Particle-vapor interaction in deposition systems: influence on deposit morphology

We have here presented methods to study interactions of vapors and particles in systems involving simultaneous deposition of vapors and particles. Besides estimating vapor and particle concentration profiles in the boundary layer adjacent to the deposition surface, their deposition rates are also calculated. In particular, we consider formation of porous preforms by deposition of silica particles and germania particles/vapors during the manufacturing of optical fibers. The process conditions not only dictate the relative rates of germania particle and vapor deposition on the deposition surface, but also controls the fraction of germania crystallinity in the resulting deposit. Moreover, the loss and migration behavior of the deposited germania during the sintering of the porous preform is extremely sensitive to the germania crystalline fraction. Our methods predict the germania weight percent deposited during the deposition process as a function of the deposition conditions, along with the fraction of germania that is crystalline/amorphous. The germania loss and migration behavior during the sintering step is also estimated. In predicting the germania loss and migration behavior, we have developed methods to systematically take into account the simultaneous heating of the preform, sintering of the porous preform, diffusion of gas species through the pores and the gas-solid reaction. Based on the methods developed here for deposition and sintering, processes have been developed which have resulted in sintered glasses with very high germania content (50 weight percent), and, without any glass quality issues of glass seeds, blank splitting or glass crizzling (devitrification).