Implementation of a Thermodynamic Framework for Damage Mechanics of Solder Interconnects in Microelectronic Packaging

Author(s):  
Cemal Basaran ◽  
Hong Tang

A thermo mechanical fatigue life prediction model based on the theory of damage mechanics is presented. The damage evolution, corresponding to the material degradation under cyclic thermo mechanical loading, is quantified thermodynamic framework. The damage, as an internal state variable, is coupled with unified viscoplastic constitutive model to characterize the response of solder alloys. The damage-coupled viscoplastic model with kinematic and isotropic hardening is implemented in ABAQUS finite element package to simulate the cyclic softening behavior of solder joints. Several computational simulations of uniaxial monotonic tensile and cyclic shear tests are conducted to validate the model with experimental results. The behavior of an actual Ball Grid Array (BGA) package under thermal fatigue loading is also simulated and compared with experimental results.

2003 ◽  
Vol 125 (1) ◽  
pp. 120-125 ◽  
Author(s):  
Hong Tang ◽  
Cemal Basaran

A thermomechanical fatigue life prediction model based on the theory of damage mechanics is presented. The damage evolution, corresponding to the material degradation under cyclic thermomechanical loading, is quantified thermodynamic framework. The damage, as an internal state variable, is coupled with unified viscoplastic constitutive model to characterize the response of solder alloys. The damage-coupled viscoplastic model with kinematic and isotropic hardening is implemented in ABAQUS finite element package to simulate the cyclic softening behavior of solder joints. Several computational simulations of uniaxial monotonic tensile and cyclic shear tests are conducted to validate the model with experimental results. The behavior of an actual ball grid array (BGA) package under thermal fatigue loading is also simulated and compared with experimental results.


Author(s):  
Xiaowei Wang ◽  
Jianming Gong ◽  
Yong Jiang ◽  
Yanping Zhao

Low cycle fatigue tests of original ferritic P92 steel at high temperatures and different strain amplitudes were conducted to investigate its cyclic softening behavior and fracture behavior. LCF tests of strain amplitudes ranging from ±0.2% to ±0.8% were performed in fully reversed manner with constant strain rate at 600 °C and 650 °C. In order to represent the different hysteresis stress-strain curves and the cyclic softening behavior of P92 steel, a cyclic plastic material model was used. In the model, improved nonlinear isotropic hardening parameter was proposed to make better simulation of the cyclic softening behavior. Based on the simulated stress-strain hysteresis loops, an energy-based life prediction model was used to predict the low cycle fatigue life. When compared with experimental responses, the simulations and predicted life were found to be quite reasonable. Low cycle fatigue fractography of the P92 steel was also observed, and it was found to be associated with the different strain amplitudes imposed on the specimen, the larger strain amplitude the more amounts of crack initiation sites could be found.


2000 ◽  
Author(s):  
Y. Wei ◽  
C. L. Chow ◽  
M. K. Neilsen ◽  
H. E. Fang

Abstract This paper presents a method of TMF analysis based on the theory of damage mechanics to examine the fatigue damage accumulation in 63Sn-37Pb solder. The method is developed by extending a viscoplastic damage model proposed earlier by the authors (Wei, et al 1999, 2000). A computer simulation is carried out to calculate hysteresis loops at three different strain ranges. The damage-coupled fatigue damage model is applied to predict the cyclic softening behavior of the material and the prediction is found to agree well with the experiment. With a proposed failure criterion based on the concept of damage accumulation, the TMF model is also found to predict successfully the fatigue life of 63Sn-37Pb solder.


Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 4018
Author(s):  
Shuming Zhang ◽  
Yuanming Xu ◽  
Hao Fu ◽  
Yaowei Wen ◽  
Yibing Wang ◽  
...  

From the perspective of damage mechanics, the damage parameters were introduced as the characterizing quantity of the decrease in the mechanical properties of powder superalloy material FGH96 under fatigue loading. By deriving a damage evolution equation, a fatigue life prediction model of powder superalloy containing inclusions was constructed based on damage mechanics. The specimens containing elliptical subsurface inclusions and semielliptical surface inclusions were considered. The CONTA172 and TARGE169 elements of finite element software (ANSYS) were used to simulate the interfacial debonding between the inclusions and matrix, and the interface crack initiation life was calculated. Through finite element modeling, the stress field evolution during the interface debonding was traced by simulation. Finally, the effect of the position and shape size of inclusions on interface debonding was explored.


2021 ◽  
Author(s):  
Fuhui Shen ◽  
Kai Chen ◽  
Junhe Lian ◽  
Sebastian Münstermann

Two categories of experiments have been performed to obtain the experimental forming limits of a ferritic stainless steel from uniaxial to equibiaxial tension, including Nakajima tests and tensile tests of flat specimens with different geometries of the central hole as well as the notched dog bone. The plasticity behavior of the investigated material is described using an evolving non-associated anisotropic plasticity model, which is calibrated based on experimental results of uniaxial tensile tests along different loading directions. A damage mechanics model is calibrated and validated based on the global force and displacement response of tensile tests. Finite element simulations of the Nakajima tests and the tensile tests of various geometries have been performed using the anisotropic material model. A novel spatio-temporal method is developed to evaluate the forming limits under different stress states by quantitatively characterizing the plastic strain distribution on the specimen surface. The forming limits have been independently determined from finite element simulation results of tensile specimens and Nakajima specimens using the spatio-temporal evaluation method. The forming limits obtained from numerical simulations of these two types of experiments are in good agreement with experimental results.


2007 ◽  
Vol 348-349 ◽  
pp. 845-848
Author(s):  
Shan Suo Zheng ◽  
Lei Li ◽  
Guo Zhuan Deng ◽  
Shun Li Che ◽  
Wei Zhao

The latest experimental study on steel reinforced high strength and high performance concrete (SRHSHPC) specimens shows that there exists interfacial bond softening phenomenon between embedded steel and high strength and high performance concrete (HSHPC), and it makes the shear transfer capacity between shaped steel and HSHPC be progressively reduced. To predict failure load in design, a theoretical model for interfacial bond softening behavior is required. As interfacial bond softening behavior is a nonlinear process involving material properties, it can be analyzed once the relation of interfacial bond stress (τ ) and slippage ( s ) is known. In this paper, the mechanism of interfacial bond-slip is studied, thus a simplified τ − s relation including ascending and descending parts is proposed and employed to analyze the interfacial nonlinear bond-slip process. Based on the interfacial equilibrium between steel and HSHPC as well as the τ − s relation, the basic governing equations in both softened region and elastic region are established and solved for steel strain or stress. At last, the application of the model is verified through comparison with experimental results. The calculating results of the model are found to be in good agreement with experimental results, showing that the model can describe the bond-slip process in real material systems.


Author(s):  
Felix Koelzow ◽  
Muhammad Mohsin Khan ◽  
Christian Kontermann ◽  
Matthias Oechsner

Abstract Several (accumulative) lifetime models were developed to assess the lifetime consumption of high-temperature components of steam and gas turbine power plants during flexible operation modes. These accumulative methods have several drawbacks, e.g. that measured loading profiles cannot be used within accumulative lifetime methods without manual corrections, and cannot be combined directly to sophisticated probabilistic methods. Although these methods are widely accepted and used for years, the accumulative lifetime prediction procedures need improvement regarding the lifetime consumption of thermal power plants during flexible operation modes. Furthermore, previous investigations show that the main influencing factor from the materials perspective, the critical damage threshold, cannot be statistically estimated from typical creep-fatigue experiments due to massive experimental effort and a low amount of available data. This paper seeks to investigate simple damage mechanics concepts applied to high-temperature components under creep-fatigue loading to demonstrate that these methods can overcome some drawbacks and use improvement potentials of traditional accumulative lifetime methods. Furthermore, damage mechanics models do not provide any reliability information, and the assessment of the resultant lifetime prediction is nearly impossible. At this point, probabilistic methods are used to quantify the missing information concerning failure probabilities and sensitivities and thus, the combination of both provides rigorous information for engineering judgment. Nearly 50 low cycle fatigue experiments of a high chromium cast steel, including dwell times and service-type cycles, are used to investigate the model properties of a simple damage evolution equation using the strain equivalence hypothesis. Furthermore, different temperatures from 300 °C to 625 °C and different strain ranges from 0.35% to 2% were applied during the experiments. The determination of the specimen stiffness allows a quantification of the damage evolution during the experiment. The model parameters are determined by Nelder-Mead optimization procedure, and the dependencies of the model parameters concerning to different temperatures and strain ranges are investigated. In this paper, polynomial chaos expansion (PCE) is used for uncertainty propagation of the model uncertainties while using non-intrusive methods (regression techniques). In a further post-processing step, the computed PCE coefficients of the damage variable are used to determine the probability of failure as a function of cycles and evolution of the probability density function (pdf). Except for the selected damage mechanics model which is considered simple, the advantages of using damage mechanics concepts combined with sophisticated probabilistic methods are presented in this paper.


2020 ◽  
Author(s):  
Bradley Scott Henderson

The meniscus is a wedge-shaped fibrocartilaginous tissue located between the femur and tibia that helps stabilize the knee and protect the underlying cartilage. There are 2.5 million reported knee injuries each year, making it the most injured joint in the human body. Nearly twenty percent of these injuries are due to a torn meniscus, leading to over half a million meniscus surgeries performed in the United States annually. Therefore, it is critical to understand the failure modes of meniscus tissue to prevent these debilitating injuries. A failure mode that accounts for one-third of all meniscus injuries is repeated exposure to low-magnitude tensile loads, known as fatigue. One approach to gain physical insight into fatigue mechanisms is through cyclic tensile experiments performed in laboratories. An alternative approach is to use constitutive mathematical models that predict and describe the material's behavior. These models can avoid the expense and time required for experimental fatigue studies, but they also must be calibrated and validated using experimental data. The aim of this study is to validate a constitutive model to predict human meniscus' observed fatigue behavior in force-controlled loading. Three variations of constitutive models were applied to test each model's ability to model fatigue induced creep. These models included a viscoelastic damage model, a continuum damage mechanics model, and a viscoelastic model. Using a custom program, each models' parameters were fit to stretch-time plots from previously performed fatigue experiments of cadaveric human meniscus. The quality of fit for each model was then measured. The results of this study show that a viscoelastic damage formulation can effectively fit force-controlled fatigue behavior and, on average, performed the best of the three models presented. On average, the resulting NRMSE values for stretch at all creep stages were 0.22%, 2.03%, and 0.45% for the visco-damage, damage-only, and visco-only models, respectively. The requirement of including both viscoelasticity and damage to model all three creep stages indicates that viscoelasticity may be the driving factor for damage accumulation in fatigue loading. Further, the relatively low damage values, ranging from 0.05 to 0.2, right before exponential increases in stretch, indicate that failure may occur from fatigue loading without a considerable accumulation of damage. The validation results showed that the model could not completely represent pull to failure experiments when using material parameters that curve fit fatigue experiments. Still, they indicated that the combination of discontinuous CDM and viscoelasticity shows potential to model both fatigue and static loadings using a single formulation. To our knowledge, this is the first study to model force-controlled fatigue induced creep in the meniscus or any other soft tissue. This study's results can be utilized to further model force-controlled fatigue to predict and prevent meniscus tissue injuries.


2021 ◽  
Author(s):  
RYOMA AOKI ◽  
RYO HIGUCHI ◽  
TOMOHIRO YOKOZEKI

This study aims to conduct a fatigue simulation for predicting the stiffness degradation of thin-ply composite laminates with several ply thicknesses. For the simulation, a fatigue evolution model of intra-laminar damage in thin-ply composite laminates considering the effect of ply thickness was proposed. The intra-laminar damage evolution was modeled using the continuum damage mechanics model and the static and fatigue evolution law were formulated by relating the transverse crack density to the damage variable. The finite element simulation using the proposed model was conducted to predict the stiffness degradation of the laminates as a function of the number of loading cycles. The simulation results show that the experimental data can be reproduced by using the proposed fatigue model.


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