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- Creators: Berman, Spring
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Description
For decades, microelectronics manufacturing has been concerned with failures related to electromigration phenomena in conductors experiencing high current densities. The influence of interconnect microstructure on device failures related to electromigration in BGA and flip chip solder interconnects has become a significant interest with reduced individual solder interconnect volumes. A survey indicates that x-ray computed micro-tomography (µXCT) is an emerging, novel means for characterizing the microstructures' role in governing electromigration failures. This work details the design and construction of a lab-scale µXCT system to characterize electromigration in the Sn-0.7Cu lead-free solder system by leveraging in situ imaging.
In order to enhance the attenuation contrast observed in multi-phase material systems, a modeling approach has been developed to predict settings for the controllable imaging parameters which yield relatively high detection rates over the range of x-ray energies for which maximum attenuation contrast is expected in the polychromatic x-ray imaging system. In order to develop this predictive tool, a model has been constructed for the Bremsstrahlung spectrum of an x-ray tube, and calculations for the detector's efficiency over the relevant range of x-ray energies have been made, and the product of emitted and detected spectra has been used to calculate the effective x-ray imaging spectrum. An approach has also been established for filtering `zinger' noise in x-ray radiographs, which has proven problematic at high x-ray energies used for solder imaging. The performance of this filter has been compared with a known existing method and the results indicate a significant increase in the accuracy of zinger filtered radiographs.
The obtained results indicate the conception of a powerful means for the study of failure causing processes in solder systems used as interconnects in microelectronic packaging devices. These results include the volumetric quantification of parameters which are indicative of both electromigration tolerance of solders and the dominant mechanisms for atomic migration in response to current stressing. This work is aimed to further the community's understanding of failure-causing electromigration processes in industrially relevant material systems for microelectronic interconnect applications and to advance the capability of available characterization techniques for their interrogation.
In order to enhance the attenuation contrast observed in multi-phase material systems, a modeling approach has been developed to predict settings for the controllable imaging parameters which yield relatively high detection rates over the range of x-ray energies for which maximum attenuation contrast is expected in the polychromatic x-ray imaging system. In order to develop this predictive tool, a model has been constructed for the Bremsstrahlung spectrum of an x-ray tube, and calculations for the detector's efficiency over the relevant range of x-ray energies have been made, and the product of emitted and detected spectra has been used to calculate the effective x-ray imaging spectrum. An approach has also been established for filtering `zinger' noise in x-ray radiographs, which has proven problematic at high x-ray energies used for solder imaging. The performance of this filter has been compared with a known existing method and the results indicate a significant increase in the accuracy of zinger filtered radiographs.
The obtained results indicate the conception of a powerful means for the study of failure causing processes in solder systems used as interconnects in microelectronic packaging devices. These results include the volumetric quantification of parameters which are indicative of both electromigration tolerance of solders and the dominant mechanisms for atomic migration in response to current stressing. This work is aimed to further the community's understanding of failure-causing electromigration processes in industrially relevant material systems for microelectronic interconnect applications and to advance the capability of available characterization techniques for their interrogation.
ContributorsMertens, James Charles Edwin (Author) / Chawla, Nikhilesh (Thesis advisor) / Alford, Terry (Committee member) / Jiao, Yang (Committee member) / Neithalath, Narayanan (Committee member) / Arizona State University (Publisher)
Created2015
Description
In this dissertation, the results of our comprehensive computational studies of disordered jammed (i.e., mechanically stable) packings of hard particles are presented, including the family of superdisks in 2D and ellipsoids in 3D Euclidean space. Following a very brief introduction to the hard-particle systems, the event driven molecular dynamics (EDMD) employed to generate the packing ensembles will be discussed. A large number of 2D packing configurations of superdisks are subsequently analyzed, through which a relatively accurate theoretical scheme for packing-fraction prediction based on local particle contact configurations is proposed and validated via additional numerical simulations. Moreover, the studies on binary ellipsoid packing in 3D are briefly discussed and the effects of different geometrical parameters on the final packing fraction are analyzed.
ContributorsXu, Yaopengxiao (Author) / Jiao, Yang (Thesis advisor) / Oswald, Jay (Committee member) / Liu, Yongming (Committee member) / Arizona State University (Publisher)
Created2014
Description
In this dissertation, three complex material systems including a novel class of hyperuniform composite materials, cellularized collagen gel and low melting point alloy (LMPA) composite are investigated, using statistical pattern characterization, stochastic microstructure reconstruction and micromechanical analysis. In Chapter 1, an introduction of this report is provided, in which a brief review is made about these three material systems. In Chapter 2, detailed discussion of the statistical morphological descriptors and a stochastic optimization approach for microstructure reconstruction is presented. In Chapter 3, the lattice particle method for micromechanical analysis of complex heterogeneous materials is introduced. In Chapter 4, a new class of hyperuniform heterogeneous material with superior mechanical properties is investigated. In Chapter 5, a bio-material system, i.e., cellularized collagen gel is modeled using correlation functions and stochastic reconstruction to study the collective dynamic behavior of the embed tumor cells. In chapter 6, LMPA soft robotic system is generated by generalizing the correlation functions and the rigidity tunability of this smart composite is discussed. In Chapter 7, a future work plan is presented.
ContributorsXu, Yaopengxiao (Author) / Jiao, Yang (Thesis advisor) / Liu, Yongming (Committee member) / Wang, Qing Hua (Committee member) / Ren, Yi (Committee member) / Arizona State University (Publisher)
Created2018
Description
The Autonomous Vehicle (AV), also known as self-driving car, promises to be a game changer for the transportation industry. This technology is predicted to drastically reduce the number of traffic fatalities due to human error [21].
However, road driving at any reasonable speed involves some risks. Therefore, even with high-tech AV algorithms and sophisticated sensors, there may be unavoidable crashes due to imperfection of the AV systems, or unexpected encounters with wildlife, children and pedestrians. Whenever there is a risk involved, there is the need for an ethical decision to be made [33].
While ethical and moral decision-making in humans has long been studied by experts, the advent of artificial intelligence (AI) also calls for machine ethics. To study the different moral and ethical decisions made by humans, experts may use the Trolley Problem [34], which is a scenario where one must pull a switch near a trolley track to redirect the trolley to kill one person on the track or do nothing, which will result in the deaths of five people. While it is important to take into account the input of members of a society and perform studies to understand how humans crash during unavoidable accidents to help program moral and ethical decision-making into self-driving cars, using the classical trolley problem is not ideal, as it is unrealistic and does not represent moral situations that people face in the real world.
This work seeks to increase the realism of the classical trolley problem for use in studies on moral and ethical decision-making by simulating realistic driving conditions in an immersive virtual environment with unavoidable crash scenarios, to investigate how drivers crash during these scenarios. Chapter 1 gives an in-depth background into autonomous vehicles and relevant ethical and moral problems; Chapter 2 describes current state-of-the-art online tools and simulators that were developed to study moral decision-making during unavoidable crashes. Chapters 3 focuses on building the simulator and the design of the crash scenarios. Chapter 4 describes human subjects experiments that were conducted with the simulator and their results, and Chapter 5 provides conclusions and avenues for future work.
However, road driving at any reasonable speed involves some risks. Therefore, even with high-tech AV algorithms and sophisticated sensors, there may be unavoidable crashes due to imperfection of the AV systems, or unexpected encounters with wildlife, children and pedestrians. Whenever there is a risk involved, there is the need for an ethical decision to be made [33].
While ethical and moral decision-making in humans has long been studied by experts, the advent of artificial intelligence (AI) also calls for machine ethics. To study the different moral and ethical decisions made by humans, experts may use the Trolley Problem [34], which is a scenario where one must pull a switch near a trolley track to redirect the trolley to kill one person on the track or do nothing, which will result in the deaths of five people. While it is important to take into account the input of members of a society and perform studies to understand how humans crash during unavoidable accidents to help program moral and ethical decision-making into self-driving cars, using the classical trolley problem is not ideal, as it is unrealistic and does not represent moral situations that people face in the real world.
This work seeks to increase the realism of the classical trolley problem for use in studies on moral and ethical decision-making by simulating realistic driving conditions in an immersive virtual environment with unavoidable crash scenarios, to investigate how drivers crash during these scenarios. Chapter 1 gives an in-depth background into autonomous vehicles and relevant ethical and moral problems; Chapter 2 describes current state-of-the-art online tools and simulators that were developed to study moral decision-making during unavoidable crashes. Chapters 3 focuses on building the simulator and the design of the crash scenarios. Chapter 4 describes human subjects experiments that were conducted with the simulator and their results, and Chapter 5 provides conclusions and avenues for future work.
ContributorsKankam, Immanuella (Author) / Berman, Spring (Thesis advisor) / Johnson, Kathryn (Committee member) / Yong, Sze Zheng (Committee member) / Arizona State University (Publisher)
Created2019
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
Nanolaminate materials are layered composites with layer thickness ≤ 100 nm. They exhibit unique properties due to their small length scale, the presence of a high number of interfaces and the effect of imposed constraint. This thesis focuses on the mechanical behavior of Al/SiC nanolaminates. The high strength of ceramics combined with the ductility of Al makes this combination desirable. Al/SiC nanolaminates were synthesized through magnetron sputtering and have an overall thickness of ~ 20 μm which limits the characterization techniques to microscale testing methods. A large amount of work has already been done towards evaluating their mechanical properties under indentation loading and micropillar compression. The effects of temperature, orientation and layer thickness have been well established. Al/SiC nanolaminates exhibited a flaw dependent deformation, anisotropy with respect to loading direction and strengthening due to imposed constraint. However, the mechanical behavior of nanolaminates under tension and fatigue loading has not yet been studied which is critical for obtaining a complete understanding of their deformation behavior. This thesis fills this gap and presents experiments which were conducted to gain an insight into the behavior of nanolaminates under tensile and cyclic loading. The effect of layer thickness, tension-compression asymmetry and effect of a wavy microstructure on mechanical response have been presented. Further, results on in situ micropillar compression using lab-based X-ray microscope through novel experimental design are also presented. This was the first time when a resolution of 50 nms was achieved during in situ micropillar compression in a lab-based setup. Pores present in the microstructure were characterized in 3D and sites of damage initiation were correlated with the channel of pores present in the microstructure.
The understanding of these deformation mechanisms paved way for the development of co-sputtered Al/SiC composites. For these composites, Al and SiC were sputtered together in a layer. The effect of change in the atomic fraction of SiC on the microstructure and mechanical properties were evaluated. Extensive microstructural characterization was performed at the nanoscale level and Al nanocrystalline aggregates were observed dispersed in an amorphous matrix. The modulus and hardness of co- sputtered composites were much higher than their traditional counterparts owing to denser atomic packing and the absence of synthesis induced defects such as pores and columnar boundaries.
The understanding of these deformation mechanisms paved way for the development of co-sputtered Al/SiC composites. For these composites, Al and SiC were sputtered together in a layer. The effect of change in the atomic fraction of SiC on the microstructure and mechanical properties were evaluated. Extensive microstructural characterization was performed at the nanoscale level and Al nanocrystalline aggregates were observed dispersed in an amorphous matrix. The modulus and hardness of co- sputtered composites were much higher than their traditional counterparts owing to denser atomic packing and the absence of synthesis induced defects such as pores and columnar boundaries.
ContributorsSingh, Somya (Author) / Chawla, Nikhilesh (Thesis advisor) / Neithalath, Narayanan (Committee member) / Jiao, Yang (Committee member) / Mara, Nathan (Committee member) / Arizona State University (Publisher)
Created2018
Description
In this paper, we propose an autonomous throwing and catching system to be developed as a preliminary step towards the refinement of a robotic arm capable of improving strength and motor function in the limb. This will be accomplished by first autonomizing simpler movements, such as throwing a ball. In this system, an autonomous thrower will detect a desired target through the use of image processing. The launch angle and direction necessary to hit the target will then be calculated, followed by the launching of the ball. The smart catcher will then detect the ball as it is in the air, calculate its expected landing location based on its initial trajectory, and adjust its position so that the ball lands in the center of the target. The thrower will then proceed to compare the actual landing position with the position where it expected the ball to land, and adjust its calculations accordingly for the next throw. By utilizing this method of feedback, the throwing arm will be able to automatically correct itself. This means that the thrower will ideally be able to hit the target exactly in the center within a few throws, regardless of any additional uncertainty in the system. This project will focus of the controller and image processing components necessary for the autonomous throwing arm to be able to detect the position of the target at which it will be aiming, and for the smart catcher to be able to detect the position of the projectile and estimate its final landing position by tracking its current trajectory.
ContributorsLundberg, Kathie Joy (Co-author) / Thart, Amanda (Co-author) / Rodriguez, Armando (Thesis director) / Berman, Spring (Committee member) / Electrical Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
This thesis details the design and construction of a torque-controlled robotic gripper for use with the Pheeno swarm robotics platform. This project required expertise from several fields of study including: robotic design, programming, rapid prototyping, and control theory. An electronic Inertial Measurement Unit and a DC Motor were both used along with 3D printed plastic components and an electronic motor control board to develop a functional open-loop controlled gripper for use in collective transportation experiments. Code was developed that effectively acquired and filtered rate of rotation data alongside other code that allows for straightforward control of the DC motor through experimentally derived relationships between the voltage applied to the DC motor and the torque output of the DC motor. Additionally, several versions of the physical components are described through their development.
ContributorsMohr, Brennan (Author) / Berman, Spring (Thesis director) / Ren, Yi (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / School for Engineering of Matter,Transport & Enrgy (Contributor) / Barrett, The Honors College (Contributor)
Created2019-05
Description
In the next decade or so, there will be a shift in the industry of transportation across the world. Already today we have autonomous vehicles (AVs) tested in the Greater Phoenix area showing that the technology has improved to a level available to the public eye. Although this technology is not yet released commercially (for the most part), it is being used and will continue to be used to develop a safer future. With a high incidence of human error causing accidents, many expect that autonomous vehicles will be safer than human drivers. They do still require driver attention and sometimes intervention to ensure safety, but for the most part are much safer. In just the United States alone, there were 40,000 deaths due to car accidents last year [1]. If traffic fatalities were considered a disease, this would be an epidemic. The technology behind autonomous vehicles will allow for a much safer environment and increased mobility and independence for people who cannot drive and struggle with public transport. There are many opportunities for autonomous vehicles in the transportation industry. Companies can save a lot more money on shipping by cutting the costs of human drivers and trucks on the road, even allowing for simpler drop shipments should the necessary AI be developed.Research is even being done by several labs at Arizona State University. For example, Dr. Spring Berman’s Autonomous Collective Systems Lab has been collaborating with Dr. Nancy Cooke of Human Systems Engineering to develop a traffic testbed, CHARTopolis, to study the risks of driver-AV interactions and the psychological effects of AVs on human drivers on a small scale. This testbed will be used by researchers from their labs and others to develop testing on reaction, trust, and user experience with AVs in a safe environment that simulates conditions similar to those experienced by full-size AVs. Using a new type of small robot that emulates an AV, developed in Dr. Berman’s lab, participants will be able to remotely drive around a model city environment and interact with other AV-like robots using the cameras and LiDAR sensors on the remotely driven robot to guide them.
Although these commercial and research systems are still in testing, it is important to understand how AVs are being marketed to the general public and how they are perceived, so that one day they may be effectively adopted into everyday life. People do not want to see a car they do not trust on the same roads as them, so the questions are: why don’t people trust them, and how can companies and researchers improve the trustworthiness of the vehicles?
Although these commercial and research systems are still in testing, it is important to understand how AVs are being marketed to the general public and how they are perceived, so that one day they may be effectively adopted into everyday life. People do not want to see a car they do not trust on the same roads as them, so the questions are: why don’t people trust them, and how can companies and researchers improve the trustworthiness of the vehicles?
ContributorsShuster, Daniel Nadav (Author) / Berman, Spring (Thesis director) / Cooke, Nancy (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2019-05
Description
Fracture phenomena have been extensively studied in the last several decades. Continuum mechanics-based approaches, such as finite element methods and extended finite element methods, are widely used for fracture simulation. One well-known issue of these approaches is the stress singularity resulted from the spatial discontinuity at the crack tip/front. The requirement of guiding criteria for various cracking behaviors, such as initiation, propagation, and branching, also poses some challenges. Comparing to the continuum based formulation, the discrete approaches, such as lattice spring method, discrete element method, and peridynamics, have certain advantages when modeling various fracture problems due to their intrinsic characteristics in modeling discontinuities.
A novel, alternative, and systematic framework based on a nonlocal lattice particle model is proposed in this study. The uniqueness of the proposed model is the inclusion of both pair-wise local and multi-body nonlocal potentials in the formulation. First, the basic ideas of the proposed framework for 2D isotropic solid are presented. Derivations for triangular and square lattice structure are discussed in detail. Both mechanical deformation and fracture process are simulated and model verification and validation are performed with existing analytical solutions and experimental observations. Following this, the extension to general 3D isotropic solids based on the proposed local and nonlocal potentials is given. Three cubic lattice structures are discussed in detail. Failure predictions using the 3D simulation are compared with experimental testing results and very good agreement is observed. Next, a lattice rotation scheme is proposed to account for the material orientation in modeling anisotropic solids. The consistency and difference compared to the classical material tangent stiffness transformation method are discussed in detail. The implicit and explicit solution methods for the proposed lattice particle model are also discussed. Finally, some conclusions and discussions based on the current study are drawn at the end.
A novel, alternative, and systematic framework based on a nonlocal lattice particle model is proposed in this study. The uniqueness of the proposed model is the inclusion of both pair-wise local and multi-body nonlocal potentials in the formulation. First, the basic ideas of the proposed framework for 2D isotropic solid are presented. Derivations for triangular and square lattice structure are discussed in detail. Both mechanical deformation and fracture process are simulated and model verification and validation are performed with existing analytical solutions and experimental observations. Following this, the extension to general 3D isotropic solids based on the proposed local and nonlocal potentials is given. Three cubic lattice structures are discussed in detail. Failure predictions using the 3D simulation are compared with experimental testing results and very good agreement is observed. Next, a lattice rotation scheme is proposed to account for the material orientation in modeling anisotropic solids. The consistency and difference compared to the classical material tangent stiffness transformation method are discussed in detail. The implicit and explicit solution methods for the proposed lattice particle model are also discussed. Finally, some conclusions and discussions based on the current study are drawn at the end.
ContributorsChen, Hailong (Author) / Liu, Yongming (Thesis advisor) / Jiao, Yang (Committee member) / Mignolet, Marc (Committee member) / Oswald, Jay (Committee member) / Solanki, Kiran (Committee member) / Arizona State University (Publisher)
Created2015