An experimental study of carbonyl powder power inductor cracking during reflow process

Purpose In surface mount assembly (SMA) process, small components are subjected to high temperature variations, which result in components’ deformation and cracking. Because of this phenomenon, cracks are formed in the body of carbonyl powder ceramic inductor (CPCI) in the preheat and cooling stages of the reflow oven. These cracks become the main cause of board failure in the ageing process. The purpose of this paper is to ascertain the thermal stress, thermal expansion of carbonyl iron ceramics and its effects on crack commencement and proliferation in the preheat stage of reflow oven. Moreover, this paper also categorized and suggested important parameters of reflow profile that could be used to eliminate these thermal shock failures. Design/methodology/approach In this paper, two different reflow profiles were studied that evaluate the thermal shock of CPCI during varying ΔT at the preheat zone of the reflow oven. In the first profile, the change in temperature ΔT at preheat zone was set to 3.26°C/s, which has resulted in a number of device failures because of migration of micro cracks through the CPCI. In the second profile, this ΔT at preheat stage is minimized to 2.06°C/s that eliminated the thermal stresses; hence, the failure rates were significantly reduced. Findings TMPC0618H series lead (Pb)-free CPCI is selected for this study and its thermal expansion and thermal shock are observed in the reflow process. It is inferred from the results that high ΔT at preheat zone generates cracks in the carbonyl powder-type ceramics that cause device failure in the board ageing process. Comparing materials, carbonyl powder ceramic components are less resistant to thermal shock and a lower rate of temperature change is desirable. Originality/value The proposed study presents an experimental analysis for mitigating the thermal shock defects. The realization of the proposed approach is validated with experimental data from the printed circuit boards manufacturing process.

Experimental Analysis of Biogas Combustion With Different Foam Materials in a Porous Media Burner

The existing biogas Conventional Burners (CBs) are less energy efficient and are designed for rich fuel combustion. Porous Media Burner (PMB), working on the principle of combustion in porous media offer several advantages including high thermal efficiency, low emissions, high power intensity, etc. In this work, a study on the effect of porous material on the thermal behaviour of a biogas operated PMB is presented. A state-of-the-art PMB working in the thermal load range of 5 to 10 kW has been developed, which can be used for both industrial and domestic purposes. It is a two section burner composed of a combustion zone and a preheat zone. Keeping the material of the preheat zone unchanged (Al2O3 ceramic), the burner is tested with two different materials in the combustion zone (SiC and ZrO2 foams). Experimental investigation has been done to analyze the stability criteria and study the temperature distribution in the PMB. This includes the identification of the stable operating limits (flashback and blow off) and measurement of temperature profiles in axial and radial direction. These assessments confirm that SiC is a better choice over ZrO2 for lean biogas combustion in PMB.

Combustion of lycopodium particles in random media: Analytical model and predicting the effect of heat loss and Lewis number

In this paper, a new analytical model is proposed to model combustion of micro organic dust particles. In contrast with previous studies, random combustion of lycopodium particles and analyze the effect of heat loss and different Lewis number on the combustion properties is taken which has not be considered before this. It is assumed that flame structure is consisted of a preheat-vaporization zone, a reaction zone and a post flame zone. Then, different Lewis numbers are applied in governing equations. To perform the random model of particle combustion, source term in energy equation has been modeled by means of random states for volatilization of particles in preheat zone. Therefore, different groups which contains random amount of particles and sense a random temperature in the preheat zone has been considered. In this analysis, the impact of random combustion, Lewis number, and particles diameter on the combustion properties of lycopodium particles such as burning velocity, flame temperature and effective equivalence ratio are studied. Consequently, comparison made between results obtained from random model by experimental data, indicated that the random model have a better agreement with experimental data than non-random model.

Impact of Geometric Parameters of Fuel-Air Distribution System on the Temperature Variation and Emission of a Sideway Faced Porous Radiant Burner (SFPRB)

The present work describes the state-of-the-art technology for a Sideway Faced Porous Radiant Burner (SFPRB) of 10–15 kW capacity, operated by liquefied petroleum gas (LPG) applicable for industrial furnace and incinerator. The newly developed SFPRB is a two layer burner, consisting of a reaction zone and a preheat zone. The combustion zone is of reticulated SiC ceramic matrix of porosity 90%, diameter 120 mm and thickness 20 mm and the preheat zone is of Al2O3 ceramic having 463 through holes (diameter 1.5 mm), with 15 mm thickness and 120 mm diameter. The work presents the effect of geometrical parameters (length of mixing pipe and diameter of orifice) on the radial temperature distribution of burner surface. Experimentation has been done in 15 kW input power to study the behavior of air-fuel mixture entering the burner. Ultimately, it is focused for uniform temperature distribution on the burner surface with a suitable arrangement. The work also presents a detailed account of the temperature distribution along the two main burner axes and the emission measurements (CO and NOx) for the suitable SFPRB. Investigation was done for an input power range of 10–15 kW with an equivalence ratio of 0.5.

Theoretical Study on Premixed Flames of Nano Aluminum Particles and Water Mixture

A theoretical model is proposed to investigate premixed combustion characteristics of Nano aluminum particles - water mixture. The effects of particle size, initial pressure, and temperature were considered as well. Computational domain is divided into 3 regions; preheat zone 1, preheat zone 2, and reaction zone. No reaction occurs in either of the preheat zones. Reaction zone, consisting of nano aluminum particles–steam mixture and the combustion products, is the region where reaction and heat-release occurs. Energy conservation is considered separately at each zones. The flame speed and temperature distribution are derived by solving the energy equation in each regime and matching the temperature and heat flux at the interfacial boundaries. Combustion time correlation of nano aluminum particle is also considered to imply complex aluminum combustion kinetics. Normalized flame speed is calculated as a function of pressure, initial particle diameter, and equivalence ratio and compared with experimental data.

An analytical study of radiation effects on the premixed laminar flames of aluminium dust clouds

A new analytical model of a quasi one-dimensional non-adiabatic dust flame is developed with the assumption that the particle burning rate in the flame front is controlled by the process of oxygen diffusion. In this model, the flame propagation mechanism is considered to be radiation, conduction, and convection. Algebraic equations defining the laminar flame speed were obtained in two limiting cases: lean and rich mixtures. The flame structure is assumed to consist of a preheat zone, a reaction zone, and a postflame zone for lean mixtures and a preheat zone and a reaction zone for rich mixtures. Under the lean mixture approximation, values of the flame speed, lean limit, and flame temperature were calculated by adding the radiation term; flame temperature in the preheat zone increased, while it decreased in the postflame zone. This phenomenon may be attributed to the radiative heat transfer from the postflame zone to the preheat zone. Also, when the radiation term was considered, the flame speed increased but the lean limit decreased. In addition, radiation in the rich mixture resulted in the increase of the flame speed and the gas phase temperature in the preheat zone, whereas in the flame zone, the gas phase temperature decreased. Calculated values of the flame speed and flame temperature are in a good agreement with the experimental data in the literature.