Identification of damage and fracture modes in power electronic packaging from experimental micro-shear tests and finite element modeling

Micro-shear tests are performed in order to characterize the mechanical behavior and the fracture of the chip/metallized ceramic substrate assemblies of power electronic devices. These assemblies are elaborated using three types of junctions: AuGe solder/Au or Ag finish, transient liquid phase bonding (TLPB) AgIn/Ag finish and Ag nanoparticles/Au or Ag finish. The experiments are associated to finite element simulations of both nano-indentation and micro-shear tests. The mechanical behavior of the different assembly interfaces is represented using an in-built cohesive zone model (CZM) available in the user friendly finite element code Abaqus. It is worth noting that the fracture mechanisms observed during the test and service periods of the power electronic packaging are not only due to the debonding at the interfaces but also to the initiation and growth of voids in the joint. Therefore, in addition to the CZM model, Gurson-Tvergaard-Needlmann (GTN) damage model is used in combination with the Rice bifurcation theory to correctly describe the fracture in the joint and, therefore the overall fracture mechanism of the entire junction. The simulation results are compared with the experimental force displacement curves and the SEM observations in order to assess the implemented model

Mechanical behaviour of human enamel and the relationship to its structural and compositional characteristics

Objectives As the outer cover of teeth structure, enamel is the hardest, stiffest and one of the most durable load-bearing tissues of the human body. Also, enamel is an elegantly designed natural biocomposite. From a material science point of view, scientists are interested in the structure and function of the nature material. How does nature design the material to meet its functional needs? From a dental clinic point of view, dental practitioners are keen to know the properties of enamel and compare it with different dental materials. What kind of dental materials can best simulate enamel as a restoration in the oral cavity? The research presented in this thesis on the mechanical behaviour of enamel in respect of its structural and compositional characteristics will attempt to provide answers or indications to the above questions. Theoretical analysis, as well as experimental investigations of both man-made and natural composites materials, has shown that hierarchical microstructure and organic matrix glues the inorganic particles together and plays an important role in regulating the mechanical properties of the composite. Bearing this finding in mind, in the current investigations, we assume the hierarchical microstructure and trace protein remnants in enamel regulate the mechanical behaviour of the natural biocomposite to meet its functional needs as a load bearing tissue with superb anti-fatigue and wear resistant properties. One of the important reasons that dental hard tissues haven’t been thoroughly investigated is due to the limited sample volume. Fortunately, with the development of nanoindentation technique and equipment, it is now possible to explore the mechanical properties of small volume samples. The application of nanoindentation on dental hard tissues has been documented. However, most investigations have concentrated on only reporting the basic mechanical properties such as elastic modulus and hardness. Very few of them have taken the role of microstructure and composition of these natural biocomposites into their considerations. The main aim of this investigation is to interpret how microstructural and compositional features of enamel regulate its mechanical behaviour. To achieve this goal, the analytical methods considering nanoindentation data need to be expanded so that more information not only elastic modulus and hardness but also stress-strain relationship, energy absorption ability, and creep behaviour may be evaluated with this technique. These new methods will also be of benefit to dental material evaluation and selection. Materials and methods Based on the Oliver-Pharr method1 for the analysis of nanoindentation data, Hertzian contact theory2 and Tabor’s theory3, a spherical nanoindentation method for measuring the stress-strain relationship was developed. Furthermore, nanoindentation energy absorption analysis method and nanoindentation creep test were developed to measure the inelastic property of enamel. With the above methods, sound enamel samples were investigated and compared with various dental materials, including dental ceramics and dental alloys. • Firstly, using a Berkovich indenter and three spherical indenters with 5, 10 and 20 µm nominal radius, the elastic modulus, hardness and stress-strain relationship of different samples were investigated and compared. • Secondly, mechanical properties of enamel in respect to its microstructure were investigated intensively using different indenters by sectioning teeth at different angles. • Thirdly, inelastic behaviour of enamel such as energy absorption and creep deformation were observed and compared with a fully sintered dense hydroxyapatite (HAP) disk to illustrate the roles of protein remnants in regulating the mechanical behaviour of enamel. • Fourthly, to confirm the functions of protein remnants in controlling mechanical behaviour of enamel, enamel samples were treated under different environments such as burning (300°C exposure for 5 min), alcohol dehydration and rehydration to change the properties of proteins before the nanoindentation tests. • Lastly, micro-Raman spectroscopy was employed to measure and compare the indentation residual stresses in enamel and HAP disk to evaluate the role of both hierarchical microstructure and protein remnants in redistributing the stresses and reinforcing the mechanical response of enamel to deformation. Results and significance Nanoindentation is an attractive method for measuring the mechanical behaviour of small specimen volumes. Using this technique, the mechanical properties of enamel were investigated at different orientations and compared with dental restorative materials. From the present study, the following results were found and conclusions were drawn. Although some newly developed dental ceramics have similar elastic modulus to enamel, the hardness of these ceramic products is still much higher than enamel; in contrast, despite the higher elastic modulus, dental metallic alloys have very similar hardness as enamel. Furthermore, enamel has similar stress-strain relationships and creep behaviour to that of dental metallic alloys. SEM also showed enamel has an inelastic deformation pattern around indentation impressions. All of these responses indicated that enamel behaves more like a metallic material rather than a ceramic. Elastic modulus of enamel is influenced by highly oriented rod units and HAP crystallites. As a result, it was found to be a function of contact area. This provides a basis to understand the different results reported in the literature from macro-scale and micro-scale tests. Anisotropic properties of enamel, which arise from the rod units, are well reflected in the stress-strain curves. The top surface (perpendicular to the rod axis) is stiffer and has higher stress-strain response than an adjacent cross section surface because of the greater influence of the prism sheaths in the latter behaviour. Enamel showed much higher energy absorption capacity and considerably more creep deformation behaviour than HAP, a ceramic material with similar mineral composition. This is argued to be due to the existence of minor protein remnants in enamel. Possible mechanisms include fluid flow within the sheath structure, protein “sacrificial bond” theory, and nano-scale friction within sheaths associated with the degustation of enamel rods. A simple model with respect of hierarchical microstructure of enamel was developed to illustrate the structural related contact deformation mechanisms of human enamel. Within the contact indentation area, thin protein layers between HAP crystallites bear most of the deformation in the form of shear strain, which is approximately 16 times bigger than contact strain in the case of a Vickers indenter. By replotting energy absorption against mean strain value of a protein layer, data from different indenters on enamel superimposed, validating the model. This model partially explained the non-linear indentation stress-strain relationship, inelastic contact response and large energy absorption ability of enamel and indicated the inelastic characteristics of enamel were related to the thin protein layers between crystallites. Following different treatments, mechanical properties of enamel changed significantly. By denaturing or destroying the protein remnants, mechanical behaviour, especially inelastic abilities of enamel decreased dramatically, which indicates matrix proteins endow enamel better performance as a load bearing calcified tissue. Comparison of Raman derived residual maps about indentations in enamel and a sintered homogeneous HAP showed the hierarchical structure influenced the residual stress distribution within enamel. Moreover, less residual stresses were found in enamel and were a consequence of the protein remnants. These are evidence as to how the microstructure meets the functional needs of the enamel tissue. In general, evidence from different approaches indicated that the hierarchical microstructure and small protein remnants regulated the mechanical behaviour of enamel significantly at various hierarchical levels utilising different mechanisms. This investigation has provided some basis for understanding natural biocomposites and assisting with dental clinic materials selection and treatment evaluation procedures. References 1. Oliver WC, Pharr GM. An improved technique for determining hardness and elastic modulus using load and displacement sensing indentation experiments. J Mater Res. 1992;7(6):1564-83. 2. Hertz H. Miscellaneous Papers. London: Jones and Schott, Macmillan; 1863. 3. Tabor D. Hardness of Metals. Oxford: Clarendon Press; 1951

Bibliography of Lewis Research Center technical publications announced in 1985

This compilation of abstracts describes and indexes the technical reporting that resulted from the scientific and engineering work performed and managed by the Lewis Research Center in 1985. All the publications were announced in the 1985 issues of STAR (Scientific and Technical Aerospace Reports) and/or IAA (International Aerospace Abstracts). Included are research reports, journal articles, conference presentations, patents and patent applications, and theses

Ceramic Materials

This is the first book of a series of forthcoming publications on this field by this publisher. The reader can enjoy both a classical printed version on demand for a small charge, as well as the online version free for download. Your citation decides about the acceptance, distribution, and impact of this piece of knowledge. Please enjoy reading and may this book help promote the progress in ceramic development for better life on earth

Continuum and crystal strain gradient plasticity with energetic and dissipative length scales

This work, standing as an attempt to understand and mathematically model the small scale materials thermal and mechanical responses by the aid of Materials Science fundamentals, Continuum Solid Mechanics, Misro-scale experimental observations, and Numerical methods. Since conventional continuum plasticity and heat transfer theories, based on the local thermodynamic equilibrium, do not account for the microstructural characteristics of materials, they cannot be used to adequately address the observed mechanical and thermal response of the micro-scale metallic structures. Some of these cases, which are considered in this dissertation, include the dependency of thin films strength on the width of the sample and diffusive-ballistic response of temperature in the course of heat transfer. A thermodynamic-based higher order gradient framework is developed in order to characterize the mechanical and thermal behavior of metals in small volume and on the fast transient time. The concept of the thermal activation energy, the dislocations interaction mechanisms, nonlocal energy exchange between energy carriers and phonon-electrons interactions are taken into consideration in proposing the thermodynamic potentials such as Helmholtz free energy and rate of dissipation. The same approach is also adopted to incorporate the effect of the material microstructural interface between two materials (e.g. grain boundary in crystals) into the formulation. The developed grain boundary flow rule accounts for the energy storage at the grain boundary due to the dislocation pile up as well as energy dissipation caused by the dislocation transfer through the grain boundary. Some of the abovementioned responses of small scale metallic compounds are addressed by means of the numerical implementation of the developed framework within the finite element context. In this regard, both displacement and plastic strain fields are independently discretized and the numerical implementation is performed in the finite element program ABAQUS/standard via the user element subroutine UEL. Using this numerical capability, an extensive study is conducted on the major characteristics of the proposed theories for bulk and interface such as size effect on yield and kinematic hardening, features of boundary layer formation, thermal softening and grain boundary weakening, and the effect of soft and stiff interfaces

Creep Behavior of a Zirconium Diboride-Silicon Carbide Composite and Preliminary ZrB2-WC Quasi-Binary Alloy Development for Long Duty Cycle Aerosurfaces and Structural Propulsion Applications

The mechanical behavior of select ultra-high temperature ceramics were studied for extreme environment aerospace applications. Hot-pressed ZrB2-20 vol% SiC composites and ZrB2-WC quasi-binary alloys were developed for assessing room temperature mechanical properties and creep behavior. A thermochemical model describing alloy phase stability and reaction equilibria, for promoting WC dissolution, is presented. Room temperature structure-property relationships were developed correlating fracture strength and KIC with microstructure constituent size. Flexural creep studies of ZrB2-20 vol% SiC were conducted over the range of 1400°C to 1820°C assessing the macroscopic creep behavior using power-law stress and temperature dependent constants. Inert environment creep experiments were conducted for probing the local grain deformation mechanism in anticipation of bridging the deformation length scales. A two decade increase in creep rate, between 1500 and 1600°C, suggests a clear transition between the low temperature (1400-1500°C) diffusion creep and high temperature (>1600°C) grain boundary sliding creep having stress exponents of unity and 1.7<n<2.2, respectively. A novel indentation deformation mapping experiment clearly defined the local ZrB2 grain boundary sliding event with its components of 80% grain translations and rotations and 20% grain deformation. EBSD and texture theory confirmed the direct observation of ZrB2 grains deforming by dislocation flow, confined to near-grain boundary (mantle) zones, accommodating the grain rotation and translation events. A transition from the grain core to mantle deformation deviated from single crystal behavior as a result of extra geometrically necessary dislocations accommodating the deformation gradient. Microstructure observations shows evidence of <5% and <20% SiC grain deformation, contributing to the macroscopic creep strain, for tension and compression bending fibers, respectively. Cavitation accounts for less than 5% contribution to the accumulated creep strain. Preliminary ZrB2-WC quasi binary alloy creep experiments reveal a decade decrease in the steady state creep rate with a 1.1 mol% increasing WC composition. Improved creep behavior is discussed in the context of solute interactions with accommodation dislocations from grain boundary sliding. Alloy creep rates of 10-7-10-6 s-1 were measured contrasting with 10-5-10-4 s-1 for the ZrB2-SiC composite approaching the design creep rate of 10-8s-1 for long duty cycle aerospace applications.Mechanical Engineering, Department o

Development of functionally graded tungsten/EUROFER coating systems

Functionally graded W/EUROFER layer on EUROFER substrate is developed for first wall application. Parameters of coating systems were determined by non-linear finite element simulations. The coating system fabricated by vacuum plasma spraying has fine linear gradient and designed thickness, low porosity (< 4%), as well as a sound interface with high interface toughness. Good thermal-mechanical properties of the coating system have been assessed and analyzed

Physics and Process Modeling (PPM) and Other Propulsion R and T

This CP contains the extended abstracts and presentation figures of 36 papers presented at the PPM and Other Propulsion R&T Conference. The focus of the research described in these presentations is on materials and structures technologies that are parts of the various projects within the NASA Aeronautics Propulsion Systems Research and Technology Base Program. These projects include Physics and Process Modeling; Smart, Green Engine; Fast, Quiet Engine; High Temperature Engine Materials Program; and Hybrid Hyperspeed Propulsion. Also presented were research results from the Rotorcraft Systems Program and work supported by the NASA Lewis Director's Discretionary Fund. Authors from NASA Lewis Research Center, industry, and universities conducted research in the following areas: material processing, material characterization, modeling, life, applied life models, design techniques, vibration control, mechanical components, and tribology. Key issues, research accomplishments, and future directions are summarized in this publication

LASER SHOCK IMPRINTING OF METALLIC NANOSTRUCTURES AND SHOCK PROCESSING OF LOW-DIMENSIONAL MATERIALS

Laser shock imprinting (LSI) is proposed and developed as a novel ultrafast room-temperature top-down technique for fabricating and tuning of plasmonic nanostructures, and processing of one-dimensional semiconductor nanowires and two-dimensional crystals. The technique utilizes a shock pressure generated by laser ablation of sacrificial materials. Compared with conventional technologies, LSI features ambient condition, good scalability, low cost and high efficiency