Numerical Approach to Cold Gas Spray on Ceramic Substrates for Power Electronics Packaging

2018 ◽  
Author(s):  
Marco J. Echeverría ◽  
Pedro O. Quintero ◽  
Dimeji Ibitayo ◽  
Lauren Boteler
Keyword(s):  
Copper Deposit ◽  
Dielectric Strength ◽  
Numerical Approach ◽  
Solid Particles ◽  
Processing Parameter ◽  
Ceramic Substrates ◽  
Manufacturing Method ◽  
Spray Process ◽  
Thermal Expansion Coefficients ◽  
Cold Gas

In power electronic, ceramic substrates are used owing to their high thermal conductivity and dielectric strength. These substrates cannot withstand high voltages in the range of 20kV because thickness limitations inherit from the direct bond copper manufacturing method. This manufacturing process uses high temperature in order to bond the material layers. This negatively affects the material’s reliability due to the differing materials thermal expansion coefficients and the resulting residual stress. All this results in hindering the ceramic substrate in obtaining a higher dielectric strength. In contrast, cold gas spray has the potential to provide higher reliability due to its bonding mechanism, which relies on plastic deformation of solid particles at very high strain rates during impact to create a mechanical bond, forming a thick deposit. However, cold gas spray on ceramics has not been widely studied due to their brittleness and their inability to form a metallic bond. This work is aimed at providing an effective processing parameter map of the cold gas spray process to achieve a thick copper deposit on aluminum nitride on the basis of the comparison of experimental results with a numerical model and finite element simulation formulated in Mathematica and ABAQUS, respectively.

Thermally Induced Delamination Buckling of a Thin Metal Layer on a Ceramic Substrate

2003 ◽  
Vol 125 (4) ◽  
pp. 512-519 ◽  
Author(s):  
C. J. Liu ◽  
L. J. Ernst ◽  
G. Wisse ◽  
G. Q. Zhang ◽  
M. Vervoort
Keyword(s):  
Failure Modes ◽  
Research Effort ◽  
Metal Layer ◽  
Electronic Packages ◽  
Ceramic Substrates ◽  
Thermally Induced ◽  
Thermal Expansion Coefficients ◽  
Interface Delamination ◽  
Delamination Buckling ◽  
Expansion Coefficients

Interface delamination failure caused by thermomechanical loading and mismatch of thermal expansion coefficients and other material properties is one of the important failure modes occurring in electronic packages, thus a threat for package reliability. To solve this problem, both academic institutions and industry have been spending tremendous research effort in order to understand the inherent failure mechanisms and to develop advanced and reliable experimental and simulation methodologies, thus to be able to predict and to avoid interface delamination before physical prototyping. Various damage mechanisms can be involved and can result in interface delamination phenomena. These are not all sufficiently addressed and/or reported so far, probably because of the complexities caused by the occurrence of strong geometric and materials nonlinearities. One of the phenomena being insufficiently understood so far is the so-called buckling-driven delamination of thin metalic layers on ceramic substrates. This phenomenon will be discussed in the present paper.

Grey modeling for thermal spray processing parameter analysis

2020 ◽  
Vol 10 (3) ◽  
pp. 265-279 ◽  
Author(s):  
Meimei Liu ◽  
Yicha Zhang ◽  
Wenjie Dong ◽  
Zexin Yu ◽  
Sifeng Liu ◽  
...  
Keyword(s):  
Thermal Spray ◽  
Processing Parameters ◽  
Industrial Applications ◽  
Parameter Analysis ◽  
Processing Parameter ◽  
Content Type ◽  
Thermal Spray Process ◽  
Spray Process ◽  
Non Linear ◽  
Spray Processing

PurposeThis paper presents the application of grey modeling for thermal spray processing parameter analysis in less data environment.Design/methodology/approachBased on processing knowledge, key processing parameters of thermal spray process are analyzed and preselected. Then, linear and non-linear grey modeling models are integrated to mine the relationships between different processing parameters.FindingsModel A reveals the linear correlation between the HVOF process parameters and the characterization of particle in-flight with average relative errors of 9.230 percent and 5.483 percent for velocity and temperature.Research limitations/implicationsThe prediction accuracies of coatings properties vary, which means that there exists more complex non-linear relationship between the identified input parameters and coating results, or more unexpected factors (e.g. factors from material side) should be further investigated.Practical implicationsAccording to the modeling case in this paper, method has potential to deal with other diverse modeling problems in different industrial applications where challenge to collecting large quantity of data sets exists.Originality/valueIt is the first time to apply grey modeling for thermal spray processing where complicated relationships among processing parameters exist. The modeling results show reasonable results to experiment and existing processing knowledge.

Modeling of Particle-Laden Cold Flow in a Cyclone Gasifier

2018 ◽  
Vol 141 (2) ◽  
Author(s):  
Pantea Hadi Jafari ◽  
Dzmitry Misiulia ◽  
J. Gunnar I. Hellström ◽  
B. Rikard Gebart
Keyword(s):  
Gas Flow ◽  
Numerical Approach ◽  
Solid Particles ◽  
Bottom Plate ◽  
Single Particles ◽  
Cold Flow ◽  
Lagrangian Simulation ◽  
Swirl Intensity ◽  
The Impact ◽  
Simulation Time

Isothermal transient Eulerian–Lagrangian simulation of the turbulent gas–solid flow in a cyclone gasifier with two inlet tubes at 890 °C has been performed. The single-phase gas flow is modeled using SSG Reynolds stress turbulence model. Ten thousand representative solid particles of different sizes are injected from each inlet continuously at every second of simulation time. Particles are finally stopped as soon as they arrive at the outlet or reach the bottom plate of the gasifier. The effect of particle-to-gas coupling on the pressure and velocity of the flow and particles motion inside the gasifier is studied. The numerical approach can reasonably predict the impact of particle load on the gas flow as presented in the experimental results. Single particles are traveled throughout the transient gas flow field by using Lagrangian approach. High temperature of the gas flow inside the gasifier has significant effects on the swirl intensity reduction, damping the turbulence in the core region, pressure, and particle behaviors. However, the presence of solid particles does not have a notable influence on the swirl intensity and turbulence.

The Effects of the Distance Between Nozzle and Substrate on Cold Gas Dynamic Spray Process

2005 ◽  
Author(s):  
Longjian Li ◽  
Wenzhi Cui ◽  
Qinghua Chen ◽  
Tien-Chien Jen ◽  
Quan Liao
Keyword(s):  
Supersonic Nozzle ◽  
Strong Shock ◽  
Two Phase ◽  
Carrier Gas ◽  
Compression Waves ◽  
Spray Process ◽  
Gas Dynamic ◽  
Cold Gas Dynamic Spray ◽  
Gas Dynamic Spray ◽  
Cold Gas

In this paper, numerical simulations were performed for the gas-particle two phase flow in the cold gas dynamic spray process to investigate the acceleration of micro- and nanoparticles with diameters ranging from 100nm to 50μm. Nitrogen (N2) and Helium (He) were chosen as the carrier gas, respectively. The acceleration of carrier gas to particles in the De-Laval-Type supersonic nozzle was strongly dependent on the characteristics of flow field, as well as the densities and the size of the particles. Two kind of particles Copper (Cu) and Platinum (Pt) were chosen as the spraying materials. The computed results showed that the flow structures of the carrier gas were very different for different gas and different spraying distance, which resulted in consequently different accelerating features. The cone-shape weak shocks (compression waves) occurred at the exit of divergent section, and the bow-shaped strong shock wave was found right before the substrate, which played a resistance role to the particles and prevented the smaller particles from approaching on the substrate.

Optimization of Cold Gas Dynamic Spray Processes by Computational Simulation

2007 ◽  
Author(s):  
Hidemasa Takana ◽  
Kazuhiro Ogawa ◽  
Tetsuo Shoji ◽  
Hideya Nishiyama
Keyword(s):  
Shock Wave ◽  
Electrostatic Force ◽  
Particle Diameter ◽  
Integrated Model ◽  
Viscous Drag ◽  
Spray Process ◽  
Gas Dynamic ◽  
Cold Gas Dynamic Spray ◽  
Gas Dynamic Spray ◽  
Cold Gas

An integrated model of compressible thermofluid, splat formation and coating formation for a cold dynamic spray process has been established. In-flight behavior of nano-micro particles and the interaction between the shock wave and the particles in a supersonic jet flow impinging onto the substrate and further particle acceleration with electrostatic force are clarified in detail by considering viscous drag force, flow acceleration, added mass, gravity, Basset history force, Saffman lift force, Brownian motion, thermophoresis and electrostatic force. The effect of electrostatic acceleration becomes more significant with the decrease in particle diameter even in the presence of unavoidable shock wave. As a result, electrostatic acceleration can broaden the application range of operating particle diameter in a cold gas dynamic spray process to form a robust and activated coating. Finally, based on the integrated model, the coating thickness characteristics in an electrostatic assisted cold dynamic spray process are evaluated.

scholarly journals Study of thermite mixture consolidated by the cold gas dynamic spray process

2014 ◽  
Vol 500 (5) ◽  
pp. 052003 ◽  
Author(s):  
A Bacciochini ◽  
G Maines ◽  
C Poupart ◽  
H Akbarnejad ◽  
M Radulescu ◽  
...  
Keyword(s):  
Spray Process ◽  
Thermite Mixture ◽  
Gas Dynamic ◽  
Cold Gas Dynamic Spray ◽  
Gas Dynamic Spray ◽  
Cold Gas
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