Scaling up the fabrication of wafer-scale Ni-MoS2/WS2 nanocomposite moulds using novel intermittent ultrasonic-assisted dual-bath micro-electroforming
In the scale-up fabrication process for electroformed Ni-MoS2/WS2 composite moulds, the formulation of nanosheets is critical, since the size, charge, and their distribution can largely affect the hardness, surface morphology and tribological properties of the moulds. Additionally, the long-term dis...
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2023-05-01
|
| Series: | Ultrasonics Sonochemistry |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S1350417723000718 |
| _version_ | 1797450921345548288 |
|---|---|
| author | Tianyu Guan Yuanzhi Lu Xinhui Wang Michael D. Gilchrist Fengzhou Fang Nan Zhang |
| author_facet | Tianyu Guan Yuanzhi Lu Xinhui Wang Michael D. Gilchrist Fengzhou Fang Nan Zhang |
| author_sort | Tianyu Guan |
| collection | DOAJ |
| description | In the scale-up fabrication process for electroformed Ni-MoS2/WS2 composite moulds, the formulation of nanosheets is critical, since the size, charge, and their distribution can largely affect the hardness, surface morphology and tribological properties of the moulds. Additionally, the long-term dispersion of hydrophobic MoS2/WS2 nanosheets in a nickel sulphamate solution is problematic. In this work, we studied the effect of ultrasonic power, processing time, surfactant types and concentrations on the properties of nanosheets to elaborate their dispersion mechanism and control their size and surface charge in divalent nickel electrolyte. The formulation of MoS2/WS2 nanosheets was optimized for effective electrodeposition along with nickel ions. A novel strategy of intermittent ultrasonication in the dual bath was proposed to resolve the problem of long-term dispersion, overheating, and deterioration of 2D material deposition under direct ultrasonication. Such strategy was then validated by electroforming 4-inch wafer-scale Ni-MoS2/WS2 nanocomposite moulds. The results indicated that the 2D materials were successfully co-deposited into composite moulds without any defects, along with the mould microhardness increasing by ∼2.8 times, the coefficient of friction reducing by two times against polymer materials, and the tool life increasing up to 8 times. This novel strategy will contribute to the industrial manufacturing of 2D material nanocomposites under ultrasonication process. |
| first_indexed | 2024-03-09T14:47:29Z |
| format | Article |
| id | doaj.art-7ce98e30bb184115aa75b22411f76cd0 |
| institution | Directory Open Access Journal |
| issn | 1350-4177 |
| language | English |
| last_indexed | 2024-03-09T14:47:29Z |
| publishDate | 2023-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Ultrasonics Sonochemistry |
| spelling | doaj.art-7ce98e30bb184115aa75b22411f76cd02023-11-27T04:14:25ZengElsevierUltrasonics Sonochemistry1350-41772023-05-0195106359Scaling up the fabrication of wafer-scale Ni-MoS2/WS2 nanocomposite moulds using novel intermittent ultrasonic-assisted dual-bath micro-electroformingTianyu Guan0Yuanzhi Lu1Xinhui Wang2Michael D. Gilchrist3Fengzhou Fang4Nan Zhang5Centre of Micro/Nano Manufacturing Technology (MNMT-Dublin), School of Mechanical & Materials Engineering, University College Dublin, Dublin 4, IrelandCentre of Micro/Nano Manufacturing Technology (MNMT-Dublin), School of Mechanical & Materials Engineering, University College Dublin, Dublin 4, IrelandCentre of Micro/Nano Manufacturing Technology (MNMT-Dublin), School of Mechanical & Materials Engineering, University College Dublin, Dublin 4, IrelandCentre of Micro/Nano Manufacturing Technology (MNMT-Dublin), School of Mechanical & Materials Engineering, University College Dublin, Dublin 4, IrelandCentre of Micro/Nano Manufacturing Technology (MNMT-Dublin), School of Mechanical & Materials Engineering, University College Dublin, Dublin 4, Ireland; State Key Laboratory of Precision Measuring Technology and Instruments, Laboratory of Micro/Nano Manufacturing Technology (MNMT), Tianjin University, Tianjin 300072, ChinaCentre of Micro/Nano Manufacturing Technology (MNMT-Dublin), School of Mechanical & Materials Engineering, University College Dublin, Dublin 4, Ireland; Corresponding author.In the scale-up fabrication process for electroformed Ni-MoS2/WS2 composite moulds, the formulation of nanosheets is critical, since the size, charge, and their distribution can largely affect the hardness, surface morphology and tribological properties of the moulds. Additionally, the long-term dispersion of hydrophobic MoS2/WS2 nanosheets in a nickel sulphamate solution is problematic. In this work, we studied the effect of ultrasonic power, processing time, surfactant types and concentrations on the properties of nanosheets to elaborate their dispersion mechanism and control their size and surface charge in divalent nickel electrolyte. The formulation of MoS2/WS2 nanosheets was optimized for effective electrodeposition along with nickel ions. A novel strategy of intermittent ultrasonication in the dual bath was proposed to resolve the problem of long-term dispersion, overheating, and deterioration of 2D material deposition under direct ultrasonication. Such strategy was then validated by electroforming 4-inch wafer-scale Ni-MoS2/WS2 nanocomposite moulds. The results indicated that the 2D materials were successfully co-deposited into composite moulds without any defects, along with the mould microhardness increasing by ∼2.8 times, the coefficient of friction reducing by two times against polymer materials, and the tool life increasing up to 8 times. This novel strategy will contribute to the industrial manufacturing of 2D material nanocomposites under ultrasonication process.http://www.sciencedirect.com/science/article/pii/S1350417723000718UltrasonicationElectroformingFrictionMouldNanosheets |
| spellingShingle | Tianyu Guan Yuanzhi Lu Xinhui Wang Michael D. Gilchrist Fengzhou Fang Nan Zhang Scaling up the fabrication of wafer-scale Ni-MoS2/WS2 nanocomposite moulds using novel intermittent ultrasonic-assisted dual-bath micro-electroforming Ultrasonics Sonochemistry Ultrasonication Electroforming Friction Mould Nanosheets |
| title | Scaling up the fabrication of wafer-scale Ni-MoS2/WS2 nanocomposite moulds using novel intermittent ultrasonic-assisted dual-bath micro-electroforming |
| title_full | Scaling up the fabrication of wafer-scale Ni-MoS2/WS2 nanocomposite moulds using novel intermittent ultrasonic-assisted dual-bath micro-electroforming |
| title_fullStr | Scaling up the fabrication of wafer-scale Ni-MoS2/WS2 nanocomposite moulds using novel intermittent ultrasonic-assisted dual-bath micro-electroforming |
| title_full_unstemmed | Scaling up the fabrication of wafer-scale Ni-MoS2/WS2 nanocomposite moulds using novel intermittent ultrasonic-assisted dual-bath micro-electroforming |
| title_short | Scaling up the fabrication of wafer-scale Ni-MoS2/WS2 nanocomposite moulds using novel intermittent ultrasonic-assisted dual-bath micro-electroforming |
| title_sort | scaling up the fabrication of wafer scale ni mos2 ws2 nanocomposite moulds using novel intermittent ultrasonic assisted dual bath micro electroforming |
| topic | Ultrasonication Electroforming Friction Mould Nanosheets |
| url | http://www.sciencedirect.com/science/article/pii/S1350417723000718 |
| work_keys_str_mv | AT tianyuguan scalingupthefabricationofwaferscalenimos2ws2nanocompositemouldsusingnovelintermittentultrasonicassisteddualbathmicroelectroforming AT yuanzhilu scalingupthefabricationofwaferscalenimos2ws2nanocompositemouldsusingnovelintermittentultrasonicassisteddualbathmicroelectroforming AT xinhuiwang scalingupthefabricationofwaferscalenimos2ws2nanocompositemouldsusingnovelintermittentultrasonicassisteddualbathmicroelectroforming AT michaeldgilchrist scalingupthefabricationofwaferscalenimos2ws2nanocompositemouldsusingnovelintermittentultrasonicassisteddualbathmicroelectroforming AT fengzhoufang scalingupthefabricationofwaferscalenimos2ws2nanocompositemouldsusingnovelintermittentultrasonicassisteddualbathmicroelectroforming AT nanzhang scalingupthefabricationofwaferscalenimos2ws2nanocompositemouldsusingnovelintermittentultrasonicassisteddualbathmicroelectroforming |