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NANO2021-Nanoteknologi og nye materiale

IN-situ Studies of highly conductive bonded interfaces between Aluminium and copper at the Nano-scalE

Alternative title: In-situ studier av ledende, spleiste grensflater mellom aluminium og kopper

Awarded: NOK 12.0 mill.

The possibility of producing dissimilar and highly conductive Cu/Al microjoints with strong and sharp interfaces is the key to success in manufacturing of all types of battery power packs. Such joints will ensure efficient reliable and sustainable energy transport and storage. So far there is no technology to produce such joints in the solid state without size limitations while maintaining full control and understanding of the process. In this project we aim to develop the solid-state Hybrid Metal Extrusion & Bonding (HYB) process (patented by the applicants) for Al/Cu microjoining at scales relevant to electronic packaging. The micro-HYB process will be studied in-situ, inside a modified Scanning Electron Microscope (SEM) equipped with a Focused Ion Beam (FIB) and dedicated devices for electrical and chemical characterization. This allows nanoscale studies and straightforward extraction of samples for subsequent atomic scale characterization by means of Transmission Electron Microscopy. We will utilize the NorFab and the NORTEM facilities at the edge of their technical capabilities. This level of control during joining will allow for a quick development of the HYB process to a level where it may outperform commonplace joining processes. Simultaneously, we will gather deep insight into dissimilar solid-state metal joining - knowledge that is limited but essential to reach the goal of continuous electrification. The IN-SANE project has support for four years, involves two PhD fellowships and is a new collaboration between two departments (Physics and Mechanical and Industrial Engineering) at NTNU and SINTEF, together with international world leading experts. Two PhD students were hired for the project in August 2020. They have now finished the courses in their study, and have learned the advanced characterization techniques (FIB-SEM and TEM). We have carried out the first joining between aluminum and aluminum inside the FIB, and are in the process of characterizing it. We have also made strength calculations and started measuring the strength of these micro-joints. We have also made different joints between aluminum and copper with the usual HYB technique (with varying parameters) and are in the process of characterizing these.

The possibility of producing dissimilar and highly conductive Cu/Al microjoints with strong and sharp interfaces is the key to success in manufacturing of all types of battery power packs. Such joints will ensure efficient reliable and sustainable energy transport and storage. Yet, no technology exists to produce the target joints in the solid state without size limitations while maintaining full control and understanding of the process. We aim to develop the solid-state Hybrid Metal Extrusion & Bonding (HYB) process (patented by the applicants) for Al/Cu microjoining at scales relevant to electronic packaging. The micro-HYB process will be studied in-situ, inside a modified Scanning Electron Microscope (SEM) equipped with a Focused Ion Beam (FIB) and dedicated devices for electrical and chemical characterization. This allows nanoscale studies and straightforward extraction of samples for subsequent atomic scale characterization by means of Transmission Electron Microscopy (TEM) utilizing the NorFab and the NORTEM facilities at the edge of their technical capabilities. This level of control during joining will allow a quick development of the HYB process to a level where it may outperform commonplace joining processes. Simultaneously, we will gather deep insight into dissimilar solid-state metal joining - knowledge that is limited but essential to reach the goal of continuous electrification. The IN-SANE project seeks support for 4 years, involves two PhD fellowships and is a new collaboration between two departments (Physics and Mechanical and Industrial Engineering) at NTNU and SINTEF, together with international world leading experts.

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NANO2021-Nanoteknologi og nye materiale