Interfacial Intermetallic Growth and Strength of Composite Lead-Free Solder Alloy Through Isothermal Aging

The effects of particle reinforcement of Sn-4.0wt.%Ag-0.5wt.%Cu (SAC405) lead-free solder on interfacial intermetallic layer growth and strength of the ensuing joints through short-term isothermal aging (150°C) were studied. Composite solders were prepared by either incorporating 2wt.% Cu (3μm to 20μm) or Cu2O (∼150nm) particles into SAC405 paste. Aggressive flux had the effect of reducing the Cu2O nanoparticles into metallic Cu which subsequently reacted with the solder alloy to form the Cu6Sn5 intermetallic. While all solders had similar interfacial intermetallic growth upon reflow, both of the composite solders' growth rates slowed through aging to reach a common growth rate exponent of approximately 0.38, considerably lower than that of the nonreinforced solder (n=0.58). The nanoscale reinforced solder additionally exhibited the highest tensile strength in both the initial and aged conditions, behavior also attributed to its quick conversion to a stable microstructur

A Study of the Shear Response of a Lead-Free Composite Solder by Experimental and Homogenization Techniques

The current study proposes a combined experimental and modeling approach to characterize the mechanical response of composite lead-free solders. The influence of the reinforcement volume fraction on the shear response of the solder material in the joint is assessed. A novel optimized geometry for single lap shear specimens is proposed. This design minimizes the effect of plastic strain localization, leading to a significant improvement of the quality of experimental data. The constitutive model of the solder material is numerically identified from the load-displacement response of the joint by using inverse finite element identification. Experimental results for a composite solder with 0.13 reinforcement volume fraction indicate that the presence of the reinforcement leads to a 23% increase of the ultimate stress and a 50% decrease of the ultimate strain. To interpret experimental data and predict the elastoplastic response of the composite solder for varying particle volume fraction, a three-dimensional (3D) homogenization model is employed. The agreement between experiments and homogenization results leads to the conclusion that the increase in the ultimate strength and the decrease in ductility are to be attributed to load sharing between matrix material and particles with the development of a significant triaxial stress state which restricts plastic flow in the matri

Transverse cracking in the bulk and at the free edge of thin-ply composites: experiments and multiscale modelling

Thin-ply composites were shown to exhibit significantly delayed transverse cracking, but the linear onset of damage scaling with ply thickness reported by Amacher et al. (2014) did not correspond to the established LEFM based in situ strength model. This study further investigates this experimental behaviour by simultaneously comparing in situ free edge crack observation with acoustic emission measurements as well as performing ex-situ X-ray tomography observations of crack propagation. A multi-scale FE model was used to better understand the damage mechanisms at play, and showed a decreasing trend of the apparent toughness with decreasing ply thickness, which explains the deviation from the existing model. Transverse cracking at the free edges was observed to propagate quickly towards the center of the specimens for the thickest plies, while in the thinnest plies it is significantly delayed, up to a point where no cracks can reach the center of the sample before final failure

A Study of the Shear Response of a Lead-Free Composite Solder by Experimental and Homogenization Techniques

The current study proposes a combined experimental and modeling approach to characterize the mechanical response of composite lead-free solders. The influence of the reinforcement volume fraction on the shear response of the solder material in the joint is assessed. A novel optimized geometry for single lap shear specimens is proposed. This design minimizes the effect of plastic strain localization, leading to a significant improvement of the quality of experimental data. The constitutive model of the solder material is numerically identified from the load-displacement response of the joint by using inverse finite element identification. Experimental results for a composite solder with 0.13 reinforcement volume fraction indicate that the presence of the reinforcement leads to a 23% increase of the ultimate stress and a 50% decrease of the ultimate strain. To interpret experimental data and predict the elastoplastic response of the composite solder for varying particle volume fraction, a three-dimensional (3D) homogenization model is employed. The agreement between experiments and homogenization results leads to the conclusion that the increase in the ultimate strength and the decrease in ductility are to be attributed to load sharing between matrix material and particles with the development of a significant triaxial stress state which restricts plastic flow in the matrix

Interfacial intermetallic growth and strength of composite lead-free solder alloy through isothermal aging

The effects of particle reinforcement of Sn-4.0wt.%Ag-0.5wt.%Cu (SAC405) lead-free solder on interfacial intermetallic layer growth and strength of the ensuing joints through short-term isothermal aging (150 degrees C) were studied. Composite solders were prepared by either incorporating 2 wt.% Cu (3 mu m to 20 mu m) or Cu2O (similar to 150 nm) particles into SAC405 paste. Aggressive flux had the effect of reducing the Cu2O nanoparticles into metallic Cu which subsequently reacted with the solder alloy to form the Cu6Sn5 intermetallic. While all solders had similar interfacial intermetallic growth upon reflow, both of the composite solders' growth rates slowed through aging to reach a common growth rate exponent of approximately 0.38, considerably lower than that of the nonreinforced solder (n = 0.58). The nanoscale reinforced solder additionally exhibited the highest tensile strength in both the initial and aged conditions, behavior also attributed to its quick conversion to a stable microstructure

L'HYDROPTERE: HOW MULTIDISCIPLINARY SCIENTIFIC RESEARCH MAY HELP BREAK THE SAILING SPEED RECORD

In 2009, l’Hydroptère broke the symbolic barrier of 50 knots and became the world fastest sailing boat over both 500 meters and 1 nautical mile. This major achievement relied on the high skills of the sailing team but also on technical advances of the boat, resulting from the scientific collaboration between the Hydroptère Design Team and the Ecole Polytechnique Fédérale de Lausanne (EPFL). In the present article, we highlight the multidisciplinary research activity performed within EPFL in the course of this collaboration involving aero- and hydrodynamics, materials and structure as well as computer vision. Various foils were tested at reduced scale in a high speed water tunnel, and the results used to validate the numerical simulations. Composite materials, their processing parameters and assembly components were tested. The structural behaviour was also investigated to determine strains and stresses in normal and extreme sailing conditions, taking waves into account, and a combined model was derived for dynamic simulation. Finally, advanced computer vision methods were developed and implemented on the boat to monitor foil immersion and cross beams deformations

Analysis of hygrothermally induced fiber fracture in single fiber composite using fiber Bragg grating

Hygro-thermal ageing of composite materials introduces a modification in the material properties of its constituents and the development of stresses that can lead to severe local damage like fracture of the reinforcing fibers and de-bonding of the latter from the matrix. The study of the complex stress field generated by this induced damage is helpful in designing more resistant materials. Modelling strain-stress filed in the vicinity of these discontinuities has led to the development of different analytical models like for instance shear lag models based on simplification assumptions. Recently the development of embedded optical sensors allowed to shed light on the assumptions made, since they can be used, at the same time, as reinforcement and sensors and thus being capable to give information on the strain distributions during the evolution of the damage. In this work a single fiber composite, whose reinforcement is an optical sensor, is used in order to investigate the complex strain field generated by the fiber fracture caused by the matrix swelling during water uptake

Crack - fiber sensor interaction and characterization of the bridging tractions in mode I delamination

Fiber bridging is regularly encountered in model delamination tests of unidirectional fiber reinforced composites. However, characterization of the bridging tractions is rather difficult. One way to indirectly evaluate the bridging traction distribution is to embed a fiber Bragg grating (FBG) sensor close to the crack tip and to measure the distributed strain along this FBG. The strain measurements from the FBG sensor are used to characterize the fiber bridging tractions by an identification method. In this work, the sensor is embedded in a unidirectional carbon/epoxy composite. Firstly, it is treated as an inclusion near the crack plane and a numerical analysis is performed to study its effect on the measured strain field and energy release rate. The results demonstrate that the sensor, located at about two fiber diameters from the crack plane, has a negligible effect on the fracture process. Secondly, among the identified linear, bilinear, and exponential bridging traction distributions, the exponential one is found to be a suitable model. Characterization of the bridging tractions allows to calculate the energy release due to the bridging fibers G(l)(b) which is similar to the difference between the initiation energy release c, and the propagation value G(l)(p). results also agree with the bridging tractions evaluated from the conventional energy release rate - crack opening displacement method. (C) 2011 Elsevier Ltd. All rights reserved