In thin film solar cells there is a front contact layer called TCO, transparent conducting oxide. This layer requires high conductivity and high transmittance. Different materials such as Tin doped indium oxide (ITO) and Aluminum doped zinc oxide (AZO) are current good alternatives but several other materials are investigated to find even better materials. One of them is tungsten doped indium oxide (IOW). This project was about investigating the deposition process for IOW and characterize the properties of IOW thin film to investigate the possibilities for implementing this material as a contact layer in thin film solar cells. The results from the two batches of depositions varied a lot. Some samples came out dark, but some were transparent and had a high transmittance, suitable for a TCO. The highest transmittance reached through this process was around 95 % in the infrared (IR) range and around 90 % in the visible range. When it comes to the resistivity, no IOW-samples reaches desired levels for a TCO. The lowest resistivity reached was 6.36 * 10-4 W cm. The results showed that the sample with the lowest resistivity was the undoped material, which is contradicting the current theory on the subject. The lowest resistivity for the IOW film was 6.50 * 10-3 W cm.

<p> A thin film thickness monitor has been designed and constructed based on the "mass loading" effect of a resonant quartz crystal. A 6.0 MHz Y-cut crystal, having a theoretical "mass determination sensitivity" of 8.15x10^7 Hz. - cm^2/gm, serves as the sensor element. This sensitivity can be closely approached in practice if the entire active area of the quartz plate is exposed to the evaporant stream. However, due to source, substrate and crystal geometry the "effective" sensitivity of the monitor is only 0.433 of the above value. </p> <p> Both film thickness and deposition rate can be measured by the monitor in terms of equivalent frequency changes. The actual thickness and rates depend upon the density of the evaporant. In the case of silver (density 10.5 gm/cm^3), the monitor measures average thicknesses from several (oA) to 1.36 microns in one single deposition. Each crystal can be used to monitor a total of 4.5 microns of silver before replacement. Deposition rates for silver can be measured from as low as 0.l (oA)/sec to 1360 (oA)/sec. </p> <p> By combining the thickness monitor with apparatus for controlled evaporation, a system was set up which can control film thickness to within 2% and deposition rate to within 5%. </p> / Thesis / Master of Engineering (MEngr)

This thesis contains both Parts A and B. / <p> Xenon induced flux oscillations are possible in large thermal reactors operating at high powers because of the inter-play between the xenon concentration, reactivity, and thermal flux, and the fact that xenon is produced mainly by radioactive decay of I-135, which has a half-life of 6.7 hours. Due to these nuclear characteristics along with size and operating conditions of the Pickering and Bruce cores, these oscillations in flux are inherently unstable with respect to xenon. That is, a local perturbation in reactivity will result in a divergent and cyclic time and space variation in the thermal flux distribution in the core.</p> <p> One group diffusion theory and a simple perturbation analysis yield for a bare thermal reactor, a threshold in the average flux level ∅ which satisfies (1) M^2λij^2 / αxe - αT/αxe ∅ = 1/1+λxe/σxe∅ - μxe / 1+(λxe + λ1)/σxe∅ for oscillations in ijth mode of the flux distribution (see Figure 1) M^2 is the migration area in cm^2, αxe is the reactivity load of Xe-135 at high flux levels; αT is the fuel temperature coefficient expressed in terms of reactivity change per unit flux. The function f(∅) depends only upon the decay constants λxe of Xe-135 and λ1 of I-135; μxe is the fraction of Xe-135 produced directly from the fission of the fuel rather than through iodine decay (which fraction is denoted by μ1). The dimensionless parameter λij^2 depends only upon the shape of the flux distribution and is equal to the difference between the bulking of the ijth mode and the fundamental model.</p> <p> The Bruce and Pickering reactors are used as models in this study to determine the threshold power level at which xenon instability is possible and in which mode this instability occurs.</p> <p> Bruce is found to be unstable in the fundamental and first azimuthal mode for fresh and equilibrium fuel conditions, and stable for the radial, axial and higher azimuthal modes.</p> <p> Pickering, on the other hand, is unstable for the equilibrium fuel condition in the fundamental and first azimuthal modes only and is stable in every mode except the fundamental in the fresh fuel condition.</p> (Part A of Thesis)-------------------------------------------------------------------------------------------------------(Part B of Thesis) </p> Trimming of thin-film resistor components by an electrical arc is investigated in this report as an inexpensive and simple alternative to the laser trim and mechanical scribe methods. A multitude of tests were effected on Garrett Manufacturing Limited production circuits containing nichrome thin film resistors. These tests included Temperature Coefficient of Resistivity, resistance stability, substrate damage, noise performance, dynamic trim with active devices operating, width of cut as compared to mechanical scribe and laser trim techniques, and optimum parameters for trimming. In all cases the trimmed circuits were within the design specifications of the resistor properties under test. It is the conclusion of the author that the obvious attributes of the arc-trim method as well as its outstanding performance in the above tests, warrants its serious consideration as a viable alternative to the laser trim and mechanical scribe methods of altering resistance levels.</p> / Thesis / Master of Engineering (MEngr)

Iron-based superconductors might be promising for high field applications due to their decent superconducting transition temperature Tc, high upper critical field and low anisotropy. However, similar to cuprates the materials suffer from the detrimental effect of large angle grain boundaries reducing significantly the critical current density J c. Therefore, a coated conductor technology must be applied to solve this issue using highly textured templates based either on the ion beam assisted deposition (IBAD) or the rolling assisted biaxial textured substrates (RABiTS) approach. The main aim of this thesis was to apply such templates and to study the correlation between the microstructure and the current transport on a local scale in epitaxial Fe(Se,Te) layers deposited on such tapes as well as on single crystals. Therefore, thin films were grown by pulsed laser deposition and studied in detail afterwards including a local texture analysis with high-resolution electron back scattering diffraction (EBSD) as well as transmission electron microscopy (TEM) to identify the local defect structure. Simultaneously, the current transport was investigated globally by magnetization measurements and on a local scale by scanning Hall probe microscopy (SHPM). X-ray diffraction studies showed a clear epitaxial relationship and a high texture quality for thin films on all templates. However, misoriented grains were observed for higher deposition rates and film thicknesses. The Tc reached values of up to 21 K on CaF2 single crystals and 18 K on metal templates, respectively. The J c determined from magnetization loops showed values above 2 MA cm−2 and 1 MA cm−2 at 2 K in self-field on single crystals and IBAD based templates, respectively, whereas the global J c for films on RABiTS templates was one magnitude lower. Detailed TEM studies revealed smooth layers on all templates with minor defects for films on single crystals, but pronounced grain boundaries for layers on metallic templates. Unfortunately, EBSD measurements on the grown films showed a low indexing rate prohibiting the analysis of the grain boundary network. In contrast, SHPM proved a homogeneous magnetization profile for Fe(Se,Te) films on singe crystals and IBAD templates, whereas a distinct magnetic granularity was observe on RABiTS tapes. Detailed TEM studies in combination with transmission Kikuchi diffraction pattern revealed a strong dependence of the film growth on the out-of-plane orientation of the Ni-W grains. In general, the local SHPM studies revealed a similar dependence of superconductivity on granularity for Fe(Se,Te) as previously observed for YBCO.

In this report, the effects of adding 11B4C as interlayers into Fe/Si multilayers is studied. Fe/Si multilayers are commonly used for neutron polarization at large research facilities, and improving the polarizing properties would improve their efficiency. To study this, DC magnetron sputtering was used to make different sets of samples varying interlayer thicknesses, period thicknesses, number of periods, layer thickness ratios and also testing it with steel instead of iron in the multilayers. The samples were then studied using a series of characterization techniques to study how different growth parameters affected the sample’s properties. X-ray diffraction(XRD) and selected area electron diffraction (ED) were used for studying the crystal structure of the samples. X-ray reflectometry (XRR) was used to for fitting layer thicknesses and interface widths, and also to compare reflectivities. Elastic recoil detection analysis (ERDA) was used to study the compositions changes of the samples. Vibrating sample magnetometry (VSM) gave information about how the magnetization changed between samples. Transmission electron microscopy (TEM) visualized the structure of the samples. Finally, polarized neutron reflectometry (PNR) was done at Institute Laue Langevin (ILL), revealing the actual polarization of the samples. The results of the measurements concluded that for a sample with 40 periods, a period thickness of approximately 16 Å and a thickness ratio of around 0.5 for iron and silicon, using 1 Å thick 11B4C interlayers improved the polarization between the Bragg peaks by 60 %, and at the angle of the spin up peak by 130 %. The results also indicate improved polarization for samples with more or thicker periods. Using low carbon steel instead of iron showed poor results for thin layers, however showed promise for thicker layers due to good reflectivity results, but further testing is required.

From space exploration and advanced aircraft to next generation weapons, achieving hypersonic speed is becoming increasingly important across a range of research domains. The immense challenge associated with this goal involves the development of suitable materials and systems for the different components of a hypersonic vehicle, each of which must have the inherent capability to resist extreme temperatures, high thermal shock due to high heat flux, and high oxidation and ablation. First, the ultra-high temperature ceramic (UHTC) zirconium diboride or ZrB2 was sintered by ultra-fast high temperature sintering (UHS). The UHS process was optimized and the sintering parameters for ZrB2 and other UHTCs were studied. ZrB2 is an ultra-high temperature ceramic (UHTC) with a very high melting point; thus, its densification is difficult, energy intensive, and time-consuming. Commercial ZrB2 powders were rapidly densified via UHS to >90% relative density within 60 second in vacuum without pressure. The effect of sintering time on densification and final grain size were studied. An innovative process for manufacturing bulk UHTC materials was studied and is detailed herein. Second, the work function (W_f) of electron emitting materials was reduced to improved performance. A reduction of W_f in multicomponent hexaborides was achieved by doping with highly electropositive Ba, which enhances electron emission. Single-phase bulk multicomponent polycrystalline hexaborides of La0.5Ba0.5B6, Ce0.5Ba0.5B6, and BaB6 powders were first synthesized and then densified by UHS sintering. W_f measurements were obtained by Kelvin probe force microscopy. Ba-substitution was found to lower W_f (~25%) in synthesized multicomponent hexaborides. The specific techniques required to engineer the W_f of these materials are also provided herein. Finally, combining low W_f materials with UHTCs was explored for thin film systems for the exterior surface of hypersonic vehicles. The thin films of CeB6, a low W_f material, was deposited on sintered ZrB2 by RF-sputtering and single crystalline SrTiO3 (STO) substrates. Epitaxial thin films of SrHfO3 (SHO) were also deposited on (100), (110) and (111) STO substrates at 600°C. X-ray diffraction (XRD) results confirmed the formation of epitaxial layer, and reciprocal space mapping (RSM) was used to characterize film's mosaicity / texture on different substrates. XRD and RSM data demonstrated that the most favorable film growth direction was (110). As detailed herein, an inexpensive thin film production process, RF-sputtering, was exploited to manufacture various epitaxial and non-epitaxial layers of low W_f materials on UHTC and single-crystal substrates for hypersonic vehicles. To summarize, a range of bulk UHTCs and low W_f materials were prepared by UHS, and various thin films of low W_f material were produced on UHTC. Thereafter, the properties of synthesized materials were studied to develop new material systems for hypersonic applications. The findings from this research shed light on the development of suitable materials for implementation of electron transpiration cooling for hypersonic vehicle development. / Doctor of Philosophy / Rapid sintering of ultra-high temperature ceramics (UHTCs) and synthesis of low work-function electron emitting materials have been performed by ultra-fast high temperature sintering technique (UHS). Sintering of UHTCs is a difficult process, due to their high melting temperature, presence of covalent bond, and slower diffusion coefficient. A long sintering duration is used to achieve a high relative density along with adding sintering aid, using fine powder (produced by milling), and utilizing pressure (such as field assisted sintering and hot-pressing technology) during sintering. Synthesis and densification of multicomponent hexaboride is difficult, involves multi-steps and complicated processes. These long and complicated processes not only prolong development of new materials but also cause chemical wastes. To overcome all the aforementioned processing issues, an advanced processing technique, UHS, is used and densified pure and commercially available UHTCs to >90% within 60 second without applying sintering aid, powder milling, and pressure. The outcome of this research demonstrates the potential for a simple, cost-effective, fast, and adjustable processes, UHS, to develop a wide range of bulk UHTCs and other technical ceramics, and it gives new insight into the mechanisms of rapid sintering of UHTCs by rapid heating. The first detailed studies (experimental report) on rapid sintering of ZrB2 (and other UHTCs) by UHS technique and a through characterizations of the UHS sintered sample were performed to understand rapid sintering mechanism and how the processing effects the microstructure and properties of UHS ZrB2. The rapid microstructural evolution during the UHS sintering is investigated at 10, 30, and 60 second sintering interval. The UHS technique enables a heating rate of 103 - 104 °C/min and reaches a sintering temperature of 2600 °C in 30 seconds. Microstructural analysis was conducted on polished sample surfaces by using ImageJ software (National Institutes of Health, version 1.53e), measuring the grain size perpendicular to two diagonals of each grain. A comparison of grain size from sample center and periphery showed a homogeneous microstructure after sintering. Furthermore, the rapid sintering did not change/effect crystallinity, boron to metal stoichiometry, and grain boundary elemental composition as observed by XRD and EDS analysis. Additional characterization of the UHS sintered ZrB2 shows a hardness and elastic modulus of 30 GPa and 412 GPa respectively by nanoindentation method. Finally, the oxidation test at 1100 °C in isothermal condition showed a weight gain of 1.4% in air. The low work-function (W_f) materials are famous for electron emitting applications like electron guns for scanning electron microscopy. DFT simulation predicts the W_f of the widely used electron emitters (such as LaB6 and CeB6) can be reduced by changing their compositions, which increase electron generation efficiency of those materials. Previously, those materials were synthesized by long processes that involved multiple processing steps, which required expensive starting materials and yielded chemical wastes. The advantages of rapid sintering technique, UHS, had been exploited to synthesize low work function electron emitting materials. Single-phase bulk polycrystalline hexaborides were produced by using electrically powered UHS technique using a vacuum atmosphere. A reaction synthesis route: B4C reduction technique was first used to form pure phase hexaboride. Then, the synthesized compositions were densified to ~90% theoretical density in 180 seconds by UHS densification. After UHS sintering, XRD analysis confirmed the presence of a phase pure cubic BaB6, La0.5Ba0.5B6, and Ce0.5Ba0.5B6. Additional analyses were conducted to determine an optimum reaction temperature 1500 and 2100 °C for the formation BaB6 and multi-component hexaborides. Microstructural analyses were conducted to observe both reaction-synthesized and densified products. EDS compositional analysis and elemental mapping revealed a stoichiometric reaction product with homogeneous metal cation and boron distributions. The W_f of BaB6, La0.5Ba0.5B6, and Ce0.5Ba0.5B6 was determined to be 1.95 ± 0.1, 2.05 ± 0.1 and 2.0 ± 0.1 eV, respectively. The addition of BaB6 in La0.5Ba0.5B6, and Ce0.5Ba0.5B6 resulted in a 25% decrease in W_f for LaB6 from 2.7 ± 0.1 to 2.00 ± 0.1 eV and a 23% decrease in W_f for CeB6 from 2.68 ± 0.08 to 2.05 ± 0.1 eV. Ba substitution is shown to be a general method for lowering W_f in a variety of multicomponent hexaborides. Finally, the polycrystalline thin films of CeB6, a low W_f material, was deposited on sintered ZrB2 by RF-sputtering technique. Additionally, epitaxial thin films of SrHfO3 (SHO) were also deposited on (100), (110) and (111) STO single crystalline substrates. Both types of thin films were deposited at 600 °C temperature and at a vacuum pressure of 10-3 Torr. After deposition of the SHO films, X-ray diffraction (XRD) was conducted to confirm the formation of epitaxial layer, and reciprocal space mapping (RSM) was used to characterize film's mosaicity / texture on different substrates. XRD and RSM data demonstrated that the most favorable film growth direction was (110). The XRD of the CeB6 film showed highly crystalline film was formed. For both the films, a detailed microstructural analysis was performed by scanning electron microscopy and film smoothness was characterized by atomic force microscopy method. As detailed herein, an inexpensive thin film production process, RF-sputtering, was exploited to manufacture various epitaxial and non-epitaxial layers of low W_f materials on UHTC and single-crystal substrates for hypersonic vehicles applications.

The acoustic emission technique is an effective way to acquire crack information from material bodies at the microscopic level. Monitoring of the acoustic emission events provides a deeper understanding regarding the structural health status of critical constructions such as bridges, railways, pipelines, pressure vessels, etc. Thanks to the acoustic emission monitoring systems, it is possible to avoid catastrophic events and save lives, time, and money. For this reason, efforts to develop new acoustic emission sensor technologies, as well as the use of current acoustic emission sensors in new research fields, will contribute to the limited literature sources. Optical sensing systems provide good alternatives to the existing sensing technologies because of their wide range of detection bandwidths, adaptation to harsh environments, and low sensitivity to electromagnetic interference. For this reason, the first part of this thesis demonstrates an optoacoustic sensing methodology that enables the detection of acoustic emissions by optics. This sensing system consists of thin-film optical filters (TFOF) and an elastic microcavity layer. The sensing mechanism is similar to the Fabry Perot structures and it relies on resonance shifts of the cavity when there is a change in the cavity thickness similar to the Fabry Perot structures. Thus, the design, fabrication, and demonstration steps of a Fabry Perot elastic microcavity have been presented. Throughout the fabrication efforts, a new deposition protocol was developed. This deposition technique has enabled the deposition of TFOF on flexible substrates via the RF-sputtering technique. Thus, a new sensing configuration has been developed using flexible optical components. In the second chapter, an optical sensing methodology based on tunable spectral filters and flexible optical components is introduced. The design, fabrication, realization, and characterization of a proof-of-concept optomechanical sensor have been presented. The design step includes optical, mechanical, and optoacoustic correlation simulations using the Transfer Matrix Method, finite element analysis, and analytical models. Moreover, the fabrication part includes multilayer deposition on silica and flexible substrates using the RF-Sputtering technique and integration of these optical components into a 3D-printed housing together with electronic components. Eventually, the performance evaluation of the optomechanical sensor has been carried out and the experimental results showed that the sensor resonance frequency is around 515 Hz and the sensor is capable of detecting static loadings from 50 Pa to 235 Pa values. In the fourth chapter, seismic vulnerability analysis of a coupled Tank-Piping System has been performed using traditional acoustic emission sensors. Real-time performance evaluation of the pipeline as well as the structural health status of the critical parts were monitored. As a result, deformation levels of each critical part were investigated, and the processing of acoustic emission signals provided a more in-depth view of damage level of the analyzed components. Throughout the thesis, TFOFs are an integral part of this thesis. Therefore, both the design and simulation of TFOFs play a crucial role throughout this research work. The Transfer Matrix Method is used to simulate the optical performance of TFOFs. Moreover, in the final chapter, an automated design framework is presented for the design of TFOFs using a nature-inspired machine learning approach called Genetic algorithm. This design approach enables the design of sophisticated geometric configurations with unique optical capabilities. Therefore, not only the improvement of sensor response but also the new ways in the development of novel optical systems are demonstrated in this final chapter.

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