Nanotechnology-Enhanced Lubricants Extend Life of Radio Frequency Switches

  • Published
  • By Heyward Burnette, AFRL/RXOB
  • Materials and Manufacturing
WRIGHT-PATTERSON AIR FORCE BASE, Ohio --  Nanoparticle lubricant (NPL) technology, developed by scientists and engineers from the Air Force Research Laboratory (AFRL), resulted in improvements in the lifecycle of noble metal ohmic contact radio frequency (RF) microelectromechanical systems (MEMS) switches developed for tactical radios. Tactical radios are used by the Air Force and Department of Defense (DoD) for communication during in-field operations. AFRL's collaboration with the University of Dayton Research Institute (UDRI) resulted in synthesis of a candidate NPL, and working in conjunction with MEMS switch developer XCOM Wireless, developed a deposition process compatible with a MEMS production assembly line.

NPL-treated noble-alloy MEMS relays, tested for hot-switch and cold-switch lifetime, showed significant improvements in lifetime; up to two times for cold switched conditions, and nearly 10 times for high-power hot-switched conditions. These improvements represent a critical leap forward for MEMS technology. Demonstrating the value of this research thrust, researchers designed and modified a prototype MEMS-tunable power amplifier using NPL and testing revealed high performance and reduced size capabilities that can be applied to state-of-the-art products. The first application targeted for improvement are tactical radios used by Air Force where the primary benefits would be improved performance, 30 percent consumed power savings, as well as cost and weight savings.

The Air Force employs numerous communication links between space-borne assets, airborne platforms, ground forces, and unattended ground sensors. Access to dependable data, increased bandwidth and situational awareness are critical enablers for in-field operations. Emerging DoD needs require increased waveform support and radio adaptability to ensure redundancy, compatibility, and bandwidth on demand, especially as sensor platforms and capabilities change and multiply. Next-generation tuners, filter modules, and amplifiers are critical to "dialing back" the size, weight and to provide power for increasingly complex radios such as the Joint Tactical Radio System, Common Soldier Radio, Warfighter Information Network-Tactical radio. Additionally, power is wasted and extra heat is generated because conventional antennas and amplifiers cannot adapt to changing radio conditions.

Further improvements in NPL deposition techniques are required to take full advantage of NPL lubricant technology for enhancement of MEMS switch survivability in government radio applications. Researchers are currently evaluating whether to initiate a project with AFRL's Manufacturing Technology Division to mature manufacturing technology and integrate NPL into MEMS processing.