Incorporation of Interfacial Intermetallic Morphology in Fracture Mechanism Map for Sn-Ag-Cu Solder Joints

A fracture mechanism map (FMM) is a powerful tool which correlates the fracture behavior of a material to its microstructural characteristics in an explicit and convenient way. In the FMM for solder joints, an effective thickness of the interfacial intermetallic compound (IMC) layer (t (eff)) and the solder yield strength (sigma (ys,eff)) are used as abscissa and ordinate axes, respectively, as these two predominantly affect the fracture behavior of solder joints. Earlier, a definition of t (eff), based on the uniform thickness of IMC (t (u)) and the average height of the IMC scallops (t (s)), was proposed and shown to aptly explain the fracture behavior of solder joints on Cu. This paper presents a more general definition of t (eff) that is more widely applicable to a range of metallizations, including Cu and electroless nickel immersion gold (ENIG). Using this new definition of t (eff), mode I FMM for SAC387/Cu joints has been updated and its validity was confirmed. A preliminary FMM for SAC387/Cu joints with ENIG metallization is also presented.

Experimental Investigation on Switching Characteristics of High-Current Insulated Gate Bipolar Transistors at Low Currents

Insulated gate bipolar transistors (IGBTs) are used in high-power voltage-source converters rated up to hundreds of kilowatts or even a few megawatts. Knowledge of device switching characteristics is required for reliable design and operation of the converters. Switching characteristics are studied widely at high current levels, and corresponding data are available in datasheets. But the devices in a converter also switch low currents close to the zero crossings of the line currents. Further, the switching behaviour under these conditions could significantly influence the output waveform quality including zero crossover distortion. Hence, the switching characteristics of high-current IGBTs (300-A and 75-A IGBT modules) at low load current magnitudes are investigated experimentally in this paper. The collector current, gate-emitter voltage and collector-emitter voltage are measured at various low values of current (less than 10% of the device rated current). A specially designed in-house constructed coaxial current transformer (CCT) is used for device current measurement without increasing the loop inductance in the power circuit. Experimental results show that the device voltage rise time increases significantly during turn-off transitions at low currents.

Effects of Microstructure and Loading on Fracture of Sn-3.8Ag-0.7Cu Joints on Cu Substrates with ENIG Surface Finish

When dropped, electronic packages often undergo failure by propagation of an interfacial crack in solder joints under a combination of tensile and shear loading. Hence, it is crucial to understand and predict the fracture behavior of solder joints under mixed-mode high-rate loading conditions. In this work, the effects of the loading conditions (strain rate and loading angle) and microstructure interfacial intermetallic compound (IMC) morphology and solder yield strength] on the mixed-mode fracture toughness of Sn-3.8 wt.%Ag-0.7 wt.%Cu solder joints sandwiched between two Cu substrates with electroless nickel immersion gold (ENIG) metallization have been studied, and compared with the fracture behavior of joints attached to bare Cu. Irrespective of the surface finish, the fracture toughness of the solder joints decreased monotonically with strain rate and mode-mixity, both resulting in increased fracture proportion through the interfacial IMC layer. Furthermore, the proportion of crack propagation through the interfacial IMC layer increased with increase in the thickness and the roughness of the interfacial IMC layer and the yield strength of the solder, resulting in a decrease in the fracture toughness of the joint. However, under most conditions, solder joints with ENIG finish showed higher resistance to fracture than joints attached directly to Cu substrates without ENIG metallization. Based on the experimental observations, a fracture mechanism map is constructed correlating the yield strength of the solder, the morphology and thickness of the interfacial IMC, and the fracture mechanisms as well as the fracture toughness values for different solder joints under mode I loading.

A general methodology for calculating mixed mode stress intensity factors and fracture toughness of solder joints with interfacial cracks

Solder joints in electronic packages undergo thermo-mechanical cycling, resulting in nucleation of micro-cracks, especially at the solder/bond-pad interface, which may lead to fracture of the joints. The fracture toughness of a solder joint depends on material properties, process conditions and service history, as well as strain rate and mode-mixity. This paper reports on a methodology for determining the mixed-mode fracture toughness of solder joints with an interfacial starter-crack, using a modified compact mixed mode (CMM) specimen containing an adhesive joint. Expressions for stress intensity factor (K) and strain energy release rate (G) are developed, using a combination of experiments and finite element (FE) analysis. In this methodology, crack length dependent geometry factors to convert for the modified CMM sample are first obtained via the crack-tip opening displacement (CTOD)-based linear extrapolation method to calculate the under far-field mode I and II conditions (f(1a) and f(2a)), (ii) generation of a master-plot to determine a(c), and (iii) computation of K and G to analyze the fracture behavior of joints. The developed methodology was verified using J-integral calculations, and was also used to calculate experimental fracture toughness values of a few lead-free solder-Cu joints. (C) 2014 Elsevier Ltd. All rights reserved.

Experimental Investigation on Switching Characteristics of High-Current Insulated Gate Bipolar Transistors at Low Currents

Insulated gate bipolar transistors (IGBTs) are used in high-power voltage-source converters rated up to hundreds of kilowatts or even a few megawatts. Knowledge of device switching characteristics is required for reliable design and operation of the converters. Switching characteristics are studied widely at high current levels, and corresponding data are available in datasheets. But the devices in a converter also switch low currents close to the zero crossings of the line currents. Further, the switching behaviour under these conditions could significantly influence the output waveform quality including zero crossover distortion. Hence, the switching characteristics of high-current IGBTs (300-A and 75-A IGBT modules) at low load current magnitudes are investigated experimentally in this paper. The collector current, gate-emitter voltage and collector-emitter voltage are measured at various low values of current (less than 10% of the device rated current). A specially designed in-house constructed coaxial current transformer (CCT) is used for device current measurement without increasing the loop inductance in the power circuit. Experimental results show that the device voltage rise time increases significantly during turn-off transitions at low currents.

Study of Degradation in Composite Lap Shear joints using a Guided Wave Technique

Experimental and numerical investigations were carried out using lamb waves to study the degradation in adhesive joints made of carbon fiber reinforced plastic (CFRP) adherends and epoxy adhesive. Degradation was inducted into the epoxy adhesive by adding different amounts of polyvinyl alcohol. Fundamental lamb wave modes were excited in the CFRP adherends using piezoelectric transducer disks and made to propagate through the adhesive layer. The received waveforms across adhesive joints with varied degradation were studied. A 2D finite element model was utilized to verify the experimental results. Good correlation was observed between numerical and experimental results. Details of the investigation and results obtained are presented in the paper.

MHD Flow of a 2nd Grade Fluid in an Orthogonal Rheometer

The magnetohydrodynamics (MHD) flow of a conducting, homogeneous incompressible Rivlin-Ericksen fluid of second grade contained between two infinite, parallel, insulated disks rotating with the same angular velocity about two noncoincident axes, under the application of a uniform transverse magnetic field, is investigated. This model represents the MHD flow of the fluid in the instrument called an orthogonal rheometer, except for the fact that in the rheometer the rotating plates are necessarily finite. An exact solution of the governing equations of motion is presented. The force components in the x and y directions on the disks are calculated. The effects of magnetic field and the viscoelastic parameter on the forces are discussed in detail.

Analysis of a finite composite plate with smooth rigid pin

A continuum method of analysis is presented in this paper for the problem of a smooth rigid pin in a finite composite plate subjected to uniaxial loading. The pin could be of interference, push or clearance fit. The plate is idealized to an orthotropic sheet. As the load on the plate is progressively increased, the contact along the pin-hole interface is partial above certain load levels in all three types of fit. In misfit pins (interference or clearance), such situations result in mixed boundary value problems with moving boundaries and in all of them the arc of contact and the stress and displacement fields vary nonlinearly with the applied load. In infinite domains similar problems were analysed earlier by ‘inverse formulation’ and, now, the same approach is selected for finite plates. Finite outer domains introduce analytical complexities in the satisfaction of boundary conditions. These problems are circumvented by adopting a method in which the successive integrals of boundary error functions are equated to zero. Numerical results are presented which bring out the effects of the rectangular geometry and the orthotropic property of the plate. The present solutions are the first step towards the development of special finite elements for fastener joints.

A Newton-Euler formulation for the inverse dynamics of the Stewart platform manipulator

This paper presents an inverse dynamic formulation by the Newton–Euler approach for the Stewart platform manipulator of the most general architecture and models all the dynamic and gravity effects as well as the viscous friction at the joints. It is shown that a proper elimination procedure results in a remarkably economical and fast algorithm for the solution of actuator forces, which makes the method quite suitable for on-line control purposes. In addition, the parallelism inherent in the manipulator and in the modelling makes the algorithm quite efficient in a parallel computing environment, where it can be made as fast as the corresponding formulation for the 6-dof serial manipulator. The formulation has been implemented in a program and has been used for a few trajectories planned for a test manipulator. Results of simulation presented in the paper reveal the nature of the variation of actuator forces in the Stewart platform and justify the dynamic modelling for control.

Spinup or spindown of a rotating electrically conducting fluid in a magnetic field

The hydromagnetic spinup or spindown of an incompressible, rotating, electrically conducting fluid over an infinite insulated disk with an applied magnetic field is studied when the impulsive motion is imparted either to the fluid or to the disk. The nonlinear partial differential equations governing the flow are solved numerically using an implicit finite-difference scheme. It is found that the spinup (or spindown) time due to impulsive motion of the disk is much shorter than the spinup (or spindown) time due to the impulsive motion of the distant fluid. The spinup (or spindown) time for the hydromagnetic case is comparatively smaller than the corresponding nonmagnetic case. Spindown is not merely a mirror reflection of spinup. Physics of Fluids is copyrighted by The American Institute of Physics.

Photoelastic studies on progress of separation in interference fits

Interference fits are used extensively in aircraft structural joints because of their improved fatigue performance. Recent advances in analysis of these joints have increased understanding of the nonlinear load-contact and load-interfacial slip variations in these joints. Experimental work in these problems is lacking due to difficulties in determining partial contact and partial slip along the pin-hole interface. In this paper, an experimental procedure is enumerated for determining load-contact relations in interference/clearance fits, using photoelastic models and applying a technique for detecting progress of separation/contact up to predetermined locations. The study incorporates a detailed procedure for model making, controlling interference, locating break of contact up to known locations around the interface, estimating optically the degree of interference, determining interfacial friction and evaluating stresses in the sheet. Experiments, simulating joints in large sheets, were carried out under both pin and plate loads. The present studies provide load-separation behavior in interference joint with finite interfacial friction.

A comprehensive study of interference and clearance fit pins in large plates

Pin joints in structures are designed for interference, push or clearance fits. That is, the diameter of the pin is made greater than, equal to or less than the hole diameter. Consider an interference fit pin in a plate subjected to a continuously increasing in-plane load.

A constraint Jacobian based approach for static analysis of pantograph masts

This paper presents a constraint Jacobian matrix based approach to obtain the stiffness matrix of widely used deployable pantograph masts with scissor-like elements (SLE). The stiffness matrix is obtained in symbolic form and the results obtained agree with those obtained with the force and displacement methods available in literature. Additional advantages of this approach are that the mobility of a mast can be evaluated, redundant links and joints in the mast can be identified and practical masts with revolute joints can be analysed. Simulations for a hexagonal mast and an assembly with four hexagonal masts is presented as illustrations.

A real-time algorithm for simulation of flexible objects and hyper-redundant manipulators

Flexible objects such as a rope or snake move in a way such that their axial length remains almost constant. To simulate the motion of such an object, one strategy is to discretize the object into large number of small rigid links connected by joints. However, the resulting discretised system is highly redundant and the joint rotations for a desired Cartesian motion of any point on the object cannot be solved uniquely. In this paper, we revisit an algorithm, based on the classical tractrix curve, to resolve the redundancy in such hyper-redundant systems. For a desired motion of the `head' of a link, the `tail' is moved along a tractrix, and recursively all links of the discretised objects are moved along different tractrix curves. The algorithm is illustrated by simulations of a moving snake, tying of knots with a rope and a solution of the inverse kinematics of a planar hyper-redundant manipulator. The simulations show that the tractrix based algorithm leads to a more `natural' motion since the motion is distributed uniformly along the entire object with the displacements diminishing from the `head' to the `tail'.

Investigations on voltages and currents in the lightning protection system of the Indian satellite launch pad-I during a stroke interception

A reliable protection against direct lightning hit is very essential for satellite launch pads. In view of this, suitable protection systems are generally employed. The evaluation of efficacy of the lightning protection schemes among others requires an accurate knowledge of the consequential potential rise at the struck point and the current injected into soil at the earth termination. The present work has made a detailed effort to deduce these quantities for the lightning protection scheme of the Indian satellite launch pad-I. A reduced scale model of the system with a frequency domain approach is employed for the experimental study. For further validation of the experimental approach, numerical simulations using numerical electromagnetic code-2 are also carried out on schemes involving single tower. The study results on the protection system show that the present design is quite safe with regard to top potential rise. It is shown that by connecting ground wires to the tower, its base current and, hence, the soil potential rise can be reduced. An evaluation of an alternate design philosophy involving insulated mast scheme is also made. The potential rise in that design is quantified and the possibility of a flashover to supporting tower is briefly looked into. The supporting tower is shown to have significant induced currents.