FABRICATION OF LARGE AREA RADIATION DETECTORS AND SHIELDING VIA FIELDASSISTED SINTERING TECHNOLOGY (FAST)
20250341021 ยท 2025-11-06
Inventors
- Douglas E. WOLFE (University Park, PA, US)
- Patrict Albert (University Park, PA, US)
- Justin Reiss (University Park, PA, US)
Cpc classification
International classification
Abstract
A method of fabricating a polycrystalline crystal of a radiation sensitive material used for radiation detectors or shielding includes providing constituent powders or a single crystal material of the radiation sensitive material or a mixed combination thereof, forming a single phase powder of the radiation sensitive material via solid-state thermochemical and/or thermomechanical reaction between constituent powders or milling the single crystal material of the radiation sensitive material into powders, and pressing the single phase powder of the radiation sensitive material via Field Assisted Sintering Technology to form a pellet, component or structure of the polycrystalline radiation sensitive material.
Claims
1. A method of fabricating or synthesizing a polycrystalline crystal of a radiation sensitive material used for radiation detectors and shielding, respectively, the method comprising the steps of: providing constituent powders or a single crystal material of the radiation sensitive material or a mixed combination thereof; forming a single phase powder of the radiation sensitive material via solid-state thermochemical and/or thermomechanical reaction between constituent powders or milling the single crystal material of the radiation sensitive material into powders; and pressing the single phase powder of the radiation sensitive material via Field Assisted Sintering Technology to form a pellet, component or structure of the polycrystalline radiation sensitive material.
2. The method according to claim 1, further comprising embedding the powder of the radiation sensitive material into matrix material before pressing.
3. The method according to claim 2, wherein the matrix material is polymeric fibers or plastics.
4. The method according to claim 1, wherein the radiation sensitive material includes metal halide perovskites, metal halide double perovskites, and high-Z materials.
5. The method according to claim 1, wherein the radiation sensitive material is CsPbBr.sub.3, the constituent powders are CsBr and PbBr.
6. The method according to claim 5, further comprising pre-milling the CsBr powder so that the CsBr and PbBr powders have a particle size on the same order of magnitude.
7. The method according to claim 1, wherein the milling technique is used to form the single phase powder of the radiation sensitive material, the milling technique includes ball milling, attrition milling, cryogenic milling, shaker jar milling.
8. The method according to claim 1, wherein a temperature for FAST is in a range of from 100 C. to 0.95T.sub.M, T.sub.M is melting temperature of the material.
9. The method according to claim 1, wherein a pressure for FAST is in a range of from 0 MPa to 200 MPa.
10. The method according to claim 1, wherein the pellet is up to 14 in diameter.
Description
BRIEF DESCRIPTION OF THE INVENTION
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DETAILED DESCRIPTION OF THE INVENTION
[0036] The presently disclosed technology provides a fabrication pathway for large area and cost effective radiation detectors and shielding by consolidation of powder materials via field-assisted sintering technology (FAST). The powder materials may be of material systems such as metal halide perovskites, double perovskites, wide band gap semiconductors, and high-Z composites.
[0037] Any of the proposed material systems can be fabricated by solid-state thermochemical and/or thermomechanical reaction between constituent powders via a variety of techniques including milling, grinding, mixing, etc. to form a single phase powder. Then the single phase powder is pressed to form a pellet via FAST. Optionally, single phase powders are embedded into matrix material (such as polymeric fibers, plastics, etc.) before being pressed into a pellet via FAST.
[0038] The powder materials can be synthesized from mixing the constituent materials powder to form single phase powder materials or can be obtained by milling single crystal material into fine powders. The material remains in the solid state throughout the entire manufacturing process. For example, CsPbBr.sub.3 powders can be obtained by mixing CsBr powder and PbBr.sub.2 powder to form single phase CsPbBr.sub.3 powders or by milling single crystal CsPbBr.sub.3 into powders.
[0039] The CsBr powder may be pre-milled so that the CsBr and PbBr powders have a particle size on the same order of magnitude. Milling techniques includes ball milling, attrition milling, cryogenic milling, shaker jar milling, etc. In the solid state, mechanical alloying using milling techniques to form single phase CsPbBr.sub.3 powder with uniform particle size distributions. CsPbBr.sub.3 pellets may then be fabricated by consolidation of the CsPbBr.sub.3 powder via FAST.
[0040] Field Assisted Sintering Technology (FAST), also known as Spark Plasma Sintering (SPS), has many advantages compared to competitive sintering processes (e.g. Hot Pressing (HP), Hot Isostatic Pressing (HIP), etc.) including higher heat rates and lower processing cycle times. The FAST process involves direct contact heating of the component, resistance heating of the graphite dies, and eddy currents leading to joule heating in conductive material. The powder material is contained in a graphite die with a controllable inert or reactive environment where pressure is applied through a hydraulic system. The combination of pressure, temperature, and localized heating at the grain boundaries result in a high sintering rates, which allow for nano-grained microstructures, compositionally graded structures, and high densities. FAST has the capability to rapidly sinter metals, ceramics, and both metal and ceramic composites. There is also a significant energy saving of 30-40% compared to other sintering techniques.
[0041] For the FAST sintering process used in the present disclosure, a typical range of the temperature would be 100 C.0.95T.sub.M, where T.sub.M is the melting temperature of the radiation sensitive material. The pressure can range from 0 MPa-200 MPa. Field strength is dependent on die size, die material, powder composition, mass of powder, geometry of component being consolidated, input power, amongst other parameters. The input power will greatly impact the boundary conditions of the applied field strength. The maximum input power is dependent on the FAST system. For example, the prototype system used in the experiment has a 100 kW max applied power.
[0042] The pellets fabricated according to the disclosed method can be used for radiation detectors or radiation shielding. A radiation detector may comprise a semiconducting material with two or more electrodes deposited onto the surface. One set of electrodes collects electrons, and the other set collects holes. The electrodes can be deposited in a variety of configurations and geometries, including but not limited to planar electrodes, pixelated electrodes, asymmetric electrodes, imbedded electrodes, multilayered electrodes, p-i-n configured electrodes, etc. The semiconductor material itself has a wide range of potential properties including a band gap 0.5-6 eV, resistivity ranging from 10.sup.6-10.sup.14 Ohm cm, and features the ability to convert absorbed photons into electron-hole pairs.
[0043] Once the pellet is fabricated, the surfaces are polished using chemo-mechanical methods in order to obtain a smooth finish. Once polished, the surfaces are passivated (i.e. oxide grown on top of the crystal) using a wide variety of methods including plasma treatments, etching, heat treatments, thermochemical reactions, thin film deposition, atomic layer deposition, etc. Then, electrodes are deposited via physical vapor deposition techniques such as thermal evaporation, electron-beam evaporation, or sputtering. Electrode materials can be comprised of any metal, metal-nitride, metal-carbide, or metal oxide. Examples of electrode materials include, but are not limited to, gold, silver, carbon, titanium, vanadium, chromium, iron, nickel, copper, zinc, gallium, aluminum, silicon, zirconium, niobium, molybdenum, palladium, ruthenium, indium, tin, hafnium tantalum, tungsten, rhenium, iridium, platinum, lead, bismuth, and subsequent nitrides, carbides, oxides, dopants, mixed concentration, etc. Specific nitrides, carbides, and oxides include titanium nitride, vanadium nitride, chromium nitride, tungsten nitride, aluminum nitride, titanium aluminum nitride, zirconium nitride, hafnium nitride, niobium nitride, titanium oxide, chromium oxide, vanadium oxide, iron oxide, copper oxide, zinc oxide, indium oxide, indium tin oxide, tin oxide, aluminum oxide, aluminum zinc oxide, nickel oxide, magnesium zinc oxide, copper chromium oxide, titanium carbide, aluminum carbide, chromium carbide, hafnium carbide, tantalum carbide, tungsten carbide, zirconium carbide, niobium carbide, vanadium carbide, and mixed compositions and dopants thereof.
[0044] Radiation detectors and radiation shielding both feature the ability to interact with high energy particles, charge particles, neutrals, neutrons, etc. But what happens after energy is absorbed by the material is different. In a radiation detector, energy is absorbed, resulting in the production of electron-hole pairs. These electron-hole pairs are then extracted from the detector under an applied electric field, and collected by the electrodes. This charge collection allows for the detection of ionizing radiation, particles, neutrons, etc. Radiation detectors require small measured currents under high applied voltage. This is generally dictated by the bulk resistivity of the semiconductor. If the semiconductor has a high enough bulk resistivity (10.sup.10-11 cm), an ohmic contact structure is preferred. If the semiconductor has a low bulk resistivity (10.sup.8-9 cm) a rectifying junction is needed. For the example of CsPbBr.sub.3, the rectifying junction is necessary for radiation detection.
[0045] In a radiation shield, the primary goal is to absorb, reflect, deflect, or scatter photons, ions, particles, neutrons, etc. The radiation shield may or may not generate electron-hole pairs under irradiation. Collecting electron-hole pairs is not the primary objective of the radiation shield, so there does not need to be a conduction pathway through the bulk to monitor radiation interactions. Radiation shields can take a variety of forms including bulk material, nanostructured material, multilayered material, composite material, nanostructured composite materials, etc.
[0046] The disclosed method can lead to room temperature X-ray/gamma-ray/-particle detectors with high energy resolution and lightweight, durable shielding.
[0047] FAST involves different parameters such as temperature, pressure, time and applied electric field, as illustrated in
[0048] The presently disclosed technology is capable of fabricating large area polycrystalline detectors and shielding via powder synthesis and subsequent FAST processing. The primary material systems of interest are metal halide perovskites, metal halide double perovskites, and high-Z materials.
[0049] An example of metal halide perovskites is ABX.sub.3, where A is Cs.sup.+, MA.sup.+, FA.sup.+, B is Pb.sup.2+, X is Cl.sup., Br.sup., I.sup.. Some examples of metal halide double perovskites are Cs.sub.2AgBiBr.sub.6, Cs.sub.2AgBiCl.sub.6, Cs.sub.2AgBiI.sub.6, Cs.sub.2NaBiBr.sub.6, Cs.sub.2NaBiCl.sub.6, Cs.sub.2NaBiI.sub.6, Cs.sub.2InBiBr.sub.6, Cs.sub.2InBiCl.sub.6, Cs.sub.2InBiI.sub.6, and subsequent doped and co-doped structures, and mixed compositions thereof. Some examples of high-Z materials are PbTe, CdTe, Pb, PbO, Bi, Bi.sub.2O.sub.3, PbSe, and CdSe, mixed cation tellurides (A.sub.1-xB.sub.x)Te, subsequent doped and co-doped structures and mixed compositions thereof. FAST will also be capable of consolidating next generation semiconductor materials including, but not limited to, Cu.sub.3NbSe.sub.4, Cd.sub.7P.sub.4Cl.sub.6, Cu.sub.3TaSe.sub.4, Tl.sub.2SnCl.sub.6, Cu.sub.3TaS.sub.4, Tl.sub.3NbSe.sub.4, Cs.sub.2HfI.sub.6, Tl.sub.3TaSe.sub.4, Tl.sub.3NbS.sub.4, NbS.sub.4Tl.sub.3, Tl.sub.2SnCl.sub.6 and other radiation sensitive materials and wide band gap semiconductors.
Polycrystalline Semiconductors
[0050] Wide band gap polycrystalline semiconductors offer substantially faster processing times, lower costs, and ability to produce large area detectors.
[0051] Engineering grain boundary chemistry and imbedding contacts within the polycrystalline structure can reduce effective ut requirements, enabling -ray detection.
Experiments
[0052] Initial work has focused on sintering the MHP composition CsPbBr.sub.3 for use as an X-ray detector; however, the fundamentals provided can be expanded to other MHPs, double perovskites, novel wide band gap semiconductors, and high-Z composites for a variety of radiation detection and shielding applications. Based on this initial work, the enhanced dense microstructure can be achieved via FAST compared to conventional sintering techniques, which will likely result in substantial performance benefits including enhanced X-ray sensitivity and -ray energy resolution.
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Results and Discussion
[0054] A series of 8 FAST trials were designed to observe the effects of temperature and pressure on the CsPbBr.sub.3 pellet microstructure.
1. Effect of Temperature
[0055] First, temperature was varied from 100 C. to 300 C., keeping pressure and time constant at 20 MPa and 10 minutes respectively. From visual observation, it was observed that the color of the pellet changed from a bright orange at 100 C. to a dark red at 300 C., with the 300 C. pellet actually failing and breaking upon cool down, as shown in
2. Effects of Pressure
[0056] As pellets are pressed as a function of pressure, the color darkens very slightly with increasing pressure, as shown in
[0057] Fracture surfaces were imaged via SEM to analyze the microstructure of the sintered compacts, as shown in
3. Comparison Between Conventional Sintering and FAST
[0058] To complement the analysis of CsPbBr.sub.3 pellets fabricated via FAST, FAPbBr.sub.3 pellets were pressed via conventional cold pressing and subsequent annealing.
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4. Radiation Detectors
[0060] A radiation detector can be a semiconducting material with two or more electrodes deposited onto the surface. One set of electrodes collects electrons, and the other set collects holes. The electrodes can be deposited in a variety of configurations and geometries, including but not limited to planar electrodes, pixelated electrodes, asymmetric electrodes, imbedded electrodes, multilayered electrodes, p-i-n configured electrodes, etc. The semiconductor material itself has a wide range of potential properties including a band gap 0.5-6 eV, resistivity ranging from 10.sup.6-10.sup.14 Ohm cm, and features the ability to convert absorbed photons into electron-hole pairs.
[0061] Once the pellet is fabricated, the surfaces are polished using chemo-mechanical methods in order to obtain a very smooth finish. Once polished, the detectors are passivated (i.e. oxide grown on top of the crystal) using a wide variety of methods including plasma treatments, etching, heat treatments, thermochemical reactions, thin film deposition, atomic layer deposition, etc. Then, electrodes are deposited via physical vapor deposition techniques such as thermal evaporation, electron-beam evaporation, or sputtering. Electrode materials can be comprised of any metal, metal-nitride, metal-carbide, or metal oxide. Examples of electrode materials include, but are not limited to, gold, silver, carbon, titanium, vanadium, chromium, iron, nickel, copper, zinc, gallium, aluminum, silicon, zirconium, niobium, molybdenum, palladium, ruthenium, indium, tin, hafnium tantalum, tungsten, rhenium, iridium, platinum, lead, bismuth, and subsequent nitrides, carbides, oxides, dopants, mixed concentration, etc. Specific nitrides, carbides, and oxides include titanium nitride, vanadium nitride, chromium nitride, tungsten nitride, aluminum nitride, titanium aluminum nitride, zirconium nitride, hafnium nitride, niobium nitride, titanium oxide, chromium oxide, vanadium oxide, iron oxide, copper oxide, zinc oxide, indium oxide, indium tin oxide, tin oxide, aluminum oxide, aluminum zinc oxide, nickel oxide, magnesium zinc oxide, copper chromium oxide, titanium carbide, aluminum carbide, chromium carbide, hafnium carbide, tantalum carbide, tungsten carbide, zirconium carbide, niobium carbide, vanadium carbide, and mixed compositions and dopants thereof.
[0062] Prototype X-ray detectors were fabricated by sputtering gold (Au) contacts on the front and back of the FAST sintered samples to form vertical Au/CsPbBr.sub.3/Au structures, as shown in
[0063] The microstructure of the sintered compacts imaged in
[0064] Low work function contacts are needed to form a rectifying junction with CsPbBr.sub.3. TIN was selected due to its work function and low reaction probability with CsPbBr.sub.3, as shown in
[0065] Radiation detectors require small measured currents under high applied voltage. This is generally dictated by the bulk resistivity of the semiconductor. If the semiconductor has a high enough bulk resistivity (10.sup.10-11 cm), an ohmic contact structure is preferred. If the semiconductor has a low bulk resistivity (10.sup.8-9 cm) a rectifying junction is needed. For the example of CsPbBr.sub.3, the rectifying junction is necessary for radiation detection.
[0066] Radiation detectors and radiation shielding both feature the ability to interact with high energy particles, charge particles, neutrals, neutrons, etc. In a radiation detector, energy is absorbed, resulting in the production of electron-hole pairs. These electron-hole pairs are then extracted from the detector under an applied electric field, and collected by the electrodes. This charge collection allows for the detection of ionizing radiation, particles, neutrons, etc. In a radiation shield, the primary goal is to absorb, reflect, deflect, or scatter photons, ions, particles, neutrons, etc. The radiation shield may or may not generate electron-hole pairs under irradiation. There does not need to be a conduction pathway through the bulk to monitor radiation interactions for a radiation shield. Radiation shields can take a variety of forms including bulk material, nanostructured material, multilayered material, composite material, nanostructured composite materials, etc.
[0067] Engineering smooth surface of MHP crystals has experienced several challenges. First, MHPs dissolve in water, rendering traditional polishing methods not viable. Second, MHPs also degrade in alcohols, making most commercial alternatives to water not viable as well. Third, MHPs have low hardness and are very brittle, making crystals prone to fracture under light loads. Soft media such as silica, ceria, kaolin, and/or talc can be incorporated to reduce surface roughness.
[0068] Various surface passivation strategies are investigated to decrease leakage current and potentially reduce surface driven ionic diffusion. FAPbBr.sub.3 crystals are prepared with various surface preparation such as Alumina based polish, UV-Ozone oxidation, SiO2 coating via PE-ALD, or PEABr passivation.
[0069] Similar to the high pressure CsPbBr.sub.3 FAST pellets, the resistivity of the conventionally sintered pellets is substantially lower than the single crystal (polycrystalline 10.sup.7 cm, single crystal 10.sup.8 cm) even with the fairly high porosity present throughout the bulk. This suggests that the electron mobility is substantially higher along the grain boundaries and free surfaces compared to the bulk, as expected. With the Au/FAPbBr.sub.3/Au contact structure applied to these samples, the dark current measured is quite high, reaching the A range. High dark currents result in large noise at high applied biases, which limits this device to low voltage operation. Application of a TiN rectifying contact will substantially lower dark current and allow the device to be operating at high reverse bias.
[0070] In application, CsPbBr.sub.3 single crystals will be operated at high reverse bias. TiN/CsPbBr.sub.3/Au devices exhibited 100 nA/cm2 dark current at 500 V/cm applied electric field, as shown in
[0071] IV characteristics of TiN/CsPbBr.sub.3/Au device showed a hysteresis behavior as voltage is swept from 20 to +20 V, and back, as shown in
[0072] X-ray sensitivity of the FAPbBr.sub.3 pellets was measured as a function of applied pressure and annealing conditions. Samples were exposed to increasing X-ray doses under a constant 2 V applied forward bias. X-ray sensitivity can be described as the amount of charge collection per unit of absorbed dose. Absorbed dose is measured in units of Gray (Gy), and an applied dose rate is simply measured in Gy/s. The measured photo current density (A/cm.sup.2) vs. the dose rate (mGy/s) plotted and a linear slope is extracted to be the amount of charge collected per unit dose, or the X-ray sensitivity (C Gy.sup.1 cm.sup.2), as shown in
[0073] As will be clear to those of skill in the art, the embodiments of the present invention illustrated and discussed herein may be altered in various ways without departing from the scope or teaching of the present invention. Also, elements and aspects of one embodiment may be combined with elements and aspects of another embodiment. It is the following claims, including all equivalents, which define the scope of the invention.