques, amplification de la luminosité et modification des échelles de temps. Les blazars sont caractérisés par une extrême variabilité à toutes les longueurs d’onde, sur des échelles de temps allant de quelques minutes à plusieurs mois. Une étude temporelle et spectrale du plus brillant d'entre ceux détectés par le LAT, 3C 454.3, a été réalisée afin de contraindre les modèles d'émission. Une nouvelle méthode de génération de courbes de lumière à échantillonnage adaptatif est également proposée dans cette thèse. Celle-ci permet d'extraire le maximum d'information des données du LAT quel que soit l'état de flux de la source. / The Fermi Gamma-ray Space Telescope was launched on 2008 June 11, carrying the Large Area Telescope(LAT), sensitive to gamma-rays in the 20 MeV – 300 GeV energy range. The data collected since then allowed to multiply by a factor of 10 the number of Active Galactic Nuclei (AGN) detected in the GeV range. Gamma-rays observed in AGNs come from energetic precesses bringing into play very high energy charged particles. These particles are confined in a magnetized plasma jet rising in a region close to the supermassive black hole in the center of the host galaxy. This jet moves away with velocities as high as 0.9999c, forming in many cases radio lobes on kiloparsec or even megaparsec scales. Among the AGNs, those whose jet inclination angle to the line of sight is small are called blazars. The combination of this small inclination angle with relativistic ejection speeds leds to relativistic effects : apparent superluminal motions, amplification of the luminosity and modification of the time scales. Blazars are characterized by extreme variability at all wavelengths, on time scales from a few minutes to several months. A temporal and spectral study of the most luminous of those detected by the LAT, 3C 454.3, was done so as to constrain emission models. A new method for generating adaptive-binning lightcurves is also suggested in this thesis. It allows to extract the maximum of information from the LAT data whatever the flux state of the source.

Dédié à l’étude du ciel en rayons gamma, le satellite Fermi comporte à son bord le Large AreaTelescope (LAT), sensible au rayonnement de 20 MeV à plus de 300 GeV. Sa sensibilité et ses performances grandissantes apportent de plus en plus de contraintes sur les nébuleuses à vent de pulsar. Ces nébuleuses sont alimentées par l’injection permanente d’un vent d’électrons et de positrons relativistes accélérés par l’onde de choc délimitant la nébuleuse. Ces particules chargées rayonnent dans les différents domaines du spectre électromagnétique et notamment dans le domaine des rayons gamma à l’aide du processus de diffusion Compton inverse. Cette thèse présente l’étude morphologique et spectrale détaillée de deux sources potentiellement associées à des nébuleuses : MSH 11-62 et HESS J1857+026, afin de déterminer si l’émission gamma est produite par des nébuleuses de pulsar. Dans un deuxième temps, l’analyse de toutes les sources reliées à des contreparties détectées par les télescopes Cerenkov permet la détection de six nouvelles nébuleuses de pulsars et candidats dans la gamme de Fermi. Ceci permet d’apporter de nouvelles contraintes sur les propriétés physiques des nébuleuses de pulsar ainsi que sur les mécanismes d’émission à l’aide de modèles et d’études sur la population totale détectée par le LAT. / The Fermi Gamma-ray Space Telescope was launched on 2008 June 11, carrying the Large Area Telescope (LAT), sensitive to gamma-rays from 20 MeV to more than 300 GeV. Its constantly improving sensitivity and performance offer a new opportunity to understand the sources of the gamma-ray sky including Pulsar Wind Nebulae (PWNe). PWNe are powered by the constant injection of a relativistic wind of electrons and positrons from their central pulsars. These charged particles are accelerated at the shock front forming the PWN and emit photons which can be observed along the entire electromagnetic spectrum, including the highenergy gamma-ray domain via inverse Compton scattering.This thesis present the detailed analysis of two sources of gamma-ray emission potentially asso4021ciated to PWNe : MSH 11-62 and HESS J1857+026. The combination of the spatial and spectral analyses provide new elements to confirm these associations.In a second step, we describe a search for counterparts to sources detected by Cerenkov telescopes.This search led to the detection of six new LAT sources potentially associated with PWNe. These studies bring new insights and constraints on the physical properties of the sources as well as on emitting processes by constraining the models and allowing population studies.

Après plus d'un siècle d'étude des rayons cosmiques, des questions persistent à propos de leur origine. À l'échelle de notre galaxie, les vestiges de supernovæ sont d'excellents candidats en tant que sources de rayons cosmiques et il est aujourd'hui avéré que ces ondes de choc générées par l'explosion d'étoiles en fin de vie accélèrent des électrons jusqu'au TeV. Cependant, des preuves tangibles manquent toujours pour confirmer que les protons, qui représentent ~90% du rayonnement cosmique, y sont également accélérés. Ces preuves sont à chercher entre 100 MeV et 10 GeV où la forme spectrale de l'émission gamma nous renseigne sur la nature des particules accélérées.Ce domaine en énergie est observé par le satellite Fermi qui scrute le ciel à haute énergie grâce au Large Area Telescope (LAT), un instrument capable de détecter les rayons gamma d'énergies comprises entre 20 MeV et plus de 300 GeV. Avec la dernière version des données en date (Pass 8) rendue publique en 2015, la surface efficace a été sensiblement accrue, notamment à haute énergie. L'objet de cette thèse a été de mettre à profit les nouvelles performances du LAT pour étudier le rayonnement provenant de jeunes vestiges de supernovæ en coquille afin d'évaluer leur capacité à accélérer des particules à haute énergie. Au total, quatre vestiges de ce type ont été étudiés en détail : RCW 86, HESS J1731-347, SN 1006 et RX J1713.7-3946.L'analyse morphologique et spatiale de ces sources nous a menés à d'importants résultats : HESS J1731-347 et SN 1006 ont été détectés pour la première fois au GeV, nous avons mis en évidence une morphologie en coquille pour RCW 86 qui était précédemment détectée comme une source ponctuelle et RX J1713.7-3946 a révélé une forme spectrale plus complexe que ce qui était alors connu. Grâce à la modélisation de l'émission non-thermique de ces sources, en s'aidant des données au TeV obtenues par H.E.S.S., nous avons montré que leur émission gamma est très largement dominée par le rayonnement Compton inverse des électrons de haute énergie diffusant sur les champs de photons ambiants. Cependant, des modifications spectrales ont également été trouvées dans certaines parties de SN 1006 et RX J1713.7-3946 où l'onde de choc est en interaction avec des régions denses en matière, traçant la possible accélération de protons en leur sein. / After more than a century of cosmic-ray studies, questions about their origin remain unanswered. In our galaxy, supernova remnants are excellent candidates to be the sources of cosmic rays and it is now certain that these shock waves created by the explosion of dying stars accelerate electrons up to TeV energies. However, undeniable proof is still missing to confirm that protons, which represent ~90% of the cosmic radiation, are also accelerated. Such proof can be searched for between 100 MeV and 10 GeV, where the spectral shape of the gamma-ray emission changes according to the nature of the particles that are accelerated.This energy range is covered by the Fermi spacecraft which observes the high energy sky with the Large Area telescope (LAT), an instrument detecting gamma-rays from 20 MeV to more than 300 GeV. With the latest version of the data, released in 2015 (Pass 8), the effective area has been greatly improved, especially at high energy. The goal of this thesis was to take advantage of the improved performance of the LAT to study the radiation coming from young shell-type supernova remnants and to evaluate their ability to accelerate particles to high energy. Four such remnants were studied in detail: RCW 86, HESS J1731-347, SN 1006 and RX J1713.7-3946.Spatial and spectral analyses of these sources yielded important results: HESS J1731-347 and SN 1006 were identified for the first time in the GeV range, we detected a shell-like morphology for RCW 86 which was previously seen as a point source, and RX J1713.7-3946 revealed an unexpected spectral shape. Broadband modeling of the non-thermal emission of these remnants, using in particular TeV data obtained with H.E.S.S., showed that their gamma-ray emission is dominated by the inverse Compton scattering of electrons on ambient photon fields. However, we also found spectral modifications in some parts of SN 1006 and RX J1713.7-3946 where the shock is interacting with dense regions that could trace the acceleration of protons.

Dédié à l’étude de l’astronomie gamma, le satellite Fermi a été lancé le 11 juin 2008. Il comporte à sonbord l’instrument Large Area Telescope (LAT), sensible au rayonnement gamma dans la gamme d’énergie de20 MeV à 300 GeV. Bien que la nébuleuse du Crabe ait été étudiée dans la gamme d’énergie 70 MeV à 30GeV couverte par son précédesseur, l’expérience CGRO-EGRET, aucune nébuleuse n’a jamais été clairementidentifiée dans le domaine des rayons gamma de haute énergie jusqu’au lancement de Fermi.Les pulsars alimentent les nébuleuses qui les entourent par l’injection permanente d’un vent d’électrons etpositrons relativistes qui, accélérés au niveau de l’onde de choc délimitant les nébuleuses de pulsars, émettentun rayonnement pouvant être observé dans les différents domaines du spectre électromagnétique, et notammentdans le domaine des rayons gamma de haute énergie.Les données recueillies par le Fermi-LAT au cours des deux premières années de mission ont désormaispermis la détection et l’identification de trois nébuleuses et de leurs pulsars associés (nébuleuses du Crabe, deVela-X et de MSH 15-52) ainsi que de la nébuleuse de pulsar HESS J1825-137 découverte par les instrumentsau sol dédiés à l’astronomie gamma de très haute énergie.Les résultats des analyses temporelle, spectrale et morphologique réalisées sur les systèmes pulsars/nébuleuses détectés par le LAT sont exposés dans ce manuscrit. La synthèse des études systématiquesréalisées (i) dans les régions comportant un pulsar émetteur en rayons gamma et (ii) dans les régions comportant une source émettrice de rayons gamma de très haute énergie étant identifiée en tant que nébuleuse depulsar ou candidate en tant que telle, sont également présentés dans cette thèse. Ces études apportent de nouvelles contraintes sur les propriétés physiques des sources ainsi que sur les mécanismes de rayonnement mis enjeu dans la magnétosphère des pulsars et au sein de leurs nébuleuses. / The Fermi Gamma-ray Space Telescope was launched on 2008 June 11, carrying the Large Area Telescope(LAT), sensitive to gamma-rays in the 20 MeV – 300 GeV energy range. The Crab Nebula had been detectedand studied in the 70 MeV – 30 GeV band using the CGRO-EGRET experiment, but no pulsar wind nebula(PWN) had ever been firmly identified in the high energy gamma-ray domain.PWNe are powered by the constant injection of a relativistic wind of electrons and positrons from theircentral pulsars. These charged particles are accelerated at the shock front forming the PWN and emit photons which can be observed along the entire electromagnetic spectrum, including the high energy gamma-raydomain.Data provided by the Fermi-LAT during the first two years of the mission have allowed the detection andthe identification of three PWNe and their associated pulsars (Crab Nebula, Vela X and MSH 15-52) as well asthe PWN HESS J1825-137 discovered by ground-based experiments sensitive to very high energy gamma-rays.Results of temporal, spectral and morphological analyses of the pulsar/PWN systems detected by Fermi-LAT, as well as results of systematic studies performed (i) around every gamma-ray pulsar detected by the LATand (ii) around every very high energy source identified as a PWN or a PWN candidate are presented in thisdissertation. These studies bring new insights and constraints on the physical properties of the sources as wellas on emitting processes in pulsar magnetospheres and in PWNe.

>Magister Scientiae - MSc / The growth rate of large-scale structure is a key probe of gravity in the accelerating Universe. Standard models of Dark Energy within General Relativity predict essentially the same growth rate, whereas Modified Gravity theories without Dark Energy predict a different growth rate. Redshift-space distortions lead to anisotropy in the power spectrum, and extracting the monopole and quadrupole allows us to determine the growth rate and thus test theories of gravity. We investigate redshift-space distortions in the intensity maps of the 21cm emission line of neutral hydrogen (HI) in galaxies after the Epoch of Reionization: HI intensity mapping delivers very accurate redshifts. We first use the standard approach based on the Fourier power spectrum. Then we explored an alternative approach, based on the spherical-harmonic angular power spectrum. Fisher forecasting was used to make predictions of the accuracy with which MeerKAT will measure the growth rate parameter, via the proposed MeerKAT Large Area Synoptic Survey (MeerKLASS). Then we extend the forecasts to consider the planned HI intensity mapping survey in Phase 1 of the Square Kilometre Array. These forecasts enable us to predict at what level of accuracy General relativity and various alternative theories could be ruled out.