Six Sigma-based approach to optimise the diffusion process of crystalline silicon solar cell manufacturing

Silicon-based photovoltaics (PV) plays the dominant role in the history of PV due to the continuous process and technology improvement in silicon solar cells and its manufacturing flow. In general, silicon solar cell process uses either p-type- or n-type-doped silicon as the starting material. Currently, most of the PV industries use p-type, boron-doped silicon wafer as the starting material. In this work too, the boron-doped wafers were considered as the starting material to create pn junction and phosphorus was used as n-type doping material. Industries use either phosphorous oxy chloride (POCl₃) or ortho phosphoric acid (H₃PO₄) as the precursor for doping phosphorous. While the industries use POCl₃ as the precursor, the throughput is lesser than that of the industries’ use of H₃PO₄ due to the manufacturing limitations of the POCl₃-based equipments. Hence, in order to achieve the operational excellence in POCl₃-based equipments, business strategies such as the Six Sigma methodology have to be adapted. This paper describes the application of Six Sigma Define–Measure–Analyze–Improve–Control methodology for throughput improvement of the phosphorus doping process. The optimised recipe has been implemented in the production and it is running successfully. As a result of this project, an effective gain of 0.9 MW was reported per annum.     

A comparative study of microstructure and mechanical behavior of CO2 and diode laser deposited Cu–38Ni alloy

Cu–38Ni alloy was deposited on C71500 (Cu–30Ni) substrates by a laser-aided direct metal deposition technique using CO₂ and diode lasers. Structure–property relationships of deposited specimens were investigated by optical microscopy, electron microscopy, X-ray diffraction techniques, and microhardness and tensile measurements. Laser-deposited specimens’ microstructures were primarily dendritic, forming columnar grains growing epitaxially from the substrate and subsequent layers along the preferred crystallographic growth. The grain growth pattern and grain size distribution was significantly different in both specimens. The lattice parameter of the solid solution phase was relatively larger in diode laser-formed specimen; CO₂ laser-formed specimens showed relatively higher but non-uniform hardness distribution whereas a very uniform hardness distribution was observed in diode laser formed specimens. Diode laser formed specimens showed higher tensile properties compared to CO₂ laser formed specimens which were comparable to C71500 substrates. Microstructure and mechanical behavior were explained based on laser processing parameters.     

Studies on Enhancement of Silt Erosion Resistance of 13/4 Martensitic Stainless Steel by Low-Temperature Salt Bath Nitriding

Low-temperature salt bath nitriding of heat treated and tempered 13/4 Martensitic stainless steel (13/4HTT) was carried at 450 °C (N450) and 500 °C (N500) for 10 h each. The nitrided samples were characterized by using x-ray diffractometer, field emission scanning electron microscope and optical microscope. The nanohardness and elastic modulus of the cross section of nitrided specimen were measured by nanoindentation test using Hysitron TI950 triboindenter. The nitrided 13/4HTT (N450 and N500) and 13/4HTT specimens were subjected to slurry erosion test in a slurry pot tester. The test was conducted for 48 h, and weight loss was measured after every 6 h. The relative speed of slurry with respect to specimen was 4.55 m/s. It was found that the weight loss due to erosion of the N450 is 83% less than that of 13/4HTT and that of N500 was 92% more than that of 13/4HTT. The erosion mechanism is correlated to the phases present in the specimens. The improvement in the slurry erosion resistance of N450 is due to presence of expanded martensite (\(\alpha_{N}\)-Fe). Increasing the temperature of nitriding to 500 °C led to the decrease in the slurry erosion resistance of N500 due to the formation of brittle CrN phase.     

Synthesis and Characterization of Nanostructured BSTO Thin-Films for Microwave Applications

Nanophase synthesis of ferroelectric thin-films of Ba_0.6Sr_0.4TiO₃ (BSTO) was studied systematically for applications in tunable microwave components. Synthesis of nanostructured BSTO was performed using a pulsed-laser deposition system with real-time in-situ process control. The main research goal was to utilize the pulsed laser deposition parameters to control the grain growth for low microwave loss nanostructured BSTO thin-films on crystalline substrates such as LaAlO₃. These parameters include the energy density of the laser pulses, wavelength, oxygen partial pressure, distance between the target and the substrate, and the substrate temperature. The nanostructural characterization was performed using XRD, SEM and AFM. Microwave characterization was done using coplanar waveguide lines to characterize the frequency dependent dielectric properties (?_r and tan δ). BSTO films were grown at the same measured temperature and energy density but in different oxygen ambient pressures from 19 mTorr through 300 mTorr. Using contact mode AFM, the grain size was found to decrease as the oxygen ambient pressure was reduced from 150 mTorr to 38 mTorr. The growth process changed when the pressure was increased above 150 mTorr. Nanocluster structures rather than nanoparticles were found at 225 mTorr. Average grain sizes less than 100 nm were obtained to oxygen pressures below 75 mTorr. The XRD spectra indicate the highly crystalline nature of the film. Microwave measurements, performed between 9–18 GHz, suggest the nano-structured BSTO thin-films on LaAlO₃ (LAO) substrates are highly tunable (up to 25%).     

Identification of MEN1 gene mutations in sporadic carcinoid tumors of the lung

Lung carcinoids occur sporadically and rarely in association with multiple endocrine neoplasia type 1 (MEN1). There are no well defined genetic abnormalities known to occur in these tumors. We studied 11 sporadic lung carcinoids for loss of heterozygosity (LOH) at the locus of the MEN1 gene on chromosome 11q13, and for mutations of the MEN1 gene using dideoxy fingerprinting. Additionally, a lung carcinoid from a MEN1 patient was studied. In four of 11 (36%) sporadic tumors, both copies of the MEN1 gene were inactivated. All four tumors showed the presence of a MEN1 gene mutation and loss of the other allele. Observed mutations included a 1 bp insertion, a 1 bp deletion, a 13 bp deletion and a single nucleotide substitution affecting a donor splice site. Each mutation predicts truncation or potentially complete loss of menin. The remaining seven tumors showed neither the presence of a MEN1 gene mutation nor 11q13 LOH. The tumor from the MEN1 patient showed LOH at chromosome 11q13 and a complex germline MEN1 gene mutation. The data implicate the MEN1 gene in the pathogenesis of sporadic lung carcinoids, representing the first defined genetic alteration in these tumors.     

Document image mosaicing: A novel approach

There are situations where it is not possible to capture large documents with the given imaging media such as scanners or copying machines in a single stretch because of their inherent limitations. This results in capture of a large document in terms of split components of a document image. Hence, the need is to mosaic the split components into the original and put together the document image. In this paper, we present a novel and simple approach to mosaic two split images of a large document based on pixel value matching. The method compares the values of pixels in the columns of split images to identify the common or overlapping region (OR) in them, which helps in mosaicing of split images of a large document     

Induced EM fields inside human bodies irradiated by EM waves of up to 500 MHz.

In this paper, the internal EM field and the specific absorption rate of EM energy induced inside human bodies by EM waves of up to 500 MHz are theoretically quantified based on a tensor integral equation method. Numerical results for a realistic model of a man of 177 cm high irradiated by EM waves of various frequencies and of vertical and horizontal polarizations are presented. The resonance phenomenon and the effect of body heterogeneity on the induced field are studied. Some theoretical results are compared with existing experimental results.     

Boric acid binding studies with diol containing polyethylenimines as determined by 11B NMR spectroscopy

Three water‐soluble polymers incorporating increasing levels of 2,3‐dihydroxy propyl attached to polyethylenimine (PEI) backbone were synthesized, characterized by NMR, and investigated for their ability to bind boric acid (BA). ¹¹B NMR spectroscopy showed that BA interacted with the polymeric 2,3‐dihydroxy propyls by forming borate monoester and borate diesters in the boron concentration range of 100–1000 ppm and at 0.0775M polymer. Borate monoester species predominated for low functionalization levels (33% of the PEI amines functionalized), whereas borate diester species dominated for the higher functionalized polymers (66–100% of the PEI amines functionalized). All three polymers showed that 100% of the BA was bound as a mixture of borate mono‐ and diesters at 100‐ppm boron. The overall best performer based on total borate ester formation was the 2/3‐PEI, with a binding K_d of 631 at 200 ppm boron. Borate ion concentration was measured from the ¹¹B NMR chemical shift of the BA/borate peak and it decreased as 1/3‐PEI > 2/3‐PEI > 3/3‐PEI. Variable temperature ¹¹B NMR showed drastic reduction of borate ester species at 65°C. Thus, PEI polymers, as the ones investigated in this work, are reasonable candidates for the selective recovery and recycle of BA. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 4411–4418, 2006     

Nonlinear material behaviour and failure of closed-cell polymer foams

Classical strength criteria, like the von Mises criterion, are used to postulate the failure of ductile materials like steel or brass. It is known that for the application of foams in modern lightweight structures extended criteria are required, since foams are sensitive to hydrostatic stress. This observation on the macroscale can be explained by the deformation mechanisms of one single foam cell. Under hydrostatic stress, the deformation of the cell causes a non-uniform stress state of the cell walls. To understand the mechanism on the microlevel, a finite element model on the basis of a tetrakaidecahedron as unit cell was implemented. Utilising a strain energy-based homogenisation concept, the effective properties of the foam can be obtained. To adapt the geometric properties of the model to the real microstructure of the foam, results of a computer tomography image analysis were used by considering several imperfections in the cell geometry. For the analysis of the stress state on the microlevel, different load cases were applied to the unit cell. By means of these simulations, the geometrically nonlinear stress–strain curves on the macrolevel were deduced. Furthermore, the analysis of the finite element model provides an insight into the deformation mechanism on the microscale and allows the prediction of failure as well. Finally, the predicted failure points are represented in the Burzyński plane and compared with experimental results. The current paper focuses on the hard foam ROHACELL\({^{\circledR}}\) IG-series (industrial grade), which is a closed-cell PMI foam produced by Evonik Industries AG, Germany.     

Treatment of Acidic Groundwater in Acid Sulfate Soil Terrain Using Recycled Concrete: Column Experiments

Acidic groundwater generated from pyrite oxidation in acid sulfate (AS) soil is a major geoenvironmental problem in Australia. This study aims to evaluate recycled concrete as a reactive material in permeable reactive barriers (PRBs) for the remediation of acidic groundwater in low-lying AS soil floodplains. Laboratory experiments were systematically conducted to investigate the acid neutralization behavior of recycled concrete and its potential to remove dissolved Al and Fe. The results confirmed that recycled concrete could effectively treat acidic groundwater from an AS soil terrain, resulting in near neutral effluent over a long period with complete removal of Al and Fe. The major mechanisms involved in neutralizing acidic groundwater are thought to be the precipitation of Al and Fe as oxides, oxyhydroxides, and hydroxides. However, the accumulation of secondary minerals could decrease the reactivity of the recycled concrete. For example, chemical armoring could decrease the neutralizing capacity of recycled concrete by up to 50% compared with the theoretical acid neutralization capacity of this material. The results reported here also show that the neutralization capacity and reactive efficiency of recycled concrete are dependent on the initial pH value and also the concentration of Al and Fe in acidic groundwater.