Theory and New Applications of Ex Situ Lift Out.

The ex situ lift out (EXLO) adhesion forces are reviewed and new applications of EXLO for focused ion beam (FIB)-prepared specimens are described. EXLO is used to manipulate electron transparent specimens on microelectromechanical systems carrier devices designed for in situ electron microscope analysis. A new patented grid design without a support film is described for EXLO. This new slotted grid design provides a surface for holding the specimen in place and also allows for post lift out processing. Specimens may be easily manipulated into a backside orientation to reduce FIB curtaining artifacts with this slotted grid. Large EXLO specimens can be manipulated from Xe+ plasma FIB prepared specimens. Finally, applications of EXLO and manipulation of FIB specimens using a vacuum probe lift out method are shown. The vacuum probe provides more control for placing specimens on the new slotted grids and also allows for easy manipulation into a backside configuration.

A unique approach to accurately measure thickness in thick multilayers.

X-ray optics called multilayer Laue lenses (MLLs) provide a promising path to focusing hard X-rays with high focusing efficiency at a resolution between 5 nm and 20 nm. MLLs consist of thousands of depth-graded thin layers. The thickness of each layer obeys the linear zone plate law. X-ray beamline tests have been performed on magnetron sputter-deposited WSi(2)/Si MLLs at the Advanced Photon Source/Center for Nanoscale Materials 26-ID nanoprobe beamline. However, it is still very challenging to accurately grow each layer at the designed thickness during deposition; errors introduced during thickness measurements of thousands of layers lead to inaccurate MLL structures. Here, a new metrology approach that can accurately measure thickness by introducing regular marks on the cross section of thousands of layers using a focused ion beam is reported. This new measurement method is compared with a previous method. More accurate results are obtained using the new measurement approach.

Sectioning of multilayers to make a multilayer Laue lens.

We report a process to fabricate multilayer Laue lenses (MLL's) by sectioning and thinning multilayer films. This method can produce a linear zone plate structure with a very large ratio of zone depth to width (e.g., >1000), orders of magnitude larger than can be attained with photolithography. Consequently, MLL's are advantageous for efficient nanofocusing of hard x rays. MLL structures prepared by the technique reported here have been tested at an x-ray energy of 19.5 keV, and a diffraction-limited performance was observed. The present article reports the fabrication techniques that were used to make the MLL's.

A Sinusoidally Architected Helicoidal Biocomposite.

A fibrous herringbone-modified helicoidal architecture is identified within the exocuticle of an impact-resistant crustacean appendage. This previously unreported composite microstructure, which features highly textured apatite mineral templated by an alpha-chitin matrix, provides enhanced stress redistribution and energy absorption over the traditional helicoidal design under compressive loading. Nanoscale toughening mechanisms are also identified using high-load nanoindentation and in situ transmission electron microscopy picoindentation.

Examining the impact of excipient material property variation on drug product quality attributes: a quality-by-design study for a roller compacted, immediate release tablet.

A quality-by-design study examining the impact of variability in excipient material properties on the quality attributes of an immediate release tablet was performed. A literature review and risk analysis identified particle size of microcrystalline cellulose (MCC), spray-dried lactose (SDL), and magnesium stearate (MgSt), and polymorph and specific surface area of MgSt as potential high-risk material properties. The following results were obtained with laboratory-scale processing equipment: (1) a 32-µm increase in d(50) (mean particle diameter) of MCC and SDL led to a ∼ 30-µm increase in blend and granulation d(50) and a statistically significant increase in the blend and granulation flow function coefficients, and (2) a 32-µm increase in d(50) of MCC and SDL, a 4.4 m(2)/g increase in the surface area, and a 19-µm decrease in the particle size of MgSt yielded an 18%-28% increase in ribbon tensile strength and tablet hardness. Confirmatory experiments with kilo-scale equipment showed impact of excipient variability on granulation particle size and tablet hardness was ∼ 50% smaller. Although the impact of these differences on overall manufacturability and performance of the tablets examined here were deemed low, the presence of statistically significant effects supports examining excipient variability as part of the design and control strategy of new drug products.

Three-dimensional reconstruction of a solid-oxide fuel-cell anode.

The drive towards increased energy efficiency and reduced air pollution has led to accelerated worldwide development of fuel cells. As the performance and cost of fuel cells have improved, the materials comprising them have become increasingly sophisticated, both in composition and microstructure. In particular, state-of-the-art fuel-cell electrodes typically have a complex micro/nano-structure involving interconnected electronically and ionically conducting phases, gas-phase porosity, and catalytically active surfaces. Determining this microstructure is a critical, yet usually missing, link between materials properties/processing and electrode performance. Current methods of microstructural analysis, such as scanning electron microscopy, only provide two-dimensional anecdotes of the microstructure, and thus limited information about how regions are interconnected in three-dimensional space. Here we demonstrate the use of dual-beam focused ion beam-scanning electron microscopy to make a complete three-dimensional reconstruction of a solid-oxide fuel-cell electrode. We use this data to calculate critical microstructural features such as volume fractions and surface areas of specific phases, three-phase boundary length, and the connectivity and tortuosity of specific subphases.

Subwavelength focusing and guiding of surface plasmons.

The constructive interference of surface plasmon polaritons (SPP) launched by nanometric holes allows us to focus SPP into a spot of high near-field intensity having subwavelength width. Near-field scanning optical microscopy is used to map the local SPP intensity. The resulting SPP patterns and their polarization dependence are accurately described in model calculations based on a dipolar model for the SPP emission at each hole. Furthermore, we show that the high SPP intensity in the focal spot can be launched and propagated on a Ag strip guide with a 250 x 50 nm2 cross section, thus overcoming the diffraction limit of conventional optics. The combination of focusing arrays and nano-waveguides may serve as a basic element in planar nano-photonic circuits.