1.1 Overview of Plasma-assisted Manufacturing

Plasma-assisted manufacturing harnesses ionized gas to enhance various production processes. This cutting-edge technique allows for precise control over material properties, enabling unique surface modifications and material synthesis methods.

From cleaning and etching to thin film deposition and welding, plasma technology revolutionizes manufacturing. By understanding thermal and non-thermal plasmas, engineers can tailor processes for specific applications, improving efficiency and product quality.

Introduction to Plasma-assisted Manufacturing

Definition of plasma-assisted manufacturing

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  Metal-catalyst-free growth of graphene on insulating substrates by ammonia-assisted microwave ... View original

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  Anti-bacterial surfaces: natural agents, mechanisms of action, and plasma surface modification ... View original

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• 

  Frontiers | Surface Modification Techniques of Titanium and its Alloys to Functionally Optimize ... View original

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  Metal-catalyst-free growth of graphene on insulating substrates by ammonia-assisted microwave ... View original

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• Utilizes plasma to enhance, modify, or enable various manufacturing processes
• Involves the use of ionized gas (plasma) to interact with materials
• Achieves high temperatures and reactive environments
• Provides precise control over process parameters
• Modifies surface properties and enables unique material synthesis

Components of plasma manufacturing systems

• Plasma source generates and sustains the plasma discharge (DC plasma torch, RF plasma generator, microwave plasma source)
• Power supply provides electrical energy to the plasma source and controls the power delivered to the plasma
• Gas delivery system supplies the working gas (argon, nitrogen, hydrogen) to the plasma source and regulates gas flow rate and composition
• Vacuum chamber or reactor contains the plasma and the workpiece and maintains the desired pressure and atmosphere
• Cooling system removes excess heat from the plasma source and other components and ensures stable operation and prevents overheating

Applications and Types of Plasma in Manufacturing

Role of plasma in manufacturing

• Surface modification
  • Plasma cleaning removes contaminants and improves adhesion
  • Plasma activation creates reactive surface groups for enhanced bonding
  • Plasma etching selectively removes material for patterning or texturing
• Thin film deposition
  • Plasma-enhanced chemical vapor deposition (PECVD) deposits thin films using plasma-activated precursors
  • Sputtering uses plasma to eject atoms from a target material and deposit them on a substrate
• Material synthesis
  • Plasma spray uses thermal plasma to melt and deposit materials, forming coatings or freestanding parts
  • Plasma-assisted sintering employs plasma to enhance the sintering process, reducing processing time and temperature
• Plasma cutting and welding
  • Plasma arc cutting uses a high-velocity plasma jet to melt and remove material, enabling precise cutting of metals (stainless steel, aluminum)
  • Plasma arc welding utilizes plasma to generate high heat and fuse materials together (titanium, nickel alloys)

Thermal vs non-thermal plasmas

• Thermal plasmas
  • High temperature ($\geq$ 10,000 K) and high electron density
  • Electrons, ions, and neutral species are in thermal equilibrium
  • Examples: DC plasma torches, plasma spray, plasma cutting, and welding
• Non-thermal plasmas
  • Low gas temperature (< 1,000 K) and high electron temperature
  • Electrons are highly energetic, while ions and neutrals remain relatively cold
  • Examples: RF and microwave plasmas, dielectric barrier discharges, corona discharges
  • Used in surface modification, thin film deposition, and material synthesis processes (plasma polymerization, plasma-assisted atomic layer deposition)