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2005-10-17 News Headlines Material
Science
Material Science Breakthrough
for The vacuum metallization process deposits a thin layer of metal on a
wide array of substrates from plastics film to TV picture tubes.
The vacuum metallization process, used to deposit a thin layer of metal
on a wide array of substrates from polyethylene terephthalate (PET) plastic
film to TV picture tubes, relies on evaporation boats that heat aluminum
and other metals to the vaporization point. In this extremely demanding
production environment, evaporation boats must withstand temperatures
of 1500 C or more, resist corrosion from different metals, and provide
even wet-out for consistency of deposition on the substrate. GE's Advanced
Materials' Quartz business has developed a new grade, in its Metallist*
line of intermetallic composite (IMC) evaporation boats, that is intended
to meet all these challenges while providing up to 65 percent longer life
than competitive boats. The superior properties of GE's VaporStar* IMC
evaporation boats can give manufacturers critical advantages including
higher-quality end products, higher productivity, faster cycle times,
and greater value.
Using its Design for Six Sigma process, GE worked with a number of key
customers throughout its development of the VaporStar boats, and conducted
extensive validation with customers to substantiate that the benefits
delivered by the boats were significant and present in real-world operating
conditions, not just in a controlled laboratory environment. The company
built a laboratory chamber to replicate customers' process environments
and developed special tests to quantify wetting and corrosion characteristics.
Quantitative field testing was conducted at more than 10 customer sites. For operators, the increased wettability of VaporStar IMC boats means
improved ease of use and better control over the metallizing process.
Operators who participated in GE testing consistently reported greater
plate uniformity and aluminum puddle stability over the complete life
cycle of the VaporStar boats. GE is committed to helping customers discover
the benefits of VaporStar boat technology in their processes, offering
training on the use of VaporStar boats, benchmarking studies to define
baseline performance of existing boats, and tests to demonstrate the improvements
possible through VaporStar boats. The Advanced Materials' GE portfolio includes silicone-based products
and technology platforms, silanes, fused quartz, ceramics, sealants and
adhesives. These material solutions are used as a catalyst for innovation
in hundreds of consumer and industrial applications ranging from car engines
to biomedical devices. Markets served include aerospace, agriculture,
appliances, automotive, construction, electronics, furniture and furnishings,
healthcare, home care, industrial, lighting, packaging, personal care,
plastics, semiconductor, telecommunications, tire, transportation, and
water purification. As a Worldwide Partner of the Olympic Games, GE is
the exclusive provider of a wide range of innovative products and services
that are integral to a successful Games.
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