Forming characteristics of coated products for packaging applications

Abstract

A comparison of forming characteristics has been conducted on two different thickness steel substrates used in the packaging industry. Three surface conditions were studied, namely, uncoated blackplate, a lacquered electrochromium coated steel (ECCS), and a typical film laminate specification. It was found that for identical forming conditions the failure rates of both blackplate and lacquered ECCS materials were higher than in the film laminated alternative. This is shown to be related to the frictional effects of the coatings. In the film laminate material, failures were only observed at high blankholder forces near the forming limit of the material. The blackplate material produced cups, which were 0·4 mm taller than both the lacquered and film laminated coatings.     

Ultrasonic characterization of the interface between a die attach adhesive and a copper leadframe in IC packaging

The silicon die (chip) and the copper leadframe in IC packaging are bonded by a die attach adhesive, and the quality of the interface is a critical issue in the reliability of IC packaging as well as during the manufacturing process. The common defects such as cracks and delamination can be detected using the C-mode scanning acoustic microscopy. However, a weak interface due to poor adhesion often goes undetected and may become a potential defective area at a later stage. This paper describes the work done to evaluate the quality of the weak interface between a die attach adhesive and a copper leadframe. An interface spring model is used to predict the ultrasonic reflection coefficients. Normal incidence reflection coefficients are measured from a two-layer specimen bonded with a die attach adhesive. The quality of the interface in the samples and its degradation are affected by copper oxidation, and by applying shear stress loading. It is shown that the reflection coefficient depends strongly on both the interface quality and stress loading, indicating that a nondestructive characterization of the interface is possible and the reflection coefficient can be used as a criterion.     

Magnesium matrix nanocomposites fabricated by ultrasonic assisted casting

Abstract

Magnesium matrix composites reinforced with nano-sized SiC particles (n-SiC_p/AZ91D) were fabricated by high intensity ultrasonic assisted casting. The microstructure of the nanocomposites was investigated by optical microscopy, scanning electronic microscopy (SEM), high resolution transmission electronic microscopy (HRTEM) and Energy Dispersive Spectroscopy (EDS) methods. The results showed that the dispersion and distribution of n-SiC_p in magnesium alloy melts were significantly improved by ultrasonic processing. Compared to the unreinforced AZ91D matrix, mechanical properties of the nanocomposites including tensile and yield strengths were remarkably improved and the yield strength increased by 117% after gravity permanent mould casting.     

Intensity of hydrodynamic movements induced by ultrasounds in ultrasonic cleaning in water solutions

Abstract

The main causative agent of ultrasonic cleaning is cavitation. A helpful factor is liquid movement induced by ultrasound, but in some organic solvents, the intensity of this movement is so high that its significance for the process of cleaning is equal to and sometimes even higher than the significance of cavitation. In the present work, the intensity of hydrodynamic movement induced by ultrasound in water was assessed and compared with those in selected organic solvents used in ultrasonic cleaning.     

Non-destructive characterization of bondlines in composite adhesive joints

Aerospace structures use polymeric composite materials extensively. These composite materials are normally bonded together by adhesives to form structural parts. The existence of any kind of defects or discontinuities in the bonds is completely undesirable for such applications. Ultrasonic imaging (UI) is a widely used technique for non-destructive evaluation (NDE) and can be adopted to evaluate the integrity of such adhesively-bonded joints. However, characterization of adhesive bonds in composite materials using UI has deficiencies due to problems such as high acoustic attenuation and high signal-to-noise ratio. These problems can be attributed to the inhomogeneity in composite structures. The present study addresses the problems of detection of disbonds and porosity in adhesively bonded carbon fiber reinforced composite panels. Five sets of adhesively-joined carbon/epoxy composites with different adherend surface preparations were fabricated and subjected to UI. The panels contained known defects in the bondline of the samples. UI results are interpreted to identify various existing defects such as voids, cracks and disbonds in the joints. Attenuation coefficient values for all types of composites are utilized to ascertain the validity of the image analysis.     

Measurement of residual stresses in austenitic stainless steel weld joints using ultrasonic technique

Abstract

A methodology has been developed using a non-destructive ultrasonic technique for measuring surface/subsurface residual stresses in 7 mm thick AISI type 316LN stainless steel weld joints made by activated tungsten inert gas and multipass tungsten inert gas welding processes. Measurement of residual stresses using an ultrasonic technique is based on the effect of stresses on the propagation velocity of elastic waves. Critically refracted longitudinal L _CR wave mode was employed and accurate transit time measurements were made across the weld joints. Quantitative values of the longitudinal residual stresses across the weld joints were estimated from the measured transit times and predetermined value of acoustoelastic constant for AISI type 316LN stainless steel. The nature of the residual stress profiles and their variations across the two types of weld joints were compared and interpreted.     

High performance automotive and railway components made from novel competitive aluminium composites

Abstract

The traditional materials encounter difficulties to comply with all the properties required by new components under service conditions. The automotive and the railway industries require low cost solutions to improve the final performance of components made from steel, cast iron, or even conventional aluminium alloys (e.g. clutch discs, brake discs, or pistons). Weight reduction, improvement in wear behaviour, high thermal conductivity, low coefficient of thermal expansion, and easy recycling are sought, among other characteristics, in order to obtain more efficient products leading to a reduction of pollutant emissions. The range of materials that can meet these requirements is presently very narrow and their final price is more expensive (e.g. aluminium matrix composites) than currently used materials. In this paper a new low cost metal matrix composite that has been used to produce pistons, clutch discs, and train brake discs is presented.     

Sounding Out Pharmaceutical Processes

High-resolution ultrasonic spectroscopy is a novel technique with enormous potential for analysis of a wide range of samples and processes. This technique is based on precision measurements of velocity and attenuation of acoustical waves at high frequencies propagating through materials. It allows fast at/on line measurements analysis of formulation consistency (composition, structure) of raw materials, ingredients and intermediates, process impurity analysis, particle sizing, batch to batch variation, stability assessment etc in pharmaceutical industry. The technology can be used for static fingerprint measurements or for dynamic analysis of systems. Optical transparency is not required as ultrasonic waves propagate through opaque samples. The analysis is fast and non-destructive. High-resolution ultrasonic spectrometers were developed, patented and brought to the market by Ultrasonic Scientific Ltd. and recognised with various international awards. These instruments require small sample volumes, down to 0.03 ml, and give excellent resolution. They can be used for the analysis of composition, aggregation, particle sizing, gelation, micellisation, crystallisation, sedimentation, enzymatic activity, conformational transitions in polymers, biopolymer-ligand binding and antigen-antibody interactions, etc. This article describes main features of High-Resolution Ultrasonic Spectroscopy and area of applications of new high-resolution HR-US series of ultrasonic spectrometers. Several applications are illustrated including the monitoring of denaturation and aggregation of proteins in antibody solution, the measurements of the particle size in emulsions, precipitation in synthetic blood substitutes and crystallisation     

Surface preparation effect on performance of adhesively-bonded graphite/epoxy composites subjected to impact

The influence of pre-bond surface preparation on performance of adhesively-bonded composites subjected to impact was investigated in this study. Impact test was carried out on adhesively bonded graphite/epoxy composite specimens at different low impact energies ranging from 5 to 20 J using the drop-weight impact test. Post-impact ultrasonic evaluation was performed in order to determine the resulting internal damage due to impact on the adhesive bondline. The ultrasonic C-scan of the gated ultrasonic wave signal was acquired and the ensuing debond area in the adhesive bond was determined quantitatively for specimens made from substrates with different surface preparations such as paper peel ply, sandblasting, and sandpaper abrasion. In order to determine the flexural load bearing capacity and stiffness reduction after impact, a three-point bending test was conducted on unimpacted and impacted specimens. A comparative study was performed to evaluate the performance of adhesively-bonded composites with different surface preparations. The results revealed that paper-peel ply performed the best in terms of resistance to debond area formation in the adhesive layer, as well as in terms of retention of flexural load bearing capacity and stiffness after impact.