Magnetron sputtering has garnered increased attention as a versatile deposition method for generating novel core–shell composite nano‐ and micro‐lattice materials spanning a wide range of properties and functionalities. Sputtering offers an expansive material workspace consisting of a wide range of ceramics, single‐element metals, and alloy systems. However, achieving uniform coatings on such fine‐featured structures remains a challenge. Thus, herein, a foundational assessment of various sputtering configurations, cathode geometries, and deposition parameters is carried out to investigate their implications on the coating thickness and uniformity of 3D micro‐lattice scaffolds. Specifically, tetrahedral‐truss structures fabricated via direct laser writing are coated by leveraging planar and inverted cylindrical magnetron cathodes at select deposition rates, sputtering powers, and Ar working pressures. Both plasma focused ion beam and microtome sectioning techniques are employed to evaluate the cross section of individual struts and assess overall uniformity. Overall, the influence of key sputtering factors on the design and development of core–shell composite nano‐ and micro‐lattice materials is highlighted and a pathway for future sputter coating optimization on these complex structures is provided.
Mechanical metamaterials can exhibit extraordinary mechanical properties due to a specific architecture rather than the base material. When the structural dimensions reach the sub-micrometer range, such micro- and nanolattices may also benefit from size-affected mechanical properties. However, well-defined geometric adjustments on this length scale are limited by the resolution limits of the underlying manufacturing technology. Here, we used a 3D direct laser writing (3D-DLW) process with integrated laser power variation to fabricate polymeric microlattices, which were then pyrolized to obtain glassy carbon structures. The laser power was varied by a quadratic function along the beams from one node to another over the length of a unit cell, thus enabling geometric adjustments in the range of a few nanometers. Rounded and notch-like joints were realized by increased and reduced laser power at the nodes, respectively. Furthermore, the beam cross section was varied along the beam length, thereby creating convex or concave beam shapes. A laser power variation opens up new design possibilities for micro- and nanolattices in the sub-micrometer range by overcoming process related limitations.
Composite peening is a novel process to introduce ceramic blasting particles into the surface of substrates. Depending on the process parameters, the penetration depth of the blasting particles can be several micrometers. In previous investigations by some of the authors, it has been found that the ceramic particles incorporated during composite peening are significantly smaller compared to 10 μm in size before peening. Herein, the microstructure after composite peening is highlighted. To investigate this microstructure, scanning electron microscopy (SEM) and transmission electron microscopy (TEM) are performed. The subsequent X-ray diffraction (XRD) analysis provides further evidence of a severely deformed, nanocrystalline ceramic layer consisting of fragmented blasting particles.
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