Search results

This paper aims to analyze the morphology transformation on the Cu₃Sn grains during the formation of full Cu₃Sn solder joints in electronic packaging.

Because of the infeasibility of analyzing the morphology transformation intuitively, a novel equivalent method is used. The morphology transformation on the Cu₃Sn grains, during the formation of full Cu₃Sn solder joints, is regarded as equivalent to the morphology transformation on the Cu₃Sn grains derived from the Cu/Sn structures with different Sn thickness.

During soldering, the Cu₃Sn grains first grew in the fine equiaxial shape in a ripening process until the critical size. Under the critical size, the Cu₃Sn grains were changed from the equiaxial shape to the columnar shape. Moreover, the columnar Cu₃Sn grains could be divided into different clusters with different growth directions. With the proceeding of soldering, the columnar Cu₃Sn grains continued to grow in a feather of the width growing at a greater extent than the length. With the growth of the columnar Cu₃Sn grains, adjacent Cu₃Sn grains, within each cluster, merged with each other. Next, the merged columnar Cu₃Sn grains, within each cluster, continued to merge with each other. Finally, the columnar Cu₃Sn grains, within each cluster, merged into one coarse columnar Cu₃Sn grain with the formation of full Cu₃Sn solder joints. The detailed mechanism, for the very interesting morphology transformation, has been proposed.

Few researchers focused on the morphology transformation of interfacial phases during the formation of full intermetallic compounds joints. To bridge the research gap, the morphology transformation on the Cu₃Sn grains during the formation of full Cu₃Sn solder joints has been studied for the first time.

This paper aims to investigate the effect of ultrasonic vibration (USV) on the evolution of intermetallic compounds (IMCs), grain morphology and shear strength of soldered Ni/Sn/Ni samples.

The Ni/Sn/Ni joints were obtained through ultrasonic-assisted soldering. The formation of IMCs, their composition, grain morphology and the fractured-surface microstructures from shear tests were characterized using scanning electron microscopy and energy-dispersive x-ray spectroscopy.

Without USV, a planar interfacial Ni₃Sn₄ layer was formed at the Ni/Sn interface, and a few Ni₃Sn₄ grains were distributed in the soldered joint. The morphology of these grains was needle-shaped. With USV, several grooves were formed at the interfacial Ni₃Sn₄ layer due to ultrasonic cavitation. Some deepened grooves led to “neck” connections at the roots of the Ni₃Sn₄ grains, which accelerated the strong detachment of Ni₃Sn₄ from the substrate. In addition, two types of Ni₃Sn₄ grains, needle-shaped and granular-shaped, were observed at the interface. Furthermore, the shear strength increased with longer USV time, which was attributed to the thinning of the interfacial IMC layers and dispersion strengthening from the Ni₃Sn₄ particles distributed evenly in the joint.

The novelty of the paper is the detailed study of the effect of USV on the morphology, size changes of interfacial IMC and joint strength. This provides guidance for the application of ultrasonic-assisted soldering in electronics packaging.

Wire-arc-based additive manufacturing (WAAM) is a promising technology for the efficient and economical fabrication of medium-large components. However, the anisotropic behavior of the multilayered WAAM-fabricated components remains a challenging problem.

The purpose of this paper is to conduct a comprehensive study of the grain morphology, crystallographic orientation and texture in three regions of the WAAM printed component. Furthermore, the interdependence of the grain morphology in different regions of the fabricated component with their mechanical and tribological properties was established.

The electron back-scattered diffraction analysis of the top and bottom regions revealed fine recrystallized grains, whereas the middle regions acquired columnar grains with an average size of approximately 8.980 µm. The analysis revealed a higher misorientation angle and an intense crystallographic texture in the upper and lower regions. The investigations found a higher microhardness value of 168.93 ± 1.71 HV with superior wear resistance in the bottom region. The quantitative evaluation of the residual stress detected higher compressive stress in the upper regions. Evidence for comparable ultimate tensile strength and greater elongation (%) compared to its wrought counterpart has been observed.

The study found a good correlation between the grain morphology in different regions of the WAAM-fabricated component and their mechanical and wear properties. The Hall–Petch relationship also established good agreement between the grain morphology and tensile test results. Improved ductility compared to its wrought counterpart was observed. The anisotropy exists with improved mechanical properties along the longitudinal direction. Moreover, cylindrical components have superior tribological properties compared with cuboidal components.

The paper aims to introduce the fabrication of a medium steel aircraft part by hybrid deposition and micro-rolling technology (HDMR) and illustrate its advantages, microstructure features and mechanical properties of the part.

The HDMR technology contains two procedures happening almost at the same time: the welding deposition procedure and then the micro-rolling procedure. It takes the gas metal arc welding as the heat source to melt a metal wire and deposit metal in the welding deposition procedure. The metal just deposited is rolled synchronously by a micro roller following the welding torch in micro-rolling procedure almost at the same time layer by layer. The paper presents a contrast of the grain morphology of metal parts produced respectively by HDMR and freedom arc deposition (FAD) and the mechanical properties of metal parts of the same metal from HDMR casting, forging and FAD methods.

HDMR breaks the dendrite grain of welding beads into the fine crisscross grains. The mechanical properties of metal parts are improved distinctly by the micro-rolling procedure compared to casting, forging and FAD.

In addition, the application of HDMR technology has succeeded in the fabrication of an eligible aircraft metal part, which is quite difficult to achieve using other additive manufacturing (AM) or casting technologies.

HDMR has the advantage of equiponderance manufacturing by micro-rolling compared to other AM technologies. The metal part fabricated by HDMR technology obtains the fine crisscross grains and brings hope for AM metal components with excellent mechanical properties for aircraft applications.

Understanding and tailoring the solidification characteristics and microstructure evolution in as-built parts fabricated by laser powder bed fusion (LPBF) is crucial as they influence the final properties. Experimental approaches to address this issue are time and capital-intensive. This study aims to develop an efficient numerical modeling approach to develop the process–structure (P-S) linkage for LPBF-processed Inconel 718.

In this study, a numerical approach based on the finite element method and cellular automata was used to model the multilayer, multitrack LPBF build for predicting the solidification characteristics (thermal gradient G and solidification rate R) and the average grain size. Validations from published experimental studies were also carried out to ensure the reliability of the proposed numerical approach. Furthermore, microstructure simulations were used to develop P-S linkage by evaluating the effects of key LPBF process parameters on G × R, G/R and average grain size. A solidification or G-R map was also developed to comprehend the P-S linkage.

It was concluded from the developed G-R map that low laser power and high scan speed will result in a finer microstructure due to an increase in G × R, but due to a decrease in G/R, columnar characteristics are also reduced. Moreover, increasing the layer thickness and decreasing the hatch spacing lowers the G × R, raises the G/R and generates a coarse columnar microstructure.

The proposed numerical modeling approach was used to parametrically investigate the effect of LPBF parameters on the resulting microstructure. A G-R map was also developed that enables the tailoring of the as-built LPBF microstructure through solidification characteristics by tuning the process parameters.

Laser powder bed fusion (LPBF) can be used to fabricate complex extrusion die without the limitation of structures. Layer-by-layer processing leads to differences in microstructures and wear properties. This study aims to investigate the microstructure evolution and effects of tungsten carbide (WC) on the wear properties of LPBF-printed 18Ni300.

Economical spherical granulation-sintering-deoxygenation (GSD) WC-reinforced 18Ni300 steel matrix composites were produced by LPBF from powder mixtures of WC and 18Ni300. The effects of WC contents on anisotropic microstructures and wear properties of the composites were investigated.

The relative density is more than 99% for all the composites except 25% WC/18Ni300 composite. The grain sizes distributed on the top cross-section are smaller than those on the side cross-section. After adding WC particles, more high-angle grain boundaries and larger Schmid factor generate, and deformed grains decrease. With increasing WC contents, the hardness first decreases and then increases but the wear volume loss decreases. The side cross-section of the composite has higher hardness and better wear resistance. The 18Ni300 exhibits adhesive wear accompanying with abrasive wear, while plowing and fatigue wear are the predominant wear mechanisms of the composites.

Economical spherical GSD WC particles can be used to improve the wear resistance. The novel WC/18Ni300 composites are suitable for the application under the abrasive wear condition with low stress.

Selective laser melting (SLM) is being investigated by Alstom and IWF due to its flexibility, cost‐ and lead‐time reduction potential for reconditioning of hot gas path components used in today's heavy‐duty gas turbines. This paper aims to address this issue.

Tensile tests as well as relaxation and creep tests were carried out to assess SLM processed IN738LC for use in high temperature applications. To evaluate potential anisotropic material behaviour resulting from the layer‐wise build up process, all specimens were built in two directions: parallel and perpendicular to the build direction, respectively. Furthermore, extensive metallurgical investigations were made to analyse the chemical homogeneity as well as the correlation between microstructure and high temperature properties of SLM processed IN738LC.

Tensile tests showed that strength properties superior to cast IN738LC can be achieved by processing this material by SLM alternatively. Due to differences in grain size, grain orientation as well as γ′size and morphology the relaxation behaviour of SLM specimens is inferior compared to cast material. However, creep tests have shown that values within the lower scatter band of cast material can still be achieved along the build direction.

Very limited knowledge exists regarding the processing of γ′precipitation‐strengthened nickel‐base superalloys by SLM and the resulting high temperature material properties. Layered manufacturing and any lack‐of‐fusion porosity influences them as well as high temperature gradients, occurring during the process. This article presents the latest insights from material testing of selective laser molten IN738LC at elevated temperatures.

Additive manufacturing (AM) is revolutionizing the manufacturing industry due to several advantages and capabilities, including use of rapid prototyping, fabrication of complex geometries, reduction of product development cycles and minimization of material waste. As metal AM becomes increasingly popular for aerospace and defense original equipment manufacturers (OEMs), a major barrier that remains is rapid qualification of components. Several potential defects (such as porosity, residual stress and microstructural inhomogeneity) occur during layer-by-layer processing. Current methods to qualify AM parts heavily rely on experimental testing, which is economically inefficient and technically insufficient to comprehensively evaluate components. Approaches for high fidelity qualification of AM parts are necessary.

This review summarizes the existing powder-based fusion computational models and their feasibility in AM processes through discrete aspects, including process and microstructure modeling.

Current progresses and challenges in high fidelity modeling of AM processes are presented.

Potential opportunities are discussed toward high-level assurance of AM component quality through a comprehensive computational tool.

In this paper, we consider intrinsic properties of copper electrodeposited as plateup on polyimide substrate, thermal response of electrodeposited copper and fatigue performance of copper and copper/polyimide construction. The critical material characteristics examined are grain morphology and structure, crystallographic texture, microhardness, uniaxial strength and ductility and isothermal cyclic fatigue life. Given optimum processing conditions, copper plateup in flexible circuits displays fine grain structure, high ductility, adequate thermal stability, freedom from thermal embrittlement and excellent fatigue endurance over a wide range of strain amplitudes.

This paper aims to investigate the influence of different post-annealing cooling conditions, i.e. furnace cooling (heat treatment (HT) 1 – slow cooling) and air cooling (HT 2 – fast cooling), on the microstructure and mechanical properties of selective laser melting (SLM) built austenitic 316L stainless steel (SS).

Three sets of 316L SS samples were fabricated using a machine standard scanning strategy. Each set consists of three tensile samples and a cubic sample for microstructural investigations. Two sets were subsequently subjected to annealing HT with different cooling conditions, i.e. HT 1 and HT 2, whereas one set was used in the as-built (AB) condition. The standard metallographic techniques of X-ray diffraction, scanning electron microscopy and electron back-scattered diffraction were used to investigate the microstructural variations induced by different cooling conditions. The resultant changes in mechanical properties were also investigated.

The phase change of SLM fabricated 316L was observed to be independent of the investigated cooling conditions and all samples consist of austenite phase only. Both HT 1 and HT 2 lead to dissolved characteristic melt pools of SLM. Noticeable increase in grain size of HT 1 and HT 2 samples was also observed. Compared with AB samples, the grain size of HT 1 and HT 2 was increased by 12.5% and 50%, respectively. A decreased hardness and strength, along with an increased ductility was also observed for HT 2 samples compared with HT 1 and AB samples.

From previous studies, it has been noticed that most investigations on HT of SLM fabricated 316L were mainly focused on the HT temperature or holding time. However, the post-HT cooling rate is also an equally important factor in deciding the microstructure and mechanical properties of heat-treated components. Therefore, this paper investigates the influence of different post-annealing cooling conditions on microstructure and mechanical properties of SLM fabricated 316L components. This study provides a foundation for considering the post-HT cooling rate as an influential parameter that controls the properties of heat-treated SLM components.