Computational modeling of laser-induced delamination testing of thin films

Thin film adhesion often determines microelectronic device reliability and it is therefore essential to have experimental techniques that accurately and efficiently characterize it. Laser-induced delamination is a novel technique that uses laser-generated stress waves to load thin films at high strain rates and extract the fracture toughness of the film/substrate interface. The effectiveness of the technique in measuring the interface properties of metallic films has been documented in previous studies. The objective of the current effort is to model the effect of residual stresses on the dynamic delamination of thin films. Residual stresses can be high enough to affect the crack advance and the mode mixity of the delimitation event, and must therefore be adequately modeled to make accurate and repeatable predictions of fracture toughness. The equivalent axial force and bending moment generated by the residual stresses are included in a dynamic, nonlinear finite element model of the delaminating film, and the impact of residual stresses on the final extent of the interfacial crack, the relative contribution of shear failure, and the deformed shape of the delaminated film is studied in detail. Another objective of the study is to develop techniques to address issues related to the testing of polymeric films. These type of films adhere well to silicon and the resulting crack advance is often much smaller than for metallic films, making the extraction of the interface fracture toughness more difficult. The use of an inertial layer which enhances the amount of kinetic energy trapped in the film and thus the crack advance is examined. It is determined that the inertial layer does improve the crack advance, although in a relatively limited fashion. The high interface toughness of polymer films often causes the film to fail cohesively when the crack front leaves the weakly bonded region and enters the strong interface. The use of a tapered pre-crack region that provides a more gradual transition to the strong interface is examined. The tapered triangular pre-crack geometry is found to be effective in reducing the stresses induced thereby making it an attractive option. We conclude by studying the impact of modifying the pre-crack geometry to enable the testing of multiple polymer films.

Fiber Bragg Gratings Strain Sensors for Railway Applications

Fiber optical sensors have played an important role in applications for monitoring the health of civil infrastructures, such as bridges, oil rigs, and railroads. Due to the reduction in cost of fiber-optic components and systems, fiber optical sensors have been studied extensively for their higher sensitivity, precision and immunity to electrical interference compared to their electrical counterparts. A fiber Bragg grating (FBG) strain sensor has been employed for this study to detect and distinguish normal and lateral loads on rail tracks. A theoretical analysis of the relationship between strain and displacement under vertical and horizontal strains on an aluminum beam has been performed, and the results are in excellent agreement with the measured strain data. Then a single FBG sensor system with erbium-doped fiber amplifier broadband source has been carried out. Force and temperature applied on the system have resulted in changes of 0.05 nm per 50 με and 0.094 nm per 10 oC at the center wavelength of the FBG. Furthermore, a low cost fiber-optic sensor system with a distributed feedback (DFB) laser as the light source has been implemented. We show that it has superior noise and sensitivity performances compared to strain gauge sensors. The design has been extended to accommodate multiple sensors with negligible cross talk. When two cascaded sensors on a rail track section are tested, strain readings of the sensor 20 inches away from the position of applied force decay to one seventh of the data of the sensor at the applied force location. The two FBG sensor systems can detect 1 ton of vertical load with a square wave pattern and 0.1 ton of lateral loads (3 tons and 0.5 ton, respectively, for strain gauges). Moreover, a single FBG sensor has been found capable of detecting and distinguishing lateral and normal strains applied at different frequencies. FBG sensors are promising alternatives to electrical sensors for their high sensitivity,ease of installation, and immunity to electromagnetic interferences.