WO2014057951A1 - 成膜方法及び成膜装置 - Google Patents
成膜方法及び成膜装置 Download PDFInfo
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- WO2014057951A1 WO2014057951A1 PCT/JP2013/077391 JP2013077391W WO2014057951A1 WO 2014057951 A1 WO2014057951 A1 WO 2014057951A1 JP 2013077391 W JP2013077391 W JP 2013077391W WO 2014057951 A1 WO2014057951 A1 WO 2014057951A1
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- Prior art keywords
- chamber
- film forming
- inert gas
- film
- powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B1/00—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
- B05B1/02—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/12—Applying particulate materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
- B05B7/1481—Spray pistols or apparatus for discharging particulate material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/04—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases
- B05D3/0486—Operating the coating or treatment in a controlled atmosphere
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
- B05B7/1404—Arrangements for supplying particulate material
- B05B7/1413—Apparatus to be carried on or by a person, e.g. by hand; Apparatus comprising a container fixed to the discharge device
- B05B7/1422—Apparatus to be carried on or by a person, e.g. by hand; Apparatus comprising a container fixed to the discharge device the means for supplying particulate material comprising moving mechanical means, e.g. to impart vibration
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/04—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases
- B05D3/0466—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases the gas being a non-reacting gas
Definitions
- the present invention relates to a film forming method and a film forming apparatus for forming a film by accelerating a raw material powder together with a gas and spraying and depositing the powder on a surface of a base material while maintaining the solid state.
- a film forming method called a cold spray method In recent years, a film forming method called a cold spray method is known.
- powder of a metal material that is below the melting point or softening point is sprayed from a nozzle together with an inert gas such as helium, argon, and nitrogen, and is allowed to collide with the substrate to be deposited in the solid state.
- an inert gas such as helium, argon, and nitrogen
- This is a method of forming a film on the surface of the substrate (see, for example, Patent Document 1).
- film formation is performed at a relatively low temperature, unlike a thermal spraying method in which a powder of a material is melted and sprayed onto a substrate (for example, see Patent Document 2).
- the influence of thermal stress can be alleviated, and a metal film having no phase transformation and suppressing oxidation can be obtained.
- both the base material and the coating material are metals
- plastic deformation occurs between the powder and the base material when the metal material powder collides with the base material (or the previously formed film). Since the anchor effect is obtained and the oxide films of each other are destroyed and metal bonds are formed by the new surfaces, a laminate with high adhesion strength can be obtained.
- the cold spray method is usually performed in the atmosphere.
- a nozzle having a small diameter with respect to the substrate is used in order to accelerate the powder at a high speed by the compressed gas.
- the film already formed may be exposed to oxygen in the atmosphere and oxidized in areas other than the area during film formation where the powder sprayed from the nozzle is sprayed.
- film formation is further performed on the upper layer of the oxidized film, bonding between the upper layer and the lower layer becomes insufficient, and the film characteristics such as bonding strength and electrical properties are affected.
- the present invention has been made in view of the above, and it is possible to suppress oxidation of a film during film formation, and the apparatus can be configured in a simple and inexpensive manner, without taking time and effort.
- Another object of the present invention is to provide a film forming method and a film forming apparatus capable of exchanging a base material to be formed.
- the film forming method according to the present invention accelerates the raw material powder together with the gas and sprays and deposits the powder on the surface of the base material while maintaining the solid state.
- a film forming method for forming a film by causing the substrate to be disposed in a chamber; and injecting the powder and an inert gas from a nozzle toward the substrate;
- a film forming step of forming a film by depositing the powder on the surface of the base material while forming a positive pressure in the chamber with a gas.
- the film formation step is performed while exhausting the inert gas from the chamber.
- the film formation step is performed while rectifying the inert gas in the chamber.
- the inert gas is rectified by supplying an inert gas into the chamber separately from the nozzle.
- a film forming apparatus is a film forming apparatus that performs film formation by accelerating a raw material powder together with a gas, and spraying and depositing the powder on a surface of a base material while maintaining the solid state. Any one of a chamber, a holding unit provided in the chamber and holding the base material, a nozzle for injecting the powder together with an inert gas, and the nozzle and the holding unit is moved with respect to the other. And a moving mechanism, wherein the inside of the chamber becomes a positive pressure by the inert gas ejected by the nozzle.
- the film forming apparatus further includes an exhaust unit that exhausts gas from the chamber.
- the film forming apparatus further includes a rectifying mechanism that rectifies the inert gas in the chamber.
- the rectifying mechanism is a gas supply unit that supplies an inert gas into the chamber.
- the rectifying mechanism is a rectifying member installed in the chamber.
- the chamber includes a container in which the holding unit is provided and a lid unit attached to the nozzle.
- the chamber includes a cover attached to the nozzle and covering the holding portion.
- the raw material powder and the inert gas are jetted from the nozzle toward the base material, and the inside of the chamber is made positive pressure by the inert gas and the powder is deposited on the surface of the base material. Is not exposed to oxygen, and oxidation of the film during film formation can be suppressed. Further, according to the present invention, it is not necessary to provide an additional device such as an exhaust device or an inert gas supply device in the chamber, so that the device can be configured simply and inexpensively. Furthermore, according to the present invention, it is not necessary to perform additional operations such as decompression in the chamber and gas exchange prior to film formation, so that it is possible to replace the substrate without taking time and effort. .
- FIG. 1 is a schematic diagram showing a film forming apparatus according to Embodiment 1 of the present invention.
- FIG. 2 is a flowchart showing the film forming method according to Embodiment 1 of the present invention.
- FIG. 3 is a schematic diagram showing Modification 1 of the film forming apparatus according to Embodiment 1 of the present invention.
- FIG. 4 is a schematic diagram illustrating another example of the rectifying unit provided in the chamber.
- FIG. 5 is a schematic diagram showing a film forming apparatus according to Embodiment 2 of the present invention.
- FIG. 6 is a graph showing the characteristics of the test pieces according to Examples and Comparative Examples.
- FIG. 1 is a schematic diagram showing a configuration of a film forming apparatus according to Embodiment 1 of the present invention.
- a film forming apparatus 100 according to Embodiment 1 is a so-called cold spray apparatus that forms a film by spraying and depositing raw material powder 2 on the surface of a substrate 1.
- a holding unit 11 that holds the substrate 1, a spray nozzle 12 that sprays the powder 2 together with an inert gas, a powder supply unit 13 that supplies the powder 2 to the spray nozzle 12, and a powder pipe 13a, and an inert gas.
- a gas heating unit (gas supply unit) 14 and a gas pipe 14a for heating and supplying gas to the spray nozzle 12, a drive unit 15 for moving the spray nozzle 12, and a control unit 16 for controlling the operation of the drive unit 15; Is provided.
- FIG. 1 only the chamber 10 is shown in cross section.
- the chamber 10 includes a bottomed columnar container 10a and a lid 10b that covers the opening of the container 10a.
- the specific shape of the container 10a is not particularly limited.
- the bottomed cylinder is provided with a flange that extends from the opening toward the outer periphery.
- the shape of the cover part 10b is prescribed
- the lid 10b is attached to the spray nozzle 12 by fastening, bonding, welding, or the like, and is supported by a support mechanism (not shown) of the spray nozzle 12 so as to be three-dimensionally movable. Further, as shown in FIG. 1, when the base material 1 is formed, the lid 10b is slightly lifted (at least to the extent that gas can pass) from the opening 10c of the container 10a. It is supported so as to be movable in a parallel plane (horizontal in FIG. 1). At this time, the gap 10d between the container 10a and the lid portion 10b functions as an exhaust port for discharging the gas in the chamber 10 to the outside.
- the diameter of the lid portion 10b depends on the movable range of the spray nozzle 12 so that the opening of the container 10a is not exposed even when the lid portion 10b is moved in a plane parallel to the opening surface 10c during film formation. It is designed to be larger than the opening diameter of the container 10a.
- the holding unit 11 is provided at the bottom of the container 10a, for example.
- the holding unit 11 includes a holding mechanism such as an electrostatic chuck, and holds the base material 1 with the film formation surface 1a of the base material 1 facing the spray nozzle 12 side.
- a holding mechanism such as an electrostatic chuck
- the film-formation surface 1a has shown the plate-shaped base material 1 which makes a plane
- the whole shape of the base material 1 and the shape of the film-formation surface 1a are not specifically limited, It can form into a film What is necessary is just to have a surface.
- the spray nozzle 12 accelerates the powder 2 supplied from the powder supply unit 13 by the inert gas supplied via the gas heating unit 14 and injects the powder 2 at a supersonic speed of, for example, 340 m / s or more.
- Compressed gas obtained by compressing an inert gas such as helium, argon or nitrogen is supplied to the powder supply unit 13 and the gas heating unit 14 from the outside.
- the powder supply unit 13 and the gas heating unit 14 are each provided with a valve (not shown) that adjusts the supply amount of the compressed gas.
- the powder supply unit 13 accommodates a metal or alloy powder 2 that is a raw material of the film.
- the powder supply unit 13 supplies the powder 2 to the spray nozzle 12 through the powder pipe 13a together with the inert gas supplied from the outside.
- the gas heating unit 14 heats an inert gas supplied from the outside to a predetermined temperature, and supplies it to the spray nozzle 12 via the gas pipe 14a.
- the temperature at which the inert gas is heated is, for example, 50 ° C. or higher, and is set to such an extent that the powder 2 does not melt (for example, about 300 ° C. to 900 ° C.) according to the type of the powder 2.
- the driving unit 15 is provided in the spray nozzle 12 and is a part of a moving mechanism that moves the spray nozzle 12 together with the lid 10b.
- a known general technique can be applied as the moving mechanism, and the entire moving mechanism is not shown in FIG.
- the control unit 16 controls the operation of such a drive unit 15.
- tip of the spray nozzle 12 has shown the flow of the inert gas typically.
- FIG. 2 is a flowchart showing the film forming method according to the first embodiment.
- the base material 1 is placed in the chamber 10.
- the material of the base material copper, copper alloy, zinc, zinc alloy, aluminum, aluminum alloy, magnesium, magnesium alloy, nickel, nickel alloy, iron, iron alloy, titanium, titanium alloy, chromium, chromium alloy, niobium, Niobium alloy, molybdenum, molybdenum alloy, silver, silver alloy, tin, tin alloy, tantalum, tantalum alloy and other metals or alloys, alumina, zirconia, yttria, yttria stabilized zirconia ceramics, etc. be able to.
- the base material 1 is held and fixed by the holding unit 11.
- the powder supply unit 13 is filled with the powder 2 that is the raw material of the film formed on the substrate 1.
- the type of powder 2 is not particularly limited, and may be copper, copper alloy, zinc, zinc alloy, aluminum, aluminum alloy, magnesium, magnesium alloy, nickel, nickel alloy, iron, iron alloy, titanium, titanium, depending on the application of the film.
- a metal or an alloy such as an alloy, chromium, a chromium alloy, niobium, a niobium alloy, molybdenum, a molybdenum alloy, silver, a silver alloy, tin, a tin alloy, tantalum, or a tantalum alloy is appropriately selected.
- the average particle diameter of the powder 2 is not particularly limited as long as it is a size capable of cold spraying (for example, about 5 to 100 ⁇ m).
- the film forming apparatus 100 is activated. Thereby, supply of the compressed gas (inert gas) to the powder supply unit 13 and the gas heating unit 14 is started, and the powder 2 and the heated inert gas are supplied to the spray nozzle 12.
- the powder 2 is put into a supersonic flow of compressed inert gas, accelerated, and sprayed from the spray nozzle 12 together with the inert gas while being kept in a solid state.
- the atmosphere in the chamber 10 is discharged from the gap 10d by the inert gas sprayed from the spray nozzle 12, and becomes a positive pressure.
- the inert gas sprayed from the spray nozzle 12 circulates in the chamber 10 after colliding with the surface of the substrate 1, and is discharged out of the chamber 10 through the gap 10d.
- the inside of the chamber 10 is at a positive pressure, the external atmosphere does not enter the chamber 10.
- the pressure of the inert gas supplied to the spray nozzle 12 is preferably about 1 to 5 MPa.
- the inside of the chamber 10 can be made positive pressure with an inert gas at an early stage, and in the subsequent step S4, the substrate 1 and the film formed thereon are formed. This is because the adhesion strength can be improved.
- step S4 a film is formed on the substrate 1. That is, while spraying the powder 2 from the spray nozzle 12 and spraying it on the film forming surface 1a, the spray nozzle 12 is moved in the horizontal direction to deposit the powder 2 on the film forming surface 1a. At this time, since the inside of the chamber 10 is filled with the inert gas ejected from the spray nozzle 12, the film on the film formation surface 1a is not exposed to oxygen in the atmosphere, and the oxidation of the film is suppressed. be able to.
- step S5 After forming a film with a desired thickness on the film formation surface 1a, the film formation apparatus 100 is stopped (step S5). Thereafter, in step S6, the lid 10b is removed from the container 10a, and the substrate 1 is taken out. Thereby, the film formed by the cold spray method is obtained. After that, another substrate may be held by the holding unit 11 of the film forming apparatus 100 and film formation may be continued.
- the inside of the chamber 10 is filled with the inert gas sprayed from the spray nozzle 12 to make a positive pressure, and the film is formed. It is possible to suppress oxidation by exposure to oxygen. Therefore, it is possible to improve physical properties such as bonding strength and electrical properties in the film.
- the inside of the chamber 10 is made positive pressure by the inert gas ejected from the spray nozzle 12, the atmosphere is removed from the chamber 10 after the substrate 1 is placed in the chamber 10. Additional work (exhaust or gas exchange, etc.) and waiting time are not required. Therefore, the substrate 1 can be easily replaced, and film formation can be performed efficiently.
- FIG. 3 is a schematic diagram showing a film forming apparatus according to the first modification of the first embodiment.
- the film forming apparatus 110 illustrated in FIG. 3 further includes a rectifying unit 17 and a gas supply unit 18 that rectify an inert gas in the chamber 10 with respect to the film forming apparatus 100.
- the rectifying unit 17 is formed by bending one end of a cylindrical member toward the inner peripheral side, and is provided so as to surround the holding unit 11 in the vicinity of the bottom of the container 10a.
- the rectifying unit 17 arranges the flow of the inert gas injected from the spray nozzle 12 so as to circulate through the chamber 10 and be discharged from the gap 10d.
- the gas supply unit 18 includes a gas ejection port 18a provided in the vicinity of the bottom of the container 10a, and forms an inert gas flow circulating in the chamber 10 by supplying the inert gas into the chamber 10.
- the inert gas can be efficiently circulated in the chamber 10 by flowing the inert gas along the inner wall surface from the vicinity of the bottom of the container 10a.
- the rectifying unit 17 and the gas supply unit 18 as described above, the discharge of the atmosphere remaining in the chamber 10 can be expedited, and the chamber 10 can be quickly filled with the inert gas sprayed from the spray nozzle 12. Therefore, it becomes possible to more effectively suppress the oxidation of the film formed on the substrate 1.
- straightening part 17 will not be limited to the example shown in FIG. 3, if the flow of the inert gas mentioned above can be formed.
- the donut-shaped rectification unit 19 having an opening formed by curving the center part of the plate-like member is set to a height at the middle of the side surface of the inner wall of the container 10a. It may be provided like a collar.
- the position and direction of the gas outlet 18a are not limited to the example shown in FIG. 3 as long as the above-described inert gas flow can be formed.
- the gap 10d provided between the container 10a and the lid 10b is used as an exhaust port.
- the form of the exhaust port is not limited to the example shown in FIG.
- an opening may be provided in the lid portion 10b and this may be used as an exhaust port.
- an opening may be provided above the side surface of the container 10a and this may be used as an exhaust port.
- the lid portion 10b can be directly placed on the opening surface 10c of the container 10a.
- FIG. 5 is a schematic diagram showing a film forming apparatus according to Embodiment 2 of the present invention.
- the film forming apparatus 200 according to the second embodiment includes a cover portion 21 that is attached to the spray nozzle 12 and provided on the base 20 instead of the chamber 10 shown in FIG. 1.
- FIG. 5 In addition, about the function and operation
- FIG. 5 only the base 20 and the cover portion 21 are shown in cross section. Further, in FIG. 5, the description of the support mechanism and the moving mechanism of the spray nozzle 12 is omitted, and only the driving unit 15 provided in the spray nozzle 12 is shown in the moving mechanism.
- the holding part 11 is provided directly on the base 20, and the cover part 21 is arranged so as to cover the holding part 11.
- the cover portion 21 may be formed of a hard member (a member that is not easily deformed) such as metal, ceramics, glass, or acrylic, or may be formed of a flexible member (a member that is easily deformed) such as rubber or polyethylene. good. Or you may form the cover part 21 combining a hard member and a flexible member.
- the cover portion 21 can be formed by forming a framework with a hard member such as metal and covering the framework with a flexible member such as a polyethylene sheet.
- openings 21a are provided above the cover portion 21 (position higher than the base material 1 held by the holding portion 11).
- the opening 21a functions as an exhaust port for discharging the gas in the cover portion 21 to the outside.
- Such a cover portion 21 is attached to the spray nozzle 12 by fastening, bonding, welding, or the like according to the material of the cover portion 21 and moves together with the spray nozzle 12.
- the base material 1 is held by the holding unit 11, and the raw material powder 2 and an inert gas are sprayed from the spray nozzle 12.
- the inside of the cover part 21 is filled with the inert gas and becomes a positive pressure.
- the spray nozzle 12 is moved in a plane parallel to the base 20 together with the cover portion 21 while spraying the powder 2 toward the film formation surface 1a of the substrate 1 to deposit the powder 2 on the film formation surface 1a.
- the configuration of the film forming apparatus 200 can be further simplified.
- the film forming apparatus 200 can be realized by adding the cover portion 21 to a cold spray apparatus having a general configuration.
- the film forming apparatus 200 may be further provided with a rectifying unit 17 and a gas supply unit 18 as in the first embodiment.
- the base material 1 is fixed and the spray nozzle 12 is moved.
- the base material 1 and the spray nozzle 12 can be moved. Any of them may be moved.
- the spray nozzle 12 side may be fixed and the base material 1 side may be moved, or both may be moved.
- a film of pure copper was formed on the substrate 1 using the film forming apparatus 100 according to the first embodiment.
- the pressure of the inert gas in the spray nozzle 12 was changed to form a plurality of types of films. And these membrane
- coats were cut out, the test piece of 2 mm x 2 mm x 40 mm was produced, and the electrical conductivity was measured by the 4-terminal method.
- a general cold spray apparatus was used to form a pure copper film in the atmosphere. And the test piece was produced similarly to the Example and the electrical conductivity was measured.
- FIG. 6 is a graph showing measurement results for the test pieces of Examples and Comparative Examples.
- the horizontal axis represents the pressure of the inert gas (gas pressure: MPa), and the vertical axis represents the conductivity of each test piece based on the conductivity of annealed pure copper (IACS: International Annealed Copper Standard). :%).
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Abstract
Description
図1は、本発明の実施の形態1に係る成膜装置の構成を示す模式図である。図1に示すように、実施の形態1に係る成膜装置100は、基材1の表面に原料の粉末2を吹き付けて堆積させることにより成膜を行う、所謂コールドスプレー装置であり、チャンバ10と、基材1を保持する保持部11と、粉末2を不活性ガスと共に噴射するスプレーノズル12と、該スプレーノズル12に粉末2を供給する粉末供給部13及び粉末用配管13aと、不活性ガスを加熱してスプレーノズル12に供給するガス加熱部(ガス供給部)14及びガス用配管14aと、スプレーノズル12を移動させる駆動部15と、駆動部15の動作を制御する制御部16とを備える。なお、図1においては、チャンバ10についてのみ、断面を示している。
まず、工程S1において、基材1をチャンバ10内に配置する。基材1の材料としては、銅、銅合金、亜鉛、亜鉛合金、アルミニウム、アルミニウム合金、マグネシウム、マグネシウム合金、ニッケル、ニッケル合金、鉄、鉄合金、チタン、チタン合金、クロム、クロム合金、ニオブ、ニオブ合金、モリブデン、モリブデン合金、銀、銀合金、錫、錫合金、タンタル、タンタル合金等の金属又は合金や、アルミナ、ジルコニア、イットリア、イットリア安定化ジルコニア等のセラミックス等、特に限定することなく用いることができる。なお、これらの材料によって形成された基材1に対し、予め表面処理を適宜施しておいても良い。チャンバ10内においては、基材1を保持部11に保持させて固定する。
次に、実施の形態1の変形例1について説明する。
図3は、実施の形態1の変形例1に係る成膜装置を示す模式図である。図3に示す成膜装置110は、成膜装置100に対し、チャンバ10内において不活性ガスを整流する整流部17及びガス供給部18をさらに備える。
次に、実施の形態1の変形例2について説明する。
上記実施の形態1においては、容器10aと蓋部10bとの間に設けた隙間10dを排気口としたが、排気口の形態は図1に示す例に限定されない。例えば、蓋部10bに開口を設け、これを排気口としても良い。或いは、容器10aの側面の上方に開口を設けて、これを排気口としても良い。これらの場合、蓋部10bを容器10aの開口面10c上に直接載置することができる。
次に、本発明の実施の形態2について説明する。
図5は、本発明の実施の形態2に係る成膜装置を示す模式図である。図5に示すように、実施の形態2に係る成膜装置200は、図1に示すチャンバ10の代わりに、スプレーノズル12に取り付けられ、ベース20上に設けられたカバー部21を備える。
実施例として、実施の形態1に係る成膜装置100を用い、基材1上に純銅の皮膜を形成した。この際、スプレーノズル12における不活性ガスの圧力を変化させて、複数種類の皮膜を形成した。そして、これらの皮膜を切り出して2mm×2mm×40mmの試験片を作製し、4端子法により導電率を測定した。一方、比較例として、一般的なコールドスプレー装置を用い、大気中において純銅の皮膜を形成した。そして、実施例と同様に試験片を作製し、導電率を測定した。
1a 成膜面
2 粉末
10 チャンバ
10a 容器
10b 蓋部
10c 開口面
10d 隙間
11 保持部
12 スプレーノズル
13 粉末供給部
13a 粉末用配管
14 ガス加熱部(ガス供給部)
14a ガス用配管
15 駆動部
16 制御部
17、19 整流部
18 ガス供給部
18a ガス噴出口
20 ベース
21 カバー部
21a 開口
100、110、200 成膜装置
Claims (11)
- 原料の粉末をガスと共に加速し、該粉末を固相状態に保ったまま基材の表面に吹き付けて堆積させることにより成膜を行う成膜方法であって、
前記基材をチャンバ内に配置する基材配置工程と、
前記粉末及び不活性ガスをノズルから前記基材に向けて噴射し、前記不活性ガスにより前記チャンバ内を陽圧にするとともに、前記基材の表面に前記粉末を堆積させて皮膜を形成する成膜工程と、
を含むことを特徴とする成膜方法。 - 前記成膜工程は、前記不活性ガスを前記チャンバから排気しつつ行われることを特徴とする請求項1に記載の成膜方法。
- 前記成膜工程は、前記チャンバ内における前記不活性ガスを整流しつつ行われることを特徴とする請求項1又は2に記載の成膜方法。
- 前記ノズルとは別に、前記チャンバ内に不活性ガスを供給することにより、前記不活性ガスを整流することを特徴とする請求項3に記載の成膜方法。
- 原料の粉末をガスと共に加速し、該粉末を固相状態に保ったまま基材の表面に吹き付けて堆積させることにより成膜を行う成膜装置であって、
チャンバと、
前記チャンバ内に設けられ、前記基材を保持する保持部と、
前記粉末を不活性ガスと共に噴射するノズルと、
前記ノズルと前記保持部とのいずれか一方を他方に対して移動させる移動機構と、
を備え、
前記ノズルが噴射する前記不活性ガスにより、前記チャンバ内が陽圧になることを特徴とする成膜装置。 - 前記チャンバ内から気体を排出する排気部をさらに備えることを特徴とする請求項5に記載の成膜装置。
- 前記チャンバ内における前記不活性ガスを整流する整流機構をさらに備えることを特徴とする請求項5又は6に記載の成膜装置。
- 前記整流機構は、前記チャンバ内に不活性ガスを供給するガス供給部であることを特徴とする請求項7に記載の成膜装置。
- 前記整流機構は、前記チャンバ内に設置された整流部材であることを特徴とする請求項7に記載の成膜装置。
- 前記チャンバは、内部に前記保持部が設けられた容器と、前記ノズルに取り付けられた蓋部とを有することを特徴とする請求項5~9のいずれか1項に記載の成膜装置。
- 前記チャンバは、前記ノズルに取り付けられ、前記保持部を覆うカバーを有することを特徴とする請求項5~9のいずれか1項に記載の成膜装置。
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EP13845899.7A EP2907896B1 (en) | 2012-10-10 | 2013-10-08 | Film formation method and film formation device |
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JP2015206067A (ja) * | 2014-04-18 | 2015-11-19 | 富士岐工産株式会社 | 成膜装置及びこれを用いた成膜方法 |
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JP6605868B2 (ja) * | 2015-07-23 | 2019-11-13 | 株式会社東芝 | コールドスプレー装置およびこれを用いた被膜形成方法 |
WO2020032074A1 (ja) * | 2018-08-10 | 2020-02-13 | 日本発條株式会社 | 積層体の製造方法 |
CN112739851B (zh) * | 2018-09-18 | 2023-04-07 | 日产自动车株式会社 | 成膜方法 |
JP7136338B2 (ja) * | 2019-03-29 | 2022-09-13 | 日産自動車株式会社 | 成膜方法 |
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TW202229581A (zh) * | 2020-08-28 | 2022-08-01 | 日商東京威力科創股份有限公司 | 成膜裝置、及具有含矽的膜之部件的製造方法 |
KR102649715B1 (ko) | 2020-10-30 | 2024-03-21 | 세메스 주식회사 | 표면 처리 장치 및 표면 처리 방법 |
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