Development of an in-situ, non-destructive ultrasonic monitoring technique for solder pastes

This paper concerns the use of a non-destructive ultrasonic technique for characterising the rheological properties of solder paste and specifically, the use of through-mode microsecond ultrasonic pulses for evaluation of viscoelastic properties of paste materials at the molecular level. Ultrasonic techniques are a widely used and a reliable form of non-destructive testing of materials. This is because techniques such as ultrasounds while used for testing or monitoring material properties, has offered immense benefits in applications where access to the sample is restricted or when handling the sample for testing could interfere with the monitoring or analysis process. Very often, this would mean that the measurements taken are not a true representation of the behaviour of the material (due to externally incorporated changes into the material's physical state during the removal or testing process). Ultrasonic based techniques are being increasingly used for quality control and production monitoring functions which requires evaluation of the changes in material properties over wide range of industrial applications such as cement paste quality, plastic/polymer extrusion process, dough, and even sugar content in beverage drinks. In addition, ultrasound techniques are of great interest for their capacity to take rapid measurements in systems which are optically opaque. The viscometer and rheometer are two of the most widely used rheological instruments used in industry for monitoring the quality of solder pastes, during the production and packaging stage. One of the potential limitations of viscometer and rheometer based measurements is that the collection and preparation of the solder paste samples can irreversibly alter the structure and flow behaviour of the sample. Hence the measurement may not represent the actual quality of the whole production batch. Secondly, rheological measurements and the interpretation of rheological data is a very technical and time consuming process, which requires professionally trained R&D personnel. It is for these reasons that materials suppliers (who formulate and produce solder pastes) and solder paste consumers (especially, contract electronics manufacturers) are keen to see the development of simple, easy to use and accurate techniques for the theological characterisation of solder pastes. The results from the work show that the technique can be used by R&D personnel involved in paste formulation and manufacture to monitor the batch-to-batch quality and consistency.

In-situ non-destructive ultrasonic rheology technique for monitoring different lead-free solder pastes for surface mount applications

This paper investigates the application of a non-destructive ultrasonic technique for characterising the rheological properties of solder paste through the use of through-mode microsecond ultrasonic pulses for evaluation of viscoelastic properties of lead-free solder paste containing different types of flux. Ultrasonic techniques offer a robust and reliable form of non-destructive testing of materials where access to the sample is restricted or when sample handling can interfere with the monitoring or analysis process due to externally incorporated changes to the material’s physical state or accidental contamination during the removal or testing process. Ultrasonic based techniques are increasingly used for quality control and production monitoring functions which requires evaluation of changes in material properties for a wide range of industrial applications such as cement paste quality, plastic/polymer extrusion process, dough and even sugar content in beverage drinks. In addition, ultrasound techniques are of great interest for their capability to take rapid measurements in systems which are optically opaque. The conventional industry approach for characterising the rheological properties of suspensions during processing/packaging stage is mainly through the use of viscometer and some through the use of rheometer. One of the potential limitations of viscometer and rheometer based measurements is that the collection and preparation of the solder paste samples can irreversibly alter the structure and flow behaviour of the sample. Hence the measurement may not represent the actual quality of the whole production batch. Secondly, rheological measurements and the interpretation of rheological data is a very technical and time consuming process, which requires professionally trained R&D personnel. The ultrasound technique being proposed provides simple, yet accurate and easy to use solution for the in-situ rheological characterisation of solder pastes which will benefit the materials suppliers (who formulate and produce solder pastes) and solder paste consumers (especially, contract electronics manufacturers). The results from the work show that the technique can be used by R&D personnel involved in paste formulation and manufacture to monitor the batch-to-batch quality and consistency.

Ultrasonic location system

Esta tese apresenta um sistema de localização baseado exclusivamente em ultrassons, não necessitando de recorrer a qualquer outra tecnologia. Este sistema de localização foi concebido para poder operar em ambientes onde qualquer outra tecnologia não pode ser utilizada ou o seu uso está condicionado, como são exemplo aplicações subaquáticas ou ambientes hospitalares. O sistema de localização proposto faz uso de uma rede de faróis fixos permitindo que estações móveis se localizem. Devido à necessidade de transmissão de dados e medição de distâncias foi desenvolvido um pulso de ultrassons robusto a ecos que permite realizar ambas as tarefas com sucesso. O sistema de localização permite que as estações móveis se localizem escutando apenas a informação em pulsos de ultrassons enviados pelos faróis usando para tal um algoritmo baseado em diferenças de tempo de chegada. Desta forma a privacidade dos utilizadores é garantida e o sistema torna-se completamente independente do número de utilizadores. Por forma a facilitar a implementação da rede de faróis apenas será necessário determinar manualmente a posição de alguns dos faróis, designados por faróis âncora. Estes irão permitir que os restantes faróis, completamente autónomos, se possam localizar através de um algoritmo iterativo de localização baseado na minimização de uma função de custo. Para que este sistema possa funcionar como previsto será necessário que os faróis possam sincronizar os seus relógios e medir a distância entre eles. Para tal, esta tese propõe um protocolo de sincronização de relógio que permite também obter as medidas de distância entre os faróis trocando somente três mensagens de ultrassons. Adicionalmente, o sistema de localização permite que faróis danificados possam ser substituídos sem comprometer a operabilidade da rede reduzindo a complexidade na manutenção. Para além do mencionado, foi igualmente implementado um simulador de ultrassons para ambientes fechados, o qual provou ser bastante preciso e uma ferramenta de elevado valor para simular o comportamento do sistema de localização sobre condições controladas.

Open source data sensing software for ultrasonic non-invasive temperature estimation

In this paper, an open source solution for measurement of temperature and ultrasonic signals (RF-lines) is proposed. This software is an alternative to the expensive commercial data acquisition software, enabling the user to tune applications to particular acquisition architectures. The collected ultrasonic and temperature signals were used for non-invasive temperature estimation using neural networks. The existence of precise temperature estimators is an essential point aiming at the secure and effective applica tion of thermal therapies in humans. If such estimators exist then effective controllers could be developed for the therapeutic instrumentation. In previous works the time-shift between RF-lines echoes were extracted, and used for creation of neural networks estimators. The obtained estimators successfully represent the temperature in the time-space domain, achieving a maximum absolute error inferior to the threshold value defined for hyperthermia/diathermia applications.

Brillouin spectroscopy : measurement of elastic and photoelastic constants of some alkali holide crystals

The assembly and testing of apparatus for the measurement of elastic and photoelastic constants by Brillouin scattering, using a Fabry-Perot interferometer and with argon ion laser excitation is described. Such measurements are performed on NaCI, KBr and LiF using the A = 488.0 nm laser line. The elastic constants obtained here are in very good agreement with the ultrasonic data for all three materials. The discrepancy between ultrasonic and hypersonic sound velocities which was reported by some authors for KBr and LiF is not confirmed, and the elastic constants obtained for LiF are the most accurate to date. Also, the present photoelastic constants are in good agreement with the data obtained by ultrasonic techniques for all three crystals. The results for the KBr and LiF crystals constitute the first set of photoelastic constants obtained for these materials by Brillouin spectroscopy. Our results for LiF are the best available to date.

Anisotropy in elastic properties of lithium sodium sulphate hexahydrate single crystal—An ultrasonic study

The double sulfate family (ABSO4), where A and B are alkali metal cations, is the object of great interest owing to the complexity and richness of its sequence of phase transition induced by temperature variation. A new sulfate salt characterized by the presence of water molecule in the unit cell with the chemical formula, Li2Na3(SO4)2⋅6H2O (LSSW), was obtained. The ultrasonic velocity measurement was done with pulse echo overlap technique [PEO]. All the six second order elastic stiffness constants, C11 = C22, C33, C44 = C55, C12, C14 and C13 = C23 are reported for the first time. The anisotropy in the elastic properties of the crystal are well explained by the pictorial representation of the polar plots of phase velocity, slowness, Young’s modulus and linear compressibility in a–b and a–c planes.

Proposed design for an ultrasonic optical force-feedback microphone

We discuss a novel approach that would lead to the development of an ultrasonic optical force-feedback measurement microphone.

Robust video/ultrasonic fusion-based estimation for automotive applications

In this paper, we use recently developed robust estimation ideas to improve object tracking by a stationary or nonstationary camera. Large uncertainties are always present in vision-based systems, particularly, in relation to the estimation of the initial state as well as the measurement of object motion. The robustness of these systems can be significantly improved by employing a robust extended Kalman filter (REKF). The system performance can also be enhanced by increasing the spatial diversity in measurements via employing additional cameras for video capture. We compare the performances of various image segmentation techniques in moving-object localization and show that normal-flow-based segmentation yields comparable results to, but requires significantly less time than, optical-flow-based segmentation. We also demonstrate with simulations that dynamic system modeling coupled with the application of an REKF significantly improves the estimation system performance, particularly, when subjected to large uncertainties.

Computer aided ultrasonic thickness strain analysis of automotive sheet metal stampings using FEA information

This paper discusses a computer-aided methodology for thickness strain analysis (TSA) of sheet metal stampings using geometry and strain information that is extracted from finite element analysis (FEA) results. The system utilises both FEA results and an ultrasonic gauge capability expert system to assist press shop personnel, providing them with capabilities such as optimum measurement point location and an estimate of gauge error. Key advantages of this enhanced TSA methodology are related to overall efficiency and accuracy gains.

Viscosity measuring cell using ultrasonic wave mode conversion

This work presents a cell to measure dynamic viscosity of liquids using ultrasonic wave mode conversion from longitudinal to shear wave. The strategy used to obtain the viscosity is based on the measurement of the complex reflection coefficient of shear waves at a solid-liquid interface. Viscosity measurements of automotive oils (SAE90 and SAE140) were obtained in the frequency range from 1 to 10 MHz. These results are compared with the Maxwell model with two relaxation times, showing the dependency of viscosity with frequency. Several parameters affecting viscosity measurements, including the solid material properties, liquid viscosity, and operating frequency are discussed.

Ultrasonic densitometer using a multiple reflection technique

This work presents recent improvements in a density measurement cell with a double-element transducer that can eliminate diffraction effects. A new mechanical design combined with the use of more appropriate materials has resulted in better parallelism between interfaces, more robust assembly, and chemical resistance. A novel method of signal processing, named energy method, is introduced to obtain the reflection coefficient, reducing sensitivity to noise and improving accuracy. The measurement cell operation is verified both theoretically, using an acoustic wave propagation model, and experimentally, using homogeneous liquids with different densities. The accuracy in the density measurement is 0.2% when compared with the measurements made with a pycnometer.

Ultrasonic material characterization using large-aperture PVDF receivers

This work describes the use of a large-aperture PVDF receiver in the measurement of liquid density and composite material elastic constants. The density measurement of several liquids is obtained with accuracy of 0.2% using a conventional NDE emitter transducer and a 70-mm-diameter, 52-mu m P(VDF-TrFE) membrane with gold electrodes. The determination of the elastic constants is based on the phase velocity measurement. Diffraction can lead to errors around 1% in velocity measurement when using alternatively the conventional pair of ultrasonic transducers (1-MHz frequency and 19-mm-diameter) operating in through-transmission mode, separated by a distance of 100 mm. This effect is negligible when using a pair of 10-MHz, 19-mm-diameter transducers. Nevertheless, the dispersion at 10 MHz can result in errors of about 0.5%, when measuring the velocity in composite materials. The use of an 80-mm diameter, 52-mu m-thick PVDF membrane receiver practically eliminates the diffraction effects in phase velocity measurement. The elastic constants of a carbon fiber reinforced polymer were determined and compared with the values obtained by a tensile test. (C) 2009 Elsevier B. V. All rights reserved.

Viscosity measurement of Newtonian liquids using the complex reflection coefficient

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Energy method to calculate the density of liquids using ultrasonic reflection techniques

In this work it is introduced a new approach to calculate the density of liquids in terms of the energies of the acoustic signals. This method is compared to other methods in the time domain (peak-to-peak amplitudes) and frequency domain magnitudes at a single frequency. It is used a measurement cell based on a multiple reflection technique, and it is developed an acoustic model for the cell. Simulations and experiments using several liquids are presented, showing that the energy method a less sensitive to noise than the other techniques. The relative errors in the density are smaller than 0.2% when compared to the values measured with a pycnometer.

Thermodynamic response of an ultrasonic densitometer

An ultrasonic densitometer is experimentally characterized as a function of temperature. The measurement of propagation velocity and density of several liquids is performed in the 15 to 40°C temperature range. Results are compared to tabulated values in the case of distilled water, showing accuracy of 0.07% for the propagation velocity. Density values are compared to those obtained with a pycnometer, showing 0.2% accuracy in density measurement for stabilized temperature and 0.4% under thermal gradient conditions.