Study of the brittle fracture of monocrystalline silicon wafers

There is a growing trend towards using thinner wafers in order to reduce the costs of solar energy. But the current tools employed during the solar cells production are not prepared to work with thinner wafers, decreasing the industrial yield due to the high number of wafers broken. To develop new tools, or modify existing ones, the mechanical properties have to be determined. This paper tackles an experimental study of the mechanical properties of wafers. First, the material characteristics are detailed and the process to obtain wafers is presented. Then, the complete test setup and the mechanical strength results interpreted by a described numerical model are shown.

Fracture strength of drilled wafers: study of the stress concentration factor and determination of the weibull distribution of the fracture stress

In the photovoltaic field, the back contact solar cells technology has appeared as an alternative to the traditional silicon modules. This new type of cells places both positive and negative contacts on the back side of the cells maximizing the exposed surface to the light and making easier the interconnection of the cells in the module. The Emitter Wrap-Through solar cell structure presents thousands of tiny holes to wrap the emitter from the front surface to the rear surface. These holes are made in a first step over the silicon wafers by means of a laser drilling process. This step is quite harmful from a mechanical point of view since holes act as stress concentrators leading to a reduction in the strength of these wafers. This paper presents the results of the strength characterization of drilled wafers. The study is carried out testing the samples with the ring on ring device. Finite Element models are developed to simulate the tests. The stress concentration factor of the drilled wafers under this load conditions is determined from the FE analysis. Moreover, the material strength is characterized fitting the fracture stress of the samples to a three-parameter Weibull cumulative distribution function. The parameters obtained are compared with the ones obtained in the analysis of a set of samples without holes to validate the method employed for the study of the strength of silicon drilled wafers.

A fracture model for pearlitic steel bars using a cohesive model

The fracture of ductile materials, such as metals, is usually explained with the theory of nucleation, growth and coalescence of microvoids. Based on this theory, many numerical models have been developed, with a special mention to Gurson-type models. These models simulate mathematically the physical growth of microvoids, leading to a progressive development of the internal damage that takes place during a tensile test. In these models, the damage starts to develop in very early stages of the test. Tests carried out by the authors suggest that, in the case of some eutectoid steels such as those used for manufacturing prestressing steel wires, the internal damage that takes place as a result of the growth of microvoids is only noticeable in very late stages of the tensile test. In the authors’ opinion, using a cohesive model as a failure criterion may be interesting in this case; a cohesive model only requires two parameters to be defined, with the fracture energy being one of them, which can be obtained experimentally. In addition to this, given that it is known that the stress triaxiality has a strong influence on the fracture of ductile materials, a cohesive model whose parameters are affected by the value of the stress triaxiality can be considered. This work presents a fracture model for steel specimens in a tensile test, based on a cohesive behaviour and taking into account the effect of stress triaxiality, which is different at each point of the fracture plane.

Fracture behaviour of notched round bars made of PMMA subjected to torsion at -60 °C

This paper presents seventy new experimental results from PMMA notched specimens tested under torsion at 60 C. The notch root radius ranges from 0.025 to 7.0 mm. At this temperature the non-linear effects previously observed on specimens of the same material tested at room temperature strongly reduce. The averaged value of the strain energy density over a control volume is used to assess the critical loads to failure. The radius of the control volume and the critical strain energy density are evaluated a priori by using in combination the mode III critical stress intensity factor from cracked-like specimens and the critical stress to failure detected from semicircular notches with a large notch root radius

Experimental validation of a fracture model for pearlitic steel bars based on the cohesive zone model

Congreso internacional celebrado en Praga sobre modelos numéricos de fractura en el campo de la ciencia de materiales y estructuras.

Effect of Stress Level on the High Temperature Deformation and Fracture Mechanisms of Ti-45Al-2Nb-2Mn-0.8 vol. pct TiB2: An In Situ Experimental Study

The effect of the applied stress on the deformation and crack nucleation and propagation mechanisms of a c-TiAl intermetallic alloy (Ti-45Al-2Nb-2Mn (at. pct)-0.8 vol. pct TiB2) was examined by means of in situ tensile (constant strain rate) and tensile-creep (constant load) experiments performed at 973 K (700 �C) using a scanning electron microscope. Colony boundary cracking developed during the secondary stage in creep tests at 300 and 400 MPa and during the tertiary stage of the creep tests performed at higher stresses. Colony boundary cracking was also observed in the constant strain rate tensile test. Interlamellar ledges were only found during the tensile-creep tests at high stresses (r>400 MPa) and during the constant strain rate tensile test. Quantitative measurements of the nature of the crack propagation path along secondary cracks and along the primary crack indicated that colony boundaries were preferential sites for crack propagation under all the conditions investigated. The frequency of interlamellar cracking increased with stress, but this fracture mechanism was always of secondary importance. Translamellar cracking was only observed along the primary crack.

Determination of the hoop fracture properties of unirradiated hydrogen-charged nuclear fuel cladding from ring compression tests

In this work, a new methodology is devised to obtain the fracture properties of nuclear fuel cladding in the hoop direction. The proposed method combines ring compression tests and a finite element method that includes a damage model based on cohesive crack theory, applied to unirradiated hydrogen-charged ZIRLOTM nuclear fuel cladding. Samples with hydrogen concentrations from 0 to 2000 ppm were tested at 20 �C. Agreement between the finite element simulations and the experimental results is excellent in all cases. The parameters of the cohesive crack model are obtained from the simulations, with the fracture energy and fracture toughness being calculated in turn. The evolution of fracture toughness in the hoop direction with the hydrogen concentration (up to 2000 ppm) is reported for the first time for ZIRLOTM cladding. Additionally, the fracture micromechanisms are examined as a function of the hydrogen concentration. In the as-received samples, the micromechanism is the nucleation, growth and coalescence of voids, whereas in the samples with 2000 ppm, a combination of cuasicleavage and plastic deformation, along with secondary microcracking is observed.

Experimental validation of a fracture model for pearlitic steel bars based on the cohesive zone model

Steel is, together with concrete, the most widely used material in civil engineering works. Not only its high strength, but also its ductility is of special interest, since it allows for more energy to be stored before failure. A better understanding of the material behaviour before failure may lead to better structural safety strategies.

Finite element simulation of sandwich panels of laminated plaster and rockwool under mixed mode fracture

Sandwich panels of laminated gypsum and rock wool have shown large pathology of cracking due to excessive slabs deflection. Currently the most widespread use of this material is as vertical elements of division or partition, with no structural function, what justifies that there are no studies on the mechanism of fracture and mechanical properties related to it. Therefore, and in order to reduce the cracking problem, it is necessary to progress in the simulation and prediction of the behaviour under tensile and shear load of such panels, although in typical applications have no structural responsability.

Fracture micromechanisms and residual stresses of a highly resistant duplex stainless steel

The paper presents some preliminary results of an ongoing research intended to qualify a highly resistant duplex stainless steel wire as prestressing steel and, gets on insight on (he wires' fracture micromechanism and residual stresses field. SEM fractographic analysis of the stainless steel wires indicates an anisotropic fracture behavior in tension, in presence of surface flaws, attributed to the residual stresses generated through the fabrication process. The residual stresses magnitude influences the damage tolerance, its knowledge being a key issue in designating/qualifying the wires as prestressing steels.

Finite element simulation of sandwich panels of plasterboard and rock wool under mixed mode fracture

This paper presents the results of research on mixed mode fracture of sandwich panels of plasterboard and rock wool. The experimental data of the performed tests are supplied. The specimens were made from commercial panels. Asymmetrical three-point bending tests were performed on notched specimens. Three sizes of geometrically similar specimens were tested for studying the size effect. The paper also includes the numerical simulation of the experimental results by using an embedded cohesive crack model.The involved parameters for modelling are previously measured by standardised tests.

Fracture of concrete structural members subjected to blast

If reinforced concrete structures are to be safe under extreme impulsive loadings such as explosions, a broad understanding of the fracture mechanics of concrete under such events is needed. Most buildings and infrastructures which are likely to be subjected to terrorist attacks are borne by a reinforced concrete (RC) structure. Up to some years ago, the traditional method used to study the ability of RC structures to withstand explosions consisted on a choice between handmade calculations, affordable but inaccurate and unreliable, and full scale experimental tests involving explosions, expensive and not available for many civil institutions. In this context, during the last years numerical simulations have arisen as the most effective method to analyze structures under such events. However, for accurate numerical simulations, reliable constitutive models are needed. Assuming that failure of concrete elements subjected to blast is primarily governed by the tensile behavior, a constitutive model has been built that accounts only for failure under tension while it behaves as elastic without failure under compression. Failure under tension is based on the Cohesive Crack Model. Moreover, the constitutive model has been used to simulate the experimental structural response of reinforced concrete slabs subjected to blast. The results of the numerical simulations with the aforementioned constitutive model show its ability of representing accurately the structural response of the RC elements under study. The simplicity of the model, which does not account for failure under compression, as already mentioned, confirms that the ability of reinforced concrete structures to withstand blast loads is primarily governed by tensile strength.

Fracture micromechanisms and residual stresses of a highly resistant duplex stainless steel

The paper presents some preliminary results of an ongoing research intended to qualify a highly resistant duplex stainless steel wire as prestressing steel and, gets on insight on (he wires' fracture micromechanism and residual stresses field. SEM fractographic analysis of the stainless steel wires indicates an anisotropic fracture behavior in tension, in presence of surface flaws, attributed to the residual stresses generated through the fabrication process. The residual stresses magnitude influences the damage tolerance, its knowledge being a key issue in designating/qualifying the wires as prestressing steels.

Post-fracture behavior of laminated plates after human impact test

For safety barriers the load bearing capacity of the glass when subjected to the soft body impact should be verified. The soft body pendulum test became a testing standard to classify safety glass plates. The classification of the safety glass do not consider the structural behavior when one sheet of a laminated glass is broken; in situations when the replacement of the plate could not be very urgent, structural behavior should be evaluated. The main objective of this paper is to present the structural behavior o laminated glass plates, though modal test and human impact test, including the post fracture behavior for the laminated cases. A god reproducibility and repeatability is obtained. Two main aspects of the structural behavior can be observed: the increment of the rupture load for laminated plates after the failure of the first sheet, and some similarities with a tempered monolithic behavior of equivalent thickness.

On the loading-rate dependence of the Al 7017-T73 fracture-initiation toughness

While static fracture toughness is a widely studied and standardised parameter, its dynamic counterpart has not been exhaustively examined. Therefore, in this research a series of quasi-static and different loading-rate dynamic tests were carried out to determine the evolution of fracture toughness with the velocity of the application of the load on aluminium 7017-T73 alloy. Three-point bending tests of pre-fatigued standard specimens (ASTM E399) at four loading-rates were carried out. The experiments were conducted by employing the subsequent apparatus ordered from lowest to highest load application velocity: a servo-hydraulic universal testing machine, a free-drop tower, a modified Split Hopkinson Pressure Bar and an explosive load testing device. In order to perform the dynamic fracture toughness tests, it was necessary to design and develop some experimental devices. The fracture-initiation toughness of the aluminium 7017-T73 alloy did not exhibit a significant variation for the studied cases. As a conclusion, the research showed that fracture-initiation toughness remained constant regardless of the velocity at which the load was applied.