Abstract

     The modern approaches to modeling for creating new nickel-based superalloys are analyzed. The computer calculation methods used in domestic and foreign practice and based on multifactor design of experiments are presented

Introduction

     Currently, the active work on creating the fifthand sixth-generation aviation gas turbine engines, which is being performed in advanced states, is accompanied by vigorous development of effective methods to significantly facilitate and shorten the time of production of new high-temperature alloys, the difficulties of manufacture of which have increased many times due to the sharp complication of alloying. The regions of optimum alloy compositions began to be located near the phase boundaries of various undesirable or harmful phases.

     This problem is challenging due to the fact that the achieved complexity of alloying (primarily cast nickel superalloys) has led to the fact that their further development and optimization of the compositions of promising alloys are associated with ensuring simultaneous consideration of a significant number of the factors directly affecting their performance.

ANALYTICAL CALCULATIONS OF PHASE DIAGRAMS

     In the 1960s–1970s of the last century, the direction of calculating and predicting phase diagrams in materials science, which today has resulted in a rather powerful and popular direction, developed very actively. The problem of finding criteria for phase diagrams of different types has been solved since the time of van der Waals [4], who, working in the field of theoretical molecular physics, studied the behavior of molecules characterizing the state of material. In 1869, he discovered the forces of interaction between molecules, which were later called the van der Waals forces. In 1873, in his dissertation for Doctor of Philosophy, he developed a model, which uniformly describes the gaseous and liquid forms of matter, and derived an equation of state for gases and liquids. About this work, Maxwell said that it immediately put his name on a par with the most outstanding names in science.

Highlights

Abstract

Graphical abstract

Keywords

Nomenclature

1. Introduction

2. Why focusing on LIB risk management and safety issues?

2. Contextualising the relative levels of risk of electric vehicle LIBs

3. Potential failure mechanisms of LIBs

4. Origins and categorisation of risks associated with LIBs

5. End of Life LIB incidents

6. Safety measures, regulatory gaps and discussions

7. Conclusions

Credit author statement

Declaration of competing interest

Acknowledgments

References

Abstract

Lithium-ion Batteries (LIB) are an essential facilitator of the decarbonisation of the transport and energy system, and their high energy densities represent a major technological achievement and resource for humankind. In this research, it has been argued that LIBs have penetrated everyday life faster than our understanding of the risks and challenges associated with them. The current safety standards in the car industry have benefited from over 130 years of evolution and refinement, and Electric Vehicle (EV) and LIB are comparably in their infancy. This paper considers some of the issues of safety over the life cycle of batteries, including: the End of Life disposal of batteries, their potential reuse in a second-life application (e.g. in Battery Energy Storage Systems), recycling and unscheduled End of Life (i.e. accidents). The failure mechanism and reports from a range of global case studies, scenarios and incidents are described to infer potential safety issues and highlight lessons that can be learned. Therefore, the safety risks of LIBs were categorised, and the regularity requirements to create and inform a wider debate on the general safety of LIBs were discussed. From the analysis, a range of gaps in current approaches have been identified and the risk management systems was discussed. Ultimately, it is concluded that robust educational and legal processes are needed to understand and manage the risks for first responders and the public at large to ensure a safe and beneficial transition to low carbon transportation and energy system.

1. Introduction

Lithium-ion batteries (LIBs) have penetrated deeply into society, finding a wide range of applications in personal electronic devices since their discovery and development in the 1980s and 90s, and more recently in larger energy systems for traction and energy storage. This is mainly owing to the unique characteristics of LIB technology, i.e. high energy densities, high voltage, good stability, low self-discharge rate, long-life cycle and availability of a wide range of chemistries with diverse electrode designs [1,2]. LIBs are incorporated into ever widening application areas and are to be found at scales as diverse as their usages. This is evidenced by the growth in the uptake of LIBs having increased eight fold between 2010 and 2018 to 160 GWh [3] and the steady increase in annual sales of LIBs which are predicted to be upwards of 4 TWh by 2040 [4]. In the UK, it is forecast that the number of LIBs reaching the end of their life from automotive applications would have reached approximately 75,000 units, or 28,000 t by 2025 [5]. The advent of lithium-ion technology and the paradigm shift in the energy and power density capabilities that it represents, are perceived as the enabling technology for an extremely broad range of energy storage applications. Accordingly, LIBs are increasingly recognised as essential and integral to enable the large-scale temporary storage of electrical energy from renewable energy sources.

2-1- Introduction

2-2- 3D printing techniques for metallic biomaterials

2-3- 3D printed metallic biomaterials

2-4- Challenges, potential and current active research in 3D printing of metallic biomaterials

2-5- Conclusion References

2-1- Introduction

Among the three-dimensional (3D) printing, or officially known as additive manufacturing (AM), techniques, the powder bed fusion (PBF) and directed energy deposition (DED) are most commonly used to process metals directly as they have the capability to produce high-quality parts that are fully dense. According to ISO/ ASTM 52900:2017, PBF is a group of AM processes in which thermal energy selectively fuses regions of a powder bed, while DED is another group of AM processes in which focused thermal energy is used to fuse materials by melting as they are being deposited. In the academia, there has been extensive studies applying 3D printing in tissue engineering (Sudarmadji et al., 2011; Yeong et al., 2009; Wiria et al., 2007; Yang et al., 2002). For example, tissue scaffolds for cardiac and bone have been fabricated successfully (Chua and Yeong, 2014; Yeong et al., 2004). These applications have mainly focused on using polymers; however, in recent years, there has been growing interest in using metallic biomaterials to create implants. This is made possible with the advancement in 3D printing and accelerated development of printable materials. In this chapter the application of these two groups of AM technologies in fabrication of metallic biomaterials is described, with specific focus on metals that are biocompatible and commonly used such as 316L stainless steel, titanium-6aluminum-4vanadium (Ti6Al4V), and cobalt-chromium-molybdenum (CoCrMo).

1- Introduction

2- Experimental method

3- Results and discussion

4- Conclusions

References

Abstract

The deuterium permeation behavior of palladium-coated 316L stainless steel and 430 stainless steel was studied by the gas permeability testing device in this study. The results show that the deuterium permeability of the palladium-coated 316L stainless steel tested at 350 °C∼650 °C was very close to the Forcey’s results. This way, the conformity to some other reported results has been verified for the gas permeability testing device. The deuterium permeability for the oxidized 430 stainless steel was compared with that for the palladium-coated 430 stainless steel at temperature range of 350 °C–600 °C. The deuterium permeability for the oxidized 430 stainless steel was reduced by one order of magnitude compared with that for the palladium-coated 430 stainless steel. However, the activation energy of deuterium permeation as gas form for the oxidized 430 stainless steel was almost the same as that for unoxidized 430 stainless steel.

Introduction

Zirconium hydride is used as the reactor moderator in the thermionic space nuclear power and it easily decomposes hydrogen in the operating environment. The released hydrogen penetrates into the core through the relevant structural components, affecting the physical parameters of the reactor [1]. Compared with 316L austenitic stainless steel, 430 ferritic stainless steel has the advantages of good thermal conductivity, low thermal expansion coefficient and low sensitivity to stress corrosion cracking. It is selected as one of the alternative reactor core materials for structural components of the thermionic space nuclear power. Therefore, investigating the hydrogen permeation behavior of 430 ferritic stainless steel has important engineering application value for the development of thermionic space nuclear power. A lot of research has been carried out on the preparation and properties evaluation of hydrogen isotope permeation barrier coatings for the fusion reactor. However, 316L stainless steel or low-activity ferritic/martensitic steel was used as the substrate material in most of these studies [2–15]. There are few reports on the hydrogen isotope permeation behavior of 430 ferritic stainless steel. In the present study, the deuterium permeability of palladium-plated 316L stainless steel was first tested and compared with the reported values to verify the conformity to other reported results for the gas permeability testing device. Then the deuterium permeation behavior of the palladium-plated 430 stainless steel as well as that with natural oxide film was investigated.

1- Introduction

2- Modeling of FG-CNTRC laminated cylindrical shells with NPR

3- Solution procedure

4- Numerical results and discussion

5- Concluding remarks

References

Abstract

This paper presents an investigation on the nonlinear flexural vibrations of carbon nanotube-reinforced composite (CNTRC) laminated cylindrical shells with negative Poisson’s ratios in thermal environments. The material properties of the CNTRCs are temperature-dependent and the functionally graded (FG) in a piece-wise pattern in the thickness direction of the shell. An extended Voigt (rule of mixture) model is employed to estimate the CNTRC material properties. The motion equations for the nonlinear flexural vibration of FG-CNTRC laminated cylindrical shells are based on the Reddy’s third order shear deformation theory and the von Kármán-type kinematic nonlinearity, and the effects of thermal environmental conditions are included. The nonlinear vibration solutions for the FG-CNTRC laminated cylindrical shells can be obtained by applying a singular perturbation technique along with a two-step perturbation approach. The effects of material property gradient, the temperature variation, shell geometric parameter, stacking sequence as well as the end conditions on the vibration characteristics of CNTRC laminated cylindrical shells are discussed in detail through a parametric study. The results show that negative Poisson’s ratio has a significant effect on the linear and nonlinear vibration characteristics of CNTRC laminated cylindrical shells.

Introduction

Composite laminated shell structures are widely used in structural applications owing to their specific higher strength-to-weight and stiffness-to-weight ratios, improved chemical and environmental resistance and the ability to tailor properties. These shell structures may be exposed to combined action of loading and various environmental conditions during their service life. This may lead to large amplitude vibration of the shells where the shell deflection may be in the order of the shell thickness. In this regard, the nonlinear vibration of composite laminated shells in thermal environments is an important consideration in engineering analysis and design. Many studies have been carried out on the nonlinear vibration behavior of composite laminated shells [1–6]. As pointed out by Shen [6], unlike in the cases of composite laminated plates, there are unresolved discrepancies between the vibration results obtained by different authors for composite laminated cylindrical shells, in particular for the cases of angle-ply laminated cylindrical shells. With growing interest in the development and manufacturing of high-performance and lightweight composite shells, auxetic composite materials and structures appear to be potential candidates. A consequence of material possessing a negative Poisson’s ratio (NPR) is that many of its mechanical properties are predicted to be enhanced by classical elasticity theory. The auxetic materials have a wide variety of multifunctional applications, for example, in energy storage, biomedical, acoustics, photonics, and thermal management [7]. There are two ways to construct auxetic structures. One way is to use auxetic metamaterial as sandwich core [8]. Another way is to change the stacking sequence and orientation of the laminates to obtain auxetic laminated shells. The production of larger values of negative Poisson’s ratio requires both a particular stacking sequence and the individual ply material being highly anisotropic [9].

1- Introduction

2- Modelling and deformation mechanism

3- Characterization of mechanical properties

4- Conclusions

References

Abstract

Artificial auxetic materials with negative Poisson’s ratio enable distinctive elastic response in the direction orthogonal to the loaded direction, i.e. shrinking when compressed and expanding when stretched, compared to conventional materials. Such distinctive mechanical characteristic makes auxetic materials unique in practice. Current studies in this aspect focus mainly on the realization of beam-dominated microstructures such as re-entrant and chiral lattices and of cellular microstructures with orthogonal elliptical hole pattern. In this study, a novel two-dimensional auxetic microstructure is designed by introducing peanut-shaped holes in solid bulk matrix. Compared to the microstructure with elliptical hole pattern, the present design can produce slightly larger negative Poisson’s ratio and achieve significantly lower stress level. The samples consisting of a number of centimeter-scale unit cells with the peanut-shaped holes are fabricated efficiently via additive manufacturing technique. Experiment and finite element simulation of tensile test are carried out on the specific sample to demonstrate the auxetic effect of the present design and simultaneously verify the computational model. Finally, effects of some parameters on Poisson’s ratio, which may control the auxetic behavior of the present microstructure, are discussed for better understanding deformation mechanism of the proposed auxetic material.

Introduction

The concept of metamaterials with specially designed artificial microstructure made by additive manufacturing technology has recently received more and more attention because of its unconventional physical properties that are previously inaccessible in conventional materials [1–4]. With these man-made metamaterials, engineering materials with various properties have been developed including negative Poisson’s ratio (auxetic properties) [5–11], zero/negative thermal expansion materials [12,13], cloaking materials [14,15], phononic materials [16–19], twistable materials [20,21], and materials with vibration absorption [22,23]. Among these examples, mechanical consistence between longitudinal and orthogonal transverse elastic deformations has been achieved in two-dimensional (2D) and three-dimensional (3D) cellular metamaterials with well-designed cellular topologies [24], i.e. re-entrant shape (Fig. 1a), chiral shape (Fig. 1b) and elliptical hole shape (Fig. 1c) [5–11]. In the static case, such mechanical consistence is conflicted to the fact that a conventional elastic solid cannot expand or shrink laterally when stretched or compressed longitudinally (Fig. 1d) [6,25,26]. It has been revealed that the auxetic behavior of a material can be regarded as a consequence of rotation of elastic cell when it is subjected to a compressive or tensile load [5]. Therefore, auxetic structures with negative Poisson’s ratio are beneficial to enhancing shear rigidity, indentation resistance, toughness, energy dissipation ability and acoustic absorption ability in various applications [27–31]. However, the current re-entrant and chiral metamaterials [9,10] with negative Poisson’s ratio are generally designed to have beamdominated microstructures with bending dominated topologies. As a result, they are known to have low macroscopic stiffness, high flexibility, and high porosity. More seriously, joints with sharp corners in the re-entrant and chiral auxetic structures could lead to high stress concentration [32]. As an alternative to the beam-dominated auxetic microstructures, the orthogonal elliptical hole pattern in solid material was revealed to be beneficial in achieving controllable auxetic response. However, the elliptical hole usually leads to high stress level too. In order to achieve the balance of stiffness and flexibility, and meanwhile possess smoothed boundary and controllable porosity, in this study, a new two-dimensional elastic cellular metamaterial with a negative Poisson’s ratio is designed, fabricated, and characterized.

1- Introduction

2- Deposition techniques for 3D printing of biomaterials

3- Materials for 3D printing of biomaterials

4- Applications of 3D printed biomaterials

5- 4D printing and its applications for biomaterials

6- Conclusions and future perspectives

References

Introduction

Three-dimensional printing (3D printing) or additive manufacturing (AM) promises to produce complex devices formulated from biomaterials and bioinspired materials from designs that are patient-specific. Since its advent as presurgical visualization technique and fabrication of tooling molds, 3D printing has evolved to yield bespoke devices, implants, scaffolds, diagnostic devices, and drug-delivery systems. As a result of recent public interest and affordable printing platforms, there is the desire to utilize this exciting technology for personalized health care. However, before AM can become a ubiquitous tool for the regeneration of complex tissues, such as bone, cartilage, muscles, vessels, nerves, and complex organs with multifaceted three-dimensional microarchitecture (e.g., kidneys, lymphoid organs), a number of technological limitations must be overcome. The development of advanced bioinks for 3D and 4D printing through the rational design of novel materials and their implementation as functional biomaterials through ever-expanding deposition techniques has improved the diversity and functionality of printed constructs outside of the traditional biofabrication window [1]. While there is the necessity for a compromise between suitability for purpose and biocompatibility, recent developments in materials science and bioink formulations have resulted in an improved range of solutions for biofabrication platforms. New biologically relevant printing formulations with highly consistent and accurate deposition parameters, attractive mechanical properties, high cytocompatibility, and the ability to modulate cellular functions are now being developed and offer prospects as biomaterials for use in a multitude of different applications; however, further work is needed before these novel materials become common place. In this chapter, we explore some of the approaches being pursued to achieve these targets in common 3D and 4D printing techniques, including an overview of the state-of-the-art technologies and formulations used in novel materials and bioinks, which are currently being developed, the techniques which are being utilized to produce 3D and 4D constructs, and the applications for which these new materials may be employed in. Key examples are highlighted to demonstrate the progress of this emerging technology and limitations to its development identified.

1- Introduction

2- Calculation details

3- Results and discussion

4- Conclusion

References

Abstract

High spin-polarized materials are expected for the development of spintronic devices. In this work, we are aiming to find new spintronic materials in Mn-based binary, ternary and quaternary Heusler alloys by using the first-principles calculations. We investigated structures, electronic properties, magnetic, tetragonal distortion and mechanic properties of Mn3Ga, Mn2YGa (Y = V, Nb, Ta) and ScMnVGa. The results show that Mn3Ga, ScMnVGa type-I, and type-II have lower energy in antiferromagnetic (AFM) states than ferromagnetic (FM) and paramagnetic (NM). Mn2YGa (Y = V, Nb, Ta) compounds are more stable in FM states. The results of electronic and magnetic properties indicate that Mn3Ga is a gapless half-metallic antiferromagnet (Gapless HM-AFM). Mn2VGa and Mn2NbGa belong to gapless half-metallic ferrimagnets (Gapless HM-FE). Mn2TaGa is ferrimagnets. ScMnVGa type-I is half-metallic antiferromagnets (HM-AFM) and type-II belongs to spin gapless semiconductors with AFM (SGSs-AFM). Inspired by Ferromagnetic shape memory alloys (FAMAs), we performed tetragonal deformation of those compounds, and we predicted that Mn3Ga, Mn2YGa (Y = V, Nb, Ta) have possible martensitic transformations. Finally, the mechanical stability and elastic properties of above-mentioned in both cubic and tetragonal structures were discussed in detail.

Introduction

Spintronics is considered to be one of the most promising subjects in the information age because spintronic devices use not only the state of charge but electronic spin to transfer and store information, which speeds up information transmission and reduces energy losses. The findings of Giant Magnetoresistance (GMR), Colossal Magnetoresistance (CMR) and Tunnel Magnetoresistance (MGR) accelerate the development of spintronics. Despite great potential advantages, spintronics still faces some challenges, such as, generate high spin injectors. However, the discovery of half-metallic ferrimagnet has improved this problem, which is an ideal semiconductor spin-injection source due to it has 100% spin polarizability. Among different halfmetallic materials, Heusler alloys are prominent especially owing to high Curie temperature and flexible electronic structures [1,2]. Since De Groot et al. [3] discovered the half-metallic ferromagnets of NiMnSb, while they were calculating the energy band using the planewave method, this intermetallic materials with unusual electronic structures arouse people’s attention. In the big family of Heusler alloys, Co-based Heusler alloys [4–6] usually show magnetism, and the source of this property is direct interaction between Co-Co atoms. Cu-based Heusler alloys [7–9] are typical representative of non-magnetic elements show ferromagnetic after high-ordered, Pd-based Heusler alloys [10,11] which contain rareearth elements is superconducting, Ni2Mn-based Heusler alloys [12–17] have both ferromagnetic properties and thermoelastic martensitic transformation, which realizing magnetic-field-induced strain, shape memory effect, magnetoresistance effect and other application functions. At present, most research focuses on ternary Mn-based Heusler alloys, and they usually behave ferromagnetic or ferromagnetic [18–21]. Actually, besides half-metallic ferromagnets and ferrimagnets, half-metallic antiferromagnets also worthy of study. Not only it has 100% spin polarizability, but its total magnetic moment is zero. Thus, it means that when HM-AFMs are applied to spintronic devices, and those alloys will get the feature of the low-stray field and low energy loss. HM-AFMs were discovered in Heusler alloys [22] and perovskite compounds [23]. Besides, the martensitic transformation was found in some Mn-based Heusler alloys [24–26].

1- Introduction

2- Thermodynamic calculation on solidification path and segregation behavior

3- Modeling of the eutectic fraction

4- Experimental procedure

5- Results and discussions

6- Conclusion

References

Abstract

The effect of cooling rate on the microstructure and TiC precipitation of TiC-reinforced wear-resistant steel was investigated by different casting techniques. Thermodynamic and solute segregation modeling was performed to determine the evolution of TiC fraction in wear-resistant steel after rapid solidification. The evolution of TiC fraction due to solute segregation within the framework of Clyne–Kurz (C-K) model was examined. The model prediction is consistent with the experimental results.

Introduction

As transition metal carbide, TiC is characterized by its excellent properties such as very high melting point and hardness [1,2]. These properties have led to their wide applications as important precipitates for strengthening steels [3,4]. The volume fraction, particle size and distribution of the reinforcing phase are significant for improving the mechanical properties [5,6]. To obtain the desired wear resistant properties and mechanical strength of steels, it is important to control the volume fraction of TiC [7]. As it is known, the inevitable solute segregation occurred in non-equilibrium solidification process enriches the solute in liquid, and influence the amount of eutectic and other phases [8]. Quantitative prediction of microsegregation is complicated by the difficulties in accounting for eutectic and secondary phase formation in steel. Within the past decades, correspondingly various analytical models were developed to predict solute redistribution and related phenomena [9-14]. Among these microsegregation models, the Clyne–Kurz model is considered to be the most popular one. However, previous works have the disadvantage that a constant partition coefficient must be assumed.

1- INTRODUCTION

2- EXPERIMENTATION

3- EXPERIMENTAL RESULTS

4- FUZZY LOGIC

5- DISCUSSION

6- CONCLUSIONS

REFERENCES

Abstract

The use of nanofluid in lubrication during machining of advanced engineering ceramics has been found to be highly efficient and eco‐friendly. This work involves experimental investigation of grinding Alumina (Al2O3) ceramic to determine the effect of the grinding variables. The grinding variables considered include depth of cut, feed rate, type of diamond wheel, and lubrication type. Moreover, the response parameters considered include grinding power, coefficient of friction, and surface quality. The responses obtained during the experiments were used to develop a fuzzy logic prediction model. The findings from this work can be concluded as follows: (a) The depth of cut and feed rate have direct proportional relationship with the grinding power and coefficient of friction. (b) The metallic bonded diamond wheel was found to have higher machining efficiency than the resinoid bonded one. (c) Higher number of diamond grits produces lower frictional coefficient. (d) The carbon nanotube based nanofluid when used in the minimum quantity lubrication (MQL) process proffers better lubrication capability than conventional flood cooling system. (e) The developed fuzzy logic models were found to have high prediction accuracies of 97.22%, 98.60%, and 96.8%, respectively, for grinding power, grinding force ratio, and surface roughness.

INTRODUCTION

Advanced engineering ceramics such as alumina, zirconia, silicon nitride etc have gained high popularity in biomedical and aerospace applications, due to their excellent hardness, high wear and thermal resistances, biocompatibility, and aesthetics. Among the conventional machining techniques used to machine advanced ceramics, surface grinding using diamond wheels is still the most efficient method utilized when processing the brittle materials. Studies have shown that machining takes up a bunch of the cost of producing advanced ceramic components. Due to their excessive hardness, there are many setbacks encountered during the machining of these kind of materials. Studies have shown that the difficulty encountered during the machining results about a great limitation to their extensive usage in various engineering fields. In addition, there is high rate formation of residual deformations such as macro and micro‐cracks, during machining of the brittle materials. These unwanted deformations have been found to deteriorate the quality of the manufactured components. As such, there is need to improve on the machining of these materials, especially improving the efficiency and achieving defect‐free components at lower costs.

1- Introduction

2- Experimental

3- Results and discussion

4- Conclusions

References

Abstract

Thin film bulk acoustic resonator (FBAR) plays a very important role in radio frequency (RF) filters used in cell phone and other wireless systems. Although FBAR is commercialized, the design/process interactions on the frequency response variation in FBAR device are still lacking. Design and fabrication are two crucial aspects affecting FBAR device performance. In this report, various solidly mounted resonators (SMR) were designed, fabricated and analyzed to study wafer-level site-to-site RF variation on design and fabrication process. As a key process step for SMR FBAR, the optimization process of Mg-doped ZnO piezoelectric thin film deposition was studied by varying thin film sputtering conditions using various sputtering targets and by post annealing treatment after the deposition. The quality of this crucial layer was verified by XRD on its (0 0 2) crystallization and wafer-level FBAR RF characterization. FBAR devices with high quality were fabricated with an excellent resonant behavior near 2 GHz and a maximum return loss of −15 to 25 dB. Quality factor Q ranges from 400 to 800, with a coupling coefficient keff2 of 1.5–3%. Wafer-level and wafer-to-wafer variation of central frequency are within 1.8–2.1 GHz. Computer simulation verified that this frequency variation correlates to the piezoelectric film variation of 1.6–1.9 μm. Process control on this piezoelectric thin film is essential to maintaining the resonator frequency-controlled value when building duplexer RF circuits. The dependency of RF performance on FBAR size, density and orientation is not obvious, compared to that of the wafer-level FBAR device variation on fabrication process. Regarding to the Mg-doping effect in MgxZn1-xO piezoelectric film, the amount of Mg in MgxZn1-xO film during the sputtering process must be properly controlled within 30% to keep the piezoelectric quality. The average acoustic speed of the Mg-doped ZnO film is 6870 m/s with the estimated range of 5760–7980 m/s, which is better than that of pure ZnO film (6330 m/s).

Introduction

Film bulk acoustic resonator (FBAR) is a promising RF device at the frequency ranging from 0.5 to 6.0 GHz due to its small size, high device power and strong potential application in both the cell phone market and sensor application [1–6]. Compared to surface acoustic devices (SAW) [7], FBAR is more powerful and advantageous especially for higher frequencies on 4G and 5G applications. Among the two types of FBAR devices, solid mounted resonator (SMR) is much more robust and therefore chosen in this work. FBAR built on silicon with Bragg reflector is also closer to CMOS integration [8] than SAW although it may also suffer from temperature sensitivity issues [9]. Just like a CMOS circuit that requires the MOSFET to have a controllable threshold voltage variation, FBAR device variation control is also essential to building an RF circuit such as duplexer in 4- and 5G mobile telecommunication systems. A duplexer demands that each FBAR in the circuit should have wafer-level homogeneity on the central frequency in RF performance as well as Q factor, and so on [10]. Although the FBAR product is commercially available in market, academic studies on the wafer-lever FBAR variation and process/design optimization are still relatively weak. In this paper, process variation effects on FBAR device performance were studied via various thin film depositions of Mg-doped MgxZn1−xO piezoelectric thin film by optimizing the sputtering power, pressure and ambient gas flow ratios as well as by altering sputtering targets (uniform MgxZn1−xO sputtering target with different Mg ingredient and dual sputtering targets of Mg and ZnO with independent control of sputtering power) and by post annealing treatment after the deposition. Design/process interactions and impacts on RF performance variation were studied via multi-FBAR device layouts in different sizes, locations and orientations on the same mask/wafer.