<p>Employing a self-designed temperature-control device for sapphire substrate polishing, the influence of external thermal fields on chemical mechanical removal mechanisms at the polishing pad/sapphire interface was investigated through combined simulation and experimental approaches. Molecular dynamics simulations were employed to investigate the chemical reactions between amorphous SiO<sub>2</sub> and sapphire substrates under hydrothermal conditions. The diamond/SiO<sub>2</sub> core-shell abrasives were prepared through an optimized sol-gel process, and the amorphous SiO<sub>2</sub> shell (10&#xa0;nm thick) was densely coated on the diamond surface. The microstructure and morphology of diamond abrasive, synthetic diamond/SiO<sub>2</sub> core-shell abrasives, and SiO<sub>2</sub> abrasives were characterized by FESEM and TEM. Sapphire substrates were polished at different temperatures, using three different types of abrasives, respectively. The material removal behavior of diamond/SiO<sub>2</sub> core-shell abrasives under thermally assisted semi-fixed abrasive polishing was discussed via analyzing the polished wear debris. Outcomes of an experiment indicated that the core-shell abrasives enabled the sapphire substrate to obtain a scratch-free surface with a 29.6% reduction in surface roughness, as well as a 179% increase in material removal rate, when the polishing interface temperature was set to 50&#xa0;°C compared to conventional diamond abrasives polishing at room temperature. The wear debris characteristics demonstrated that sustained solid-state chemical interactions between abrasives and the substrate were enhanced through thermal assistance, thereby facilitating the formation of the soft reaction layer (AlOOH and Al<sub>2</sub>Si<sub>2</sub>O<sub>7</sub>). This study clarifies the chemo-mechanical synergy of core-shell abrasives in thermally assisted polishing, offering foundations for sapphire ultra-precision machining optimization.</p>

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Enhanced performance of thermal-assisted semi-fixed abrasive polishing on sapphire substrate using different types of abrasives

  • Yongchao Xu,
  • Ruiyu Wu,
  • Guangen Zhao,
  • Zige Tian,
  • Qianting Wang,
  • Youji Zhan,
  • Bingsan Chen

摘要

Employing a self-designed temperature-control device for sapphire substrate polishing, the influence of external thermal fields on chemical mechanical removal mechanisms at the polishing pad/sapphire interface was investigated through combined simulation and experimental approaches. Molecular dynamics simulations were employed to investigate the chemical reactions between amorphous SiO2 and sapphire substrates under hydrothermal conditions. The diamond/SiO2 core-shell abrasives were prepared through an optimized sol-gel process, and the amorphous SiO2 shell (10 nm thick) was densely coated on the diamond surface. The microstructure and morphology of diamond abrasive, synthetic diamond/SiO2 core-shell abrasives, and SiO2 abrasives were characterized by FESEM and TEM. Sapphire substrates were polished at different temperatures, using three different types of abrasives, respectively. The material removal behavior of diamond/SiO2 core-shell abrasives under thermally assisted semi-fixed abrasive polishing was discussed via analyzing the polished wear debris. Outcomes of an experiment indicated that the core-shell abrasives enabled the sapphire substrate to obtain a scratch-free surface with a 29.6% reduction in surface roughness, as well as a 179% increase in material removal rate, when the polishing interface temperature was set to 50 °C compared to conventional diamond abrasives polishing at room temperature. The wear debris characteristics demonstrated that sustained solid-state chemical interactions between abrasives and the substrate were enhanced through thermal assistance, thereby facilitating the formation of the soft reaction layer (AlOOH and Al2Si2O7). This study clarifies the chemo-mechanical synergy of core-shell abrasives in thermally assisted polishing, offering foundations for sapphire ultra-precision machining optimization.