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- All Subjects: engineering
- All Subjects: Characterization
- Creators: Goryll, Michael
- Creators: Jiao, Yang
Description
Increasing density of microelectronic packages, results in an increase in thermal and mechanical stresses within the various layers of the package. To accommodate the high-performance demands, the materials used in the electronic package would also require improvement. Specifically, the damage that often occurs in solders that function as die-attachment and thermal interfaces need to be addressed. This work evaluates and characterizes thermo-mechanical damage in two material systems – Electroplated Tin and Sintered Nano-Silver solder.
Tin plated electrical contacts are prone to formation of single crystalline tin whiskers which can cause short circuiting. A mechanistic model of their formation, evolution and microstructural influence is still not fully understood. In this work, growth of mechanically induced tin whiskers/hillocks is studied using in situ Nano-indentation and Electron Backscatter Diffraction (EBSD). Electroplated tin was indented and monitored in vacuum to study growth of hillocks without the influence of atmosphere. Thermal aging was done to study the effect of intermetallic compounds. Grain orientation of the hillocks and the plastically deformed region surrounding the indent was studied using Focused Ion Beam (FIB) lift-out technique. In addition, micropillars were milled on the surface of electroplated Sn using FIB to evaluate the yield strength and its relation to Sn grain size.
High operating temperature power electronics use wide band-gap semiconductor devices (Silicon Carbide/Gallium Nitride). The operating temperature of these devices can exceed 250oC, preventing use of traditional Sn-solders as Thermal Interface materials (TIM). At high temperature, the thermomechanical stresses can severely degrade the reliability and life of the device. In this light, new non-destructive approach is needed to understand the damage mechanism when subjected to reliability tests such as thermal cycling. In this work, sintered nano-Silver was identified as a promising high temperature TIM. Sintered nano-Silver samples were fabricated and their shear strength was evaluated. Thermal cycling tests were conducted and damage evolution was characterized using a lab scale 3D X-ray system to periodically assess changes in the microstructure such as cracks, voids, and porosity in the TIM layer. The evolution of microstructure and the effect of cycling temperature during thermal cycling are discussed.
Tin plated electrical contacts are prone to formation of single crystalline tin whiskers which can cause short circuiting. A mechanistic model of their formation, evolution and microstructural influence is still not fully understood. In this work, growth of mechanically induced tin whiskers/hillocks is studied using in situ Nano-indentation and Electron Backscatter Diffraction (EBSD). Electroplated tin was indented and monitored in vacuum to study growth of hillocks without the influence of atmosphere. Thermal aging was done to study the effect of intermetallic compounds. Grain orientation of the hillocks and the plastically deformed region surrounding the indent was studied using Focused Ion Beam (FIB) lift-out technique. In addition, micropillars were milled on the surface of electroplated Sn using FIB to evaluate the yield strength and its relation to Sn grain size.
High operating temperature power electronics use wide band-gap semiconductor devices (Silicon Carbide/Gallium Nitride). The operating temperature of these devices can exceed 250oC, preventing use of traditional Sn-solders as Thermal Interface materials (TIM). At high temperature, the thermomechanical stresses can severely degrade the reliability and life of the device. In this light, new non-destructive approach is needed to understand the damage mechanism when subjected to reliability tests such as thermal cycling. In this work, sintered nano-Silver was identified as a promising high temperature TIM. Sintered nano-Silver samples were fabricated and their shear strength was evaluated. Thermal cycling tests were conducted and damage evolution was characterized using a lab scale 3D X-ray system to periodically assess changes in the microstructure such as cracks, voids, and porosity in the TIM layer. The evolution of microstructure and the effect of cycling temperature during thermal cycling are discussed.
ContributorsLujan Regalado, Irene (Author) / Chawla, Nikhilesh (Thesis advisor) / Frear, Darrel (Committee member) / Rajagopalan, Jagannathan (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2018
Description
A hybrid molecular dynamics (MD) simulation framework is developed to emulate mechanochemical reaction of mechanophores in epoxy-based nanocomposites. Two different force fields, a classical force field and a bond order based force field are hybridized to mimic the experimental processes from specimen preparation to mechanical loading test. Ultra-violet photodimerization for mechanophore synthesis and epoxy curing for thermoset polymer generation are successfully simulated by developing a numerical covalent bond generation method using the classical force field within the framework. Mechanical loading tests to activate mechanophores are also virtually conducted by deforming the volume of a simulation unit cell. The unit cell deformation leads to covalent bond elongation and subsequent bond breakage, which is captured using the bond order based force field. The outcome of the virtual loading test is used for local work analysis, which enables a quantitative study of mechanophore activation. Through the local work analysis, the onset and evolution of mechanophore activation indicating damage initiation and propagation are estimated; ultimately, the mechanophore sensitivity to external stress is evaluated. The virtual loading tests also provide accurate estimations of mechanical properties such as elastic, shear, bulk modulus, yield strain/strength, and Poisson’s ratio of the system. Experimental studies are performed in conjunction with the simulation work to validate the hybrid MD simulation framework. Less than 2% error in estimations of glass transition temperature (Tg) is observed with experimentally measured Tgs by use of differential scanning calorimetry. Virtual loading tests successfully reproduce the stress-strain curve capturing the effect of mechanophore inclusion on mechanical properties of epoxy polymer; comparable changes in Young’s modulus and yield strength are observed in experiments and simulations. Early damage signal detection, which is identified in experiments by observing increased intensity before the yield strain, is captured in simulations by showing that the critical strain representing the onset of the mechanophore activation occurs before the estimated yield strain. It is anticipated that the experimentally validated hybrid MD framework presented in this dissertation will provide a low-cost alternative to additional experiments that are required for optimizing material design parameters to improve damage sensing capability and mechanical properties.
In addition to the study of mechanochemical reaction analysis, an atomistic model of interphase in carbon fiber reinforced composites is developed. Physical entanglement between semi-crystalline carbon fiber surface and polymer matrix is captured by introducing voids in multiple graphene layers, which allow polymer matrix to intertwine with graphene layers. The hybrid MD framework is used with some modifications to estimate interphase properties that include the effect of the physical entanglement. The results are compared with existing carbon fiber surface models that assume that carbon fiber has a crystalline structure and hence are unable to capture the physical entanglement. Results indicate that the current model shows larger stress gradients across the material interphase. These large stress gradients increase the viscoplasticity and damage effects at the interphase. The results are important for improved prediction of the nonlinear response and damage evolution in composite materials.
In addition to the study of mechanochemical reaction analysis, an atomistic model of interphase in carbon fiber reinforced composites is developed. Physical entanglement between semi-crystalline carbon fiber surface and polymer matrix is captured by introducing voids in multiple graphene layers, which allow polymer matrix to intertwine with graphene layers. The hybrid MD framework is used with some modifications to estimate interphase properties that include the effect of the physical entanglement. The results are compared with existing carbon fiber surface models that assume that carbon fiber has a crystalline structure and hence are unable to capture the physical entanglement. Results indicate that the current model shows larger stress gradients across the material interphase. These large stress gradients increase the viscoplasticity and damage effects at the interphase. The results are important for improved prediction of the nonlinear response and damage evolution in composite materials.
ContributorsKoo, Bonsung (Author) / Chattopadhyay, Aditi (Thesis advisor) / Dai, Lenore (Committee member) / Jiang, Hanqing (Committee member) / Jiao, Yang (Committee member) / Rajadas, John (Committee member) / Arizona State University (Publisher)
Created2017
Description
Granular materials demonstrate complexity in many physical attributes with various shapes and sizes, varying from several centimeters down to less than a few microns. Some materials are highly cohesive, while others are free-flowing. Despite such complexity in their physical properties, they are extremely important in industries dealing with bulk materials. Through this research, the factors affecting flowability of particulate solids and their interaction with projectiles were explored. In Part I, a novel set of characterization tools to relate various granular material properties to their flow behavior in confined and unconfined environments was investigated. Through this work, a thorough characterization study to examine the effects of particle size, particle size distribution, and moisture on bulk powder flowability were proposed. Additionally, a mathematical model to predict the flow function coefficient (FFC) was developed, based on the surface mean diameter and moisture level, which can serve as a flowability descriptor.
Part II of this research focuses on the impact dynamics of low velocity projectiles on granular media. Interaction of granular media with external foreign bodies occurs in everyday events like a human footprint on the beach. Several studies involving numerical and experimental methods have focused on the study of impact dynamics in both dry and wet granular media. However, most of the studies involving impact dynamics considered spherical projectiles under different conditions, while practical models should involve more complex, realistic shapes. Different impacting geometries with conserved density, volume, and velocity on a granular bed may experience contrasting drag forces upon penetration. This is due to the difference in the surface areas coming into contact with the granular media. In this study, a set of non-spherical geometries comprising cuboids, cylinders, hexagonal prisms and triangular prisms with constant density, volume, and impact velocities, were released onto a loosely packed, non-cohesive, dry granular bed. From these experimental results, a model to determine the penetration depth of projectiles upon impact was developed and how it is influenced by the release height and surface area of the projectiles in contact with the granular media was studied.
ContributorsVajrala, Spandana (Author) / Emady, Heather N (Thesis advisor) / Marvi, Hamidreza (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2021
Description
Two fatigue life prediction methods using the energy-based approach have been proposed. A number of approaches have been developed in the past five decades. This study reviews some common models and discusses the model that is most suitable for each different condition, no matter whether the model is designed to solve uniaxial, multiaxial, or biaxial loading paths in fatigue prediction. In addition, different loading cases such as various loading and constant loading are also discussed. These models are suitable for one or two conditions in fatigue prediction. While most of the existing models can only solve single cases, the proposed new energy-based approach not only can deal with different loading paths but is applicable for various loading cases. The first energy-based model using the linear cumulative rule is developed to calculate random loading cases. The method is developed by combining Miner’s rule and the rainflow-counting algorithm. For the second energy-based method, I propose an alternative method and develop an approach to avert the rainflow-counting algorithm. Specifically, I propose to use an energy-based model by directly using the time integration concept. In this study, first, the equivalent energy concept that can transform three-dimensional loading into an equivalent loading will be discussed. Second, the new damage propagation method modified by fatigue crack growth will be introduced to deal with cycle-based fatigue prediction. Third, the time-based concept will be implemented to determine fatigue damage under every cycle in the random loading case. The formulation will also be explained in detail. Through this new model, the fatigue life can be calculated properly in different loading cases. In addition, the proposed model is verified with experimental datasets from several published studies. The data include both uniaxial and multiaxial loading paths under constant loading and random loading cases. Finally, the discussion and conclusion based on the results, are included. Additional loading cases such as the spectrum including both elastic and plastic regions will be explored in future research.
ContributorsTien, Shih-Chuan (Author) / Liu, Yongming (Thesis advisor) / Nian, Qiong (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2021
Description
A Microbial fuel cell (MFC) is a bio-inspired carbon-neutral, renewable electrochemical converter to extract electricity from catabolic reaction of micro-organisms. It is a promising technology capable of directly converting the abundant biomass on the planet into electricity and potentially alleviate the emerging global warming and energy crisis. The current and power density of MFCs are low compared with conventional energy conversion techniques. Since its debut in 2002, many studies have been performed by adopting a variety of new configurations and structures to improve the power density. The reported maximum areal and volumetric power densities range from 19 mW/m2 to 1.57 W/m2 and from 6.3 W/m3 to 392 W/m3, respectively, which are still low compared with conventional energy conversion techniques. In this dissertation, the impact of scaling effect on the performance of MFCs are investigated, and it is found that by scaling down the characteristic length of MFCs, the surface area to volume ratio increases and the current and power density improves. As a result, a miniaturized MFC fabricated by Micro-Electro-Mechanical System(MEMS) technology with gold anode is presented in this dissertation, which demonstrate a high power density of 3300 W/m3. The performance of the MEMS MFC is further improved by adopting anodes with higher surface area to volume ratio, such as carbon nanotube (CNT) and graphene based anodes, and the maximum power density is further improved to a record high power density of 11220 W/m3. A novel supercapacitor by regulating the respiration of the bacteria is also presented, and a high power density of 531.2 A/m2 (1,060,000 A/m3) and 197.5 W/m2 (395,000 W/m3), respectively, are marked, which are one to two orders of magnitude higher than any previously reported microbial electrochemical techniques.
ContributorsRen, Hao (Author) / Chae, Junseok (Thesis advisor) / Bakkaloglu, Bertan (Committee member) / Phillips, Stephen (Committee member) / Goryll, Michael (Committee member) / Arizona State University (Publisher)
Created2016
Description
This report summarizes the development of a test stand used to measure the thrust or impulse of pulsed plasma thrusters (PPT). Currently, there is a lack of accessible, cost-efficient methods for measuring thrust in the market due to the difficulties associated with developing a test stand for extremely low thrust outputs. Despite the difficulties, there is an ever-growing need to develop new methods of measuring thrust as the increased demand for small satellites has prompted investors from the government and private sectors to conduct further research into the development of better propulsion systems for space applications. A part of the developmental process of making propulsion systems is being able to test the thrust of these propulsion systems under vacuum conditions that simulate a space environment. This report details the research conducted on existing test stands as well as the process of designing, manufacturing, and testing a thrust measurement device.
ContributorsYu, Finley (Author) / Goryll, Michael (Thesis director) / Sharp, Thomas (Committee member) / Barrett, The Honors College (Contributor) / Mechanical and Aerospace Engineering Program (Contributor)
Created2024-05