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In land grid array hybrid or system in package type products passive integration on silicon dies are flip chip mounted on a laminate substrate using Pb‐free solder. To increase the solder bump fatigue life, underfill is applied. The application of underfill resulted in the occurrence of an unexpected and unwanted phenomenon: solder flowing out of the underfill during a second level reflow test. The occurrence of solder flow‐out seemed associated with moisturizing as part of a moisture sensitivity level assessment. The solder flow‐out is preceded by delamination, initiated by mismatch in coefficient of thermal expansion between copper through‐holes and laminate. This paper aims to describe the phenomenon and possible solutions by combining experiments with finite element (FE) simulations.

Ways to prevent this kind of overstress failures are investigated by design of experiments and observed trends are compared with thermo‐mechanical FE simulations. A significant contribution is made by through‐holes close to the bump and underfill fillet.

The FE simulations confirmed increased thermo‐mechanical induced stress levels by bad positioning of vias, underfill and solder. The integrity of the flip chip construction is substantially improved by optimising product design, underfill material and the associated assembly process.

This paper is a useful source of information on the causes of delamination and solder flow‐out.

The purpose of this paper is to develop a mathematical model for surface roughness and delamination through response surface methodology (RSM) and analyse the influences of the entire individual input machining parameters (cutting speed, fibre orientation angle, depth of cut and feed rate) on the responses in milling of glass fibre reinforced plastics (GFRP) composites with solid carbide end mill cutter coated with PCD.

Four factors, five level central composites and a rotatable design matrix in response surface methodology were employed to carry out the experimental investigation. “Design Expert 8.0” software was used for regression and graphical analysis of the data were collected. The optimum values of the selected variables were obtained by solving the regression equation and by analyzing the response surface contour plots. Analysis of variance (ANOVA) was applied to check the validity of the model and for finding the significant parameters.

The developed second order response surface model was used to calculate the surface roughness and delamination of the machined surfaces at different cutting conditions with the chosen range with 95 per cent confidence intervals. Using such a model, remarkable savings in time and cost can be obtained.

The effect of fibre orientation during milling of GFRP laminates using RSM has not been previously attempted for analysis.

This study aimed to develop a mathematical model for delamination and surface roughness during end milling by using grey relational analysis (GRA) and to determine how the input parameters (cutting speed, depth of cut, helix angle and feed rate) influence the output response (delamination and surface roughness) in machining of hybrid glass fibre-reinforced plastic (GFRP) (abaca and glass) composite using solid carbide end mill cutter.

The Four factors, three levels Taguchi orthogonal array design in GRA is used to conduct the experimental investigation. The Shop Vision inspection system is used to measure the width of maximum damage of the machined hybrid GFRP composite. The Shop Handysurf E-35A surface roughness tester is used to measure the surface roughness of the machined hybrid GFRP composite. “Minitab 14” is used to analyse the data collected graphically. Analysis of variance is conducted to validate the model in determining the most significant parameter.

The GRA is used to predict the input factors influencing the delamination and surface roughness on the machined surfaces of the hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination and surface roughness has been conducted using GRA.

Effect of milling of the hybrid GFRP composite on delamination and surface roughness with various helix angle solid carbide end mill has not been analysed yet using the GRA technique.

A delamination fracture analysis of two-dimensional functionally graded multilayered end-loaded split beam configuration with non-linear mechanical behaviour of material is conducted. The beam is made of an arbitrary number of longitudinal layers. Perfect adhesion between layers is assumed. The material is two-dimensional functionally graded in the cross-section of each layer. Also, each layer has individual thickness and material properties. A delamination crack is located arbitrary along the beam height. The paper aims to discuss these issues.

The delamination fracture behaviour is investigated analytically in terms of the strain energy release rate by analysing the balance of the energy. An additional analysis of the delamination fracture is performed by applying the J-integral approach for verification.

The solutions derived are used to evaluate the effects of crack location, material gradients and material non-linearity on the delamination fracture behaviour of end-loaded split beam. The effect of material gradient on the distribution of the J-integral value along the crack front is elucidated too.

Delamination in the multilayered functionally graded end-loaded split beam exhibiting non-linear mechanical behaviour of the material is analysed assuming that the material property is distributed non-linearly in both thickness and width directions in each layer.

This paper aims to deal with the influence of cutting parameters on drill thrust force, delamination and surface roughness in the drilling of laminated jute/carbon hybrid composites.

The hybrid composites were fabricated with four layers of fabrics, which are arranged in different sequences using the hand-layup technique. Drilling experiments involved drilling of 6 mm diameter holes on the prepared composite plates using high-speed steel and solid carbide drill materials. Analysis of variance was used to find the influence, percentage contribution and significance of drilling parameters on drilling-induced damages. Scanning electron microscopy analysis was also conducted to understand the fracture behavior and surface morphology of the drilled holes.

The experimental study reveals that the most significant effect was the feed rate influenced the drill thrust force and the drill speed influenced both delamination factor and surface roughness of hybrid fiber-reinforced composites. From observations, the suggested combination for drilling jute/carbon hybrid composites is carbide drill, spindle speed of 1,750 rpm and feed of 0.03 mm/rev.

The new lightweight and low-cost hybrid composites were developed by hybridizing jute with carbon fabrics in the epoxy matrix with interplay arrangements. The influence of cutting speed and feed rate on delamination damage and surface roughness in the drilling of hybrid composites have been experimentally evaluated.

Flip chip technology involves the attachment of active side of the silicon chip onto printed circuit board or substrate. The interconnections are provided by solder bumps, which are arranged in the area under the chip. Encapsulation helps reduce the impact of the thermal stress that results from the mismatch in the coefficient of thermal expansion between the silicon chip and the substrate. The adhesion of the encapsulant to the chip and the board coating are essential to the reliability of the package. This paper studies the adhesion characteristics of an encapsulant to a flip chip package. The quality of the encapsulation was inspected using a scanning acoustic microscope. The electrical continuity of the assemblies was tested during the liquid‐to‐liquid thermal shock testing. The various delamination mechanisms were then studied. Delamination was found predominantly at the interface between the passivation layer and the encapsulant material. Comparisons were made between samples assembled by different materials used, such as chip passivation layer, encapsulant materials, and fluxes. Finally, the best material combination was determined.

Glass is a promising interposer substrate for 2.5 D integration; yet detailed analysis of the interfacial reliability of through-glass vias (TGVs) has been lacking. The purpose of this paper is to investigate the design and material factors responsible for the interfacial delamination in TGVs and identify methods to improve reliability.

The interfacial reliability of TGVs is studied both analytically and numerically. An analytical solution is presented to show the dependence of the energy release rate (ERR) for interfacial delamination on the via design and the thermal mismatch strain. Then, finite element analysis (FEA) is used to investigate the influence of detailed design and material factors, including the pitch distance, via aspect ratio, via geometry and the glass and via materials, on the susceptibility to interfacial delamination.

ERR for interfacial delamination is directly proportional to the via diameter and the thermal mismatch strain. Thinner wafers with smaller aspect ratios show larger ERRs. Changing the via geometry from a fully filled via to an annular via leads to lower ERR. FEA results also show that certain material combinations have lower thermal mismatch strains, thus less prone to delamination.

The results and approach presented in this paper can guide the design and development of more reliable 2.5 D glass interposers.

This paper represents the first attempt to comprehensively evaluate the impact of design and material selection on the interfacial reliability of TGVs.

In general two main types of criteria are essential for the sizing of aircraft structural panels, namely, stability and damage tolerance. The way these criteria act and interact is very different for metallic and composite building blocks. While interaction of both types of criteria is relatively clear for composite parts, this is normally not the case for metallic ones. What is common for both is the fact that, if an interaction occurs, the impact is essential. The paper aims to discuss these issues.

This is a survey paper.

There is a strong mutual influence of buckling and damage in many cases.

It shows the significance of both, buckling and damage as a combined phenomenon.

The purpose of this paper is to assess a numerical tool to simulate and predict the onset and the propagation of the delaminations in a composite structure.

The approach to the work is done through the cohesive zone model technique applied to the finite element method.

Double cantilever beam, end notched flexure and mixed mode bending tests have been performed and correlated to benchmark cases, in order to validate the procedure. Numerical test campaign on specimens of the skirts with delaminations has been performed to analyze the behaviour under compressive load and the buckling.

This tool is applied to the study of the behaviour of some components in carbon/epoxy composite of a space structure in which one or more delaminations are eventually present following impact damage or manufacturing process. The components in particular are the booster's skirts of a small class launcher, subjected to a compressive load.

The purpose of this paper is to originate a statistical model for delamination factor, surface roughness, machining force and also to determine and compare the effects of machining parameters (spindle speed, fiber orientation angle, helix angle and feed rate) on the output responses during end-milling of glass fiber reinforced polymers (GFRP) by using desirability functional analysis (DFA) and grey relational analysis (GRA).

Based on Taguchi’s L27 orthogonal array, milling experiments were carried on GFRP composite plates employing solid carbide end mills with different helix angles. The machining parameters were optimized by an approach based on DFA and GRA, which were useful tools for optimizing multi-response considerations, namely, machining force, surface roughness and delamination factor. A composite desirability index was obtained for multi-responses using individual desirability values from DFA. Based on this index and grey relational grade the optimum levels of parameters were identified and significant contribution of parameters was ascertained by analysis of variance.

Fiber orientation angle (66.75 percent) was the significant parameter preceded by feed rate (15.05 percent), helix angle (7.76 percent) and spindle speed (0.30 percent) for GFRP composite plates.

Multi-objective optimization in end-milling of GFRP composites using DFA and GRA has not been performed yet.