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<p>The continuous casting of glass-coated microwires using the Taylor-Ulitovsky process offers significant potential for nanoscale dimensional control, tunable cooling rates, and the discovery of new material compositions. However, its broader adoption is limited by an incomplete mechanistic understanding, resulting in high R&amp;D costs that constrain both scientific exploration and commercial impact. In this work, we present a High Throughput Experimental System (HTES) designed to automate and accelerate the identification of steady-state casting parameters while enabling comprehensive in-situ data collection. The system integrates a single-turn, cup-type induction coil operating at ~ 1&#xa0;MHz with water jet cooling to suppress magnetohydrodynamic instabilities and promote controlled solidification. Demonstrated through a case study on Pyrex glass-coated SnAgCu (SAC) alloy microwires, the HTES identified stable casting conditions achieving core and outer diameters of ~ 40&#xa0;μm and ~ 65&#xa0;μm, respectively, at a casting speed of 1&#xa0;m/s. The resulting experimental dataset provides a valuable resource for validating theoretical models and supports the development of data-driven approaches for process optimization. This research lays the groundwork for AI-assisted discovery of novel microwire compositions and advances scalable micro- and nanoscale manufacturing.</p>

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A high throughput experimental system for the continuous casting of glass-coated microwires

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • Ahmed Alajlouni,
  • Sajjad Boorghan Farahan,
  • Mohammad Mohammad Hosseini,
  • Jingzhou Zhao

摘要

The continuous casting of glass-coated microwires using the Taylor-Ulitovsky process offers significant potential for nanoscale dimensional control, tunable cooling rates, and the discovery of new material compositions. However, its broader adoption is limited by an incomplete mechanistic understanding, resulting in high R&D costs that constrain both scientific exploration and commercial impact. In this work, we present a High Throughput Experimental System (HTES) designed to automate and accelerate the identification of steady-state casting parameters while enabling comprehensive in-situ data collection. The system integrates a single-turn, cup-type induction coil operating at ~ 1 MHz with water jet cooling to suppress magnetohydrodynamic instabilities and promote controlled solidification. Demonstrated through a case study on Pyrex glass-coated SnAgCu (SAC) alloy microwires, the HTES identified stable casting conditions achieving core and outer diameters of ~ 40 μm and ~ 65 μm, respectively, at a casting speed of 1 m/s. The resulting experimental dataset provides a valuable resource for validating theoretical models and supports the development of data-driven approaches for process optimization. This research lays the groundwork for AI-assisted discovery of novel microwire compositions and advances scalable micro- and nanoscale manufacturing.