Fabrication process and thermal properties of SiCp/Al metal matrix composites for electronic packaging applications

The fabrication process and thermal properties of 50–71 vol% SiC_p/Al metal matrix composites (MMCs) for electronic packaging applications have been investigated. The preforms consisted with 50–71 vol% SiC particles were fabricated by the ball milling and pressing method. The SiC particles were mixed with SiO₂ as an inorganic binder, and cationic starch as a organic binder in distilled water. The mixtures were consolidated in a mold by pressing and dried in two step process, followed by calcination at 1100 °C. The SiC_p/Al composites were fabricated by the infiltration of Al melt into SiC preforms using squeeze casting process. The thermal conductivity ranged 120–177 W/mK and coefficient of thermal expansion ranged 6–10 × 10^–6/K were obtained in 50–71 vol% SiC_p/Al MMCs. The thermal conductivity of SiC_p/Al composite decreased with increasing volume fraction of SiC_p and with increasing the amount of inorganic binder. The coefficient of thermal expansion of SiC_p/Al composite decreased with increasing volume fraction of SiC_p, while thermal conductivity was insensitive to the amount of inorganic binder. The experimental values of the coefficient of thermal expansion and thermal conductivity were in good agreement with the calculated coefficient of thermal expansion based on Turner's model and the calculated thermal conductivity based on Maxwell's model.     

Statistical analysis for strength and spatial distribution of reinforcement in SiC particulate reinforced aluminum alloy composites fabricated by die-casting

Statistical analysis for strength and spatial distribution of reinforcement in die-cast SiC_p/Al alloy composites was performed in order to predict the reliability of composites. Microstructural analysis was also done to determine the critical features of the composites. Die-casting was carried out using the preheated die at the casting temperature range of 620–750°C. It was found that the SiC pacticulates were homogeneously dispersed in die-cast Al matrix alloy, resulting from the refinement of dendritic cell size due to rapid cooling rate. The tensile strength of die-cast SiC_p/Al alloy composites was higher than that of die-cast Al matrix alloy. Also, the tensile strength was slightly increased with increasing SiC particulate volume fraction at the casting temperature range of 650–700°C. It was concluded that the die-cast temperatures of 750 and 700°C are optimum condition for the distribution of SiC particulates in consequence of good fluidity of melt for 10 and 20 vol.% SiC_p/Al alloy composites, respectively. However, the strength scattering of composites was increased with increasing SiC particulate volume fraction. For the statistical evaluation of strength, the maximum Weibull modulus of die-cast SiC_p/Al alloy composites, which was obtained at the cast temperature of 700°C, was 29.6 in Al matrix alloy, 22.2 in 10 vol.% SiC_p and 14.2 in 20 vol.% SiC_p, respectively.     

Pressure infiltration casting process and thermophysical properties of high volume fraction SiCp/Al metal matrix composites

Abstract

SiC_p/Al composites containing high volume fraction SiC particles were fabricated using a pressure infiltration casting process, and their thermophysical properties, such as thermal conductivity and coefficient of thermal expansion (CTE), were characterised. High volume fraction SiC particulate preforms containing 50–70 vol.-%SiC particles were fabricated by ball milling and a pressing process, controlling the size of SiC particles and contents of an inorganic binder. 50–70 vol.-%SiC_p/Al composites were fabricated by high pressure infiltration casting an Al melt into the SiC particulate preforms. Complete infiltration of the Al melt into SiC preform was successfully achieved through the optimisation of process parameters, such as temperature of Al melt, preheat temperature of preform, and infiltration pressure and infiltration time after pouring. Microstructures of 50–70 vol.-%SiC_p/Al composites showed that pores resided preferentially at interfaces between the SiC particles and Al matrix with increasing volume fraction of SiC particles. The measured coefficients of thermal expansion of SiC_p/Al composites were in good agreement with the estimated values based on Turner's model. The measured thermal conductivity of SiC_p/Al composites agreed well with estimated values based on the 'rule of mixture' up to 70 vol.-% of SiC particles, while they were lower than the estimated values above 70 vol.-% of SiC particles, mainly due to the residual pores at SiC/Al interfaces. The high volume fraction SiC_p/Al composite is a good candidate material to substitute for conventional thermal management materials in advanced electronic packages due to their tailorable thermophysical properties.     

Processing and properties of Al–Li–SiCp composites

Al–Li–SiC_p composites were fabricated by a modified version of the conventional stir casting technique. Composites containing 8, 12 and 18 vol% SiC particles (40 μm) were fabricated. Hardness, tensile and compressive strengths of the unreinforced alloy and composites were determined. Ageing kinetics and effect of ageing on properties were also investigated. Additions of SiC particles increase the hardness, 0.2% proof stress, ultimate tensile strength and elastic modulus of Al–Li–8%SiC and Al–Li–12%SiC composites. In case of the composite reinforced with 18% SiC particles, although the elastic modulus increases the 0.2% proof stress and compressive strength were only marginally higher than the unreinforced alloy and lower than those of Al–Li–8%SiC and Al–Li–12%SiC composites. Clustering of SiC particles appears to be responsible for reduced the strength of Al–Li–18%SiC composite. The fracture surface of unreinforced 8090 Al-Li alloy (8090Al) shows a dimpled structure, indicating ductile mode of failure. Fracture in composites occurs by a mixed mode, giving rise to a bimodal distribution of dimples in the fracture surface. Cleavage of SiC particles was also observed in the fracture surface of composites. Composites show higher peak hardness and lower peak ageing time compared with unreinforced 8090Al alloy. Macro- and microhardness increase significantly after peak ageing. Ageing also results in considerable improvement in strength of the unreinforced 8090Al alloy and its composites. This is attributed to formation of δ^′ (Al₃Li) and S^′ (Al₂CuMg) precipitates during ageing. Per cent elongation, however, decreases due to age hardening. Al–Li–12%SiC, which shows marginally lower UTS and compressive strength than the Al–Li–8%SiC composite in extruded condition, exhibits higher strength than Al–Li–8%SiC in peak-aged condition.     

Refining SiCp in reinforced Al–SiC composites using equal-channel angular pressing

Aluminum–silicon carbide composite (Al–SiC_p) is one of the most promising metal matrix composites for their enhanced mechanical properties and wear resistance. In the present study, Al–SiC (average size 55 μm) composites with 5% and 10% by volume were fabricated by stir casting technique. The equal-channel angular pressing (ECAP) was then applied on the cast composites at room temperature in order to study the effect of ECAP passes on the SiC_p size and distribution. The ECAP process was successfully carried out up to 12(8) passes for Al–5%(10%)SiC samples. Microstructure study revealed that the highest refinement by breakage of SiC_p was achieved after the first ECAP pass and that further refinement took place in the next passes. More breakage of the SiC_p was found in the composite richer in reinforcing particles so that the SiC_p reached approximately 1 μm in the Al–10%SiC after 8 passes and 4 μm in Al–5%SiC after 12 ECAP passes. The distribution of SiC reinforcement particles also improved after applying ECAP. The factors including decrease in reinforcing particle size, improvement in their distribution, decrease in porosity in addition to strain hardening and grain refining of the matrix resulted in enhancement of tensile and compressive strengths as well as hardness by more than threefold for the Al–5%SiC after 12 passes and for Al–10%SiC after 8 passes compared to the cast composites. Additionally, the composite remained ductile after the ECAP process. The fracture surface indicated good bond between the matrix and the reinforcement.     

Improvement of SiCf/SiC density by slurry infiltration and tape stacking

SiC fiber-reinforced SiC–matrix ceramic composites (SiC_f/SiC) were fabricated by vacuum infiltration of a SiC slurry into Tyranno™-SA grade-3 fabrics coated with a 200 nm-thick pyrolytic carbon (PyC) layer followed by hot pressing using a transient eutectic-phase. The density of the composite was improved using a special infiltration apparatus with a pressure gradient and alternating tape insertion between fabrics. Their overall properties were compared with those of monolithic SiC and composite containing chopped fibers. Although the density of the composites decreased with increasing fiber fraction, SiC_f/SiC containing 50 vol.% fibers had a density of 3.13 g/cm³, which is the highest reported thus far. The composites containing continuous fibers had a maximum flexural strength of 607 MPa and a step increase in the stress–displacement behavior during the three-point bending test due to fiber reinforcement, which was not observed in the monolith.     

Microstructure and mechanical properties of SiC<Subscript>P</Subscript>/SiC and SiC<Subscript>W</Subscript>/SiC composites by CVI

37.2 vol.% SiC_P/SiC and 25.0 vol.% SiC_W/SiC composites were prepared by chemical vapor infiltration (CVI) process through depositing SiC matrix in the porous particulate and whisker preforms, respectively. The particulate (or whisker) preforms has two types of pores; one is small pores of several micrometers at inter-particulates (or whiskers) and the other one is large pores of hundreds micrometers at inter-agglomerates. The microstructure and mechanical properties of 37.2 vol.% SiC_P/SiC and 25.0 vol.% SiC_W/SiC composites were studied. 37.2 vol.% SiC_P/SiC (or 25.0 vol.% SiC_W/SiC) consisted of the particulate (or whisker) reinforced SiC agglomerates, SiC matrix phase located inter-agglomerates and two types of pores located inter-particulates (or whiskers) and inter-agglomerates. The density, fracture toughness evaluated by SENB method, and flexural strength of 37.2 vol.% SiC_P/SiC and 25.0 vol.% SiC_W/SiC composites were 2.94 and 2.88 g/cm³, 6.18 and 8.34 MPa m^1/2, and 373 and 425 MPa, respectively. The main toughening mechanism was crack deflection and bridging.     

Effect of size of reinforcement on thickness of anodized coatings on SiC/Al matrix composites

The effect of size of reinforcements on morphology and thickness of anodic coatings on 3.5 μm and 10 μm SiC particles reinforced 2024Al metal matrix composites (SiC_p/Al MMCs) formed in sulfuric acid was investigated with optical microscopy and scanning electron microscopy. The thickness of anodized coating on the MMCs is strongly dependent of size of SiC particles, and it is smaller for the MMC with smaller SiC particles because growth of more pores is affected when the concentration of SiC particles is fixed. The oxide/substrate interface became locally scalloped, and the anodized coatings formed on the MMCs were non-uniform in thickness, especially for the MMC reinforced by bigger particles.     

Effects of particle size on fatigue crack initiation and small crack growth in SiC particulate-reinforced aluminium alloy composites

Fatigue crack initiation and small crack growth were studied under axial loading using powder metallurgy 2024 aluminum-matrix composites reinforced with SiC particles of three different sizes of 5, 20 and 60 μm. The 5 and 20 μm SiC_p/Al composites exhibited nearly the same fatigue strength as the unreinforced alloy, while the 60 μm SiC_p/Al composite showed a significantly lower fatigue strength due to its inferior crack initiation resistance that could be attributed to interface debonding between particles and the matrix. Small crack growth behaviour was different depending on stress level. At a low applied stress, the addition of SiC particles enhanced the growth resistance, particularly in the composites reinforced with coarser particles, while at a high applied stress, the 60 μm SiC_p/Al composite showed a considerably low growth resistance, which could be attributed to interaction and coalescence of multiple cracks. In the 5 μm SiC_p/Al composite, small cracks grew avoiding particles and thus few particles appearing on the fracture surfaces were seen, particularly in small crack size region. In the 20 and 60 μm SiC_p/Al composites, they grew along interfaces between particles and the matrix and the number of particles appearing on the fracture surfaces increased with increasing crack size or maximum stress intensity factor.     

Creep properties of (Si–Al–O–N)SiC whisker composites

(Si–Al–O–N) (sialon)–SiC whisker (SiC_w) composites containing up to 10 mass% SiC_w were prepared by hot isostatic pressing. The strengths and the fracture toughness of composites remained relatively unchanged with the amount of SiC_w. The addition of SiC_w enabled us to improve the creep properties of sialon ceramics. The total creep strain and steady-state creep rate at 1473 K under a stress of 400–500 MPa decreased with increasing the amount of SiC_w. The experimental creep exponent values of monolithic sialon and sialon–SiC_w composites were nearly 1. It is supposed that the creep of both monolithic sialon and sialon–SiC_w composites are dominated by the viscous flow of the interglanular glassy phase.     

Fatigue properties and fatigue fracture mechanisms of SiC whiskers or SiC particulate-reinforced aluminium composites

Fatigue properties and fracture mechanisms were examined for three commercially fabricated aluminium matrix composites containing SiC whiskers (SiC_w) and SiC particles (SiC_p) using a rotating bending test. The fatigue strengths were over 60% higher for SiC_w/A2024 composites than that for the unreinforced rolled material, while for the SiC_p/A357 composites, fatigue strengths were also higher than that for the unreinforced reference material. For the SiC_p/A356 composites at a volume fraction of 20%, the fatigue strength was slightly higher than that of the unreinforced material. Fractography revealed that the Mode I fatigue crack was initiated by the Stage I mechanism for the SiC_w/A2024 and SiC_p/A357 composites, while for the SiC_p/A356 composite, the fatigue crack initiated at the voids situated beneath the specimen surfaces. On the other hand, the fatigue crack propagated to the whisker/matrix interface following the formation of dimple patterns or the formation of striation patterns for SiC_w/A2024 composites, while for the SiC_p/A356 and SiC_p/A357 composites the fatigue crack propagated in the matrix near the crack origin and striation patterns were found. Near final failure, dimple patterns, initiated at silicon carbide particles, were frequently observed. Mode I fatigue crack initiation and propagation models were proposed for discontinuous fibre-reinforced aluminium composites. It is suggested that the silicon carbide whiskers or particles would have a very significant effect on the fatigue crack initiation and crack propagation near the fatigue limit.     

Enhanced thermal conductivity and retained electrical insulation for polyimide composites with SiC nanowires grown on graphene hybrid fillers

Polyimide (PI) composites containing one-dimensional SiC nanowires grown on two-dimensional graphene sheets (1D–2D SiC_NWs-GSs) hybrid fillers were successfully prepared. The PI/SiC_NWs-GSs composites synchronously exhibited high thermal conductivity and retained electrical insulation. Moreover, the heat conducting properties of PI/SiC_NWs-GSs films present well reproducibility within the temperature range from 25 to 175 °C. The maximum value of thermal conductivity of PI composite is 0.577 W/mK with 7 wt% fillers loading, increased by 138% in comparison with that of the neat PI. The 1D SiC nanowires grown on the GSs surface prevent the GSs contacting with each other in the PI matrix to retain electrical insulation of PI composites. In addition, the storage modulus and Young’s modulus of PI composites are remarkably improved in comparison with that of the neat PI.     

Tensile properties and thermal expansion behaviors of continuous molybdenum fiber reinforced aluminum matrix composites

The tensile properties and thermal expansion behaviors of continuous molybdenum fiber reinforced aluminum matrix composites (Mo_f/Al) have been studied. The Mo_f/Al composites containing different volume percents of Mo fibers were processed by diffusion bonding. The strengths of unidirectional Mo_f/Al composites were close to the rule-of-mixtures. The strengths of 0°/90° dual-directional composites increased with fiber content, while those of 45°/135° composites remained relatively low. The coefficients of thermal expansion (CTEs) of the composites decreased as the fiber content increased, close to the values of Mo fibers. With increasing temperature, the CTEs of unidirectional composites increased, while those of dual-directional composites decreased due to large accumulated thermal stresses. The CTEs of 45°/135° composites were lower than those of 0°/90° composites because of contraction effect. At temperatures above 250 °C, the CTEs of the dual-directional composites gradually increased due to matrix yielding and interfacial decohesion.     

Nanoscale dynamic wetting and spreading of molten Ti alloy on 6H–SiC

We have investigated nanoscale features at the reactive wetting front of the molten Ag–27.4 wt.% Cu–4.9 wt.% Ti on 6H–SiC using video movies recorded in situ on a high-temperature stage of a high-resolution transmission electron microscope and also proposed a model of a chemical reaction at each tip. One of the features of reactive wetting and spreading at 1073 K in 4 × 10⁻⁵ Pa was the discontinuous motion of the tip, and the halting time depended on the thickness of an amorphous Si–O layer on SiC, which can be explained by the time needed for the decomposition of the layer by Ti atoms to form TiC nanoparticles since Ti atoms in the molten alloy sufficiently rapidly diffuse to the tip on the SiC surface. Molten Ti and TiC nanolayers preceded the Ti₅Si₃ nanolayer at the tip. The reaction required to form the TiC nanolayer is also the rate-determining step for spreading. The contact angle of the tip increased up to 60–80° when the tip halted, whereas the tip decreased down to 10° on the nonbasal plane and 20° on the basal plane of SiC when it traveled rapidly. The high traveling angle of the molten tip on the basal polar plane of SiC indicates a high interfacial energy between Ti and SiC(0 0 0 1).     

The thermal expansion and mechanical properties of high reinforcement content SiCp/Al composites fabricated by squeeze casting technology

With mixing different sized SiC particles, high reinforcement content SiCp/Al composites (V_p=50, 60 and 70%) for electronic packaging applications were fabricated by squeeze casting technology. The composites were free of porosity and SiC particles distributed uniformly in the composite. The mean linear coefficients of thermal expansion (20–100 °C) of SiCp/Al composites ranged from 8.3 to 10.8×10⁻⁶/°C and decreased with an increase in volume fraction of SiC content. The experimental coefficients of thermal expansion agreed well with predicted values based on Kerner's model. The Brinell hardness increased from 188.6 to 258.0, and the modulus increased from 148 to 204 GPa for the corresponding composites. The bending strengths were larger than 370 MPa, but no obvious trend between bending strength and SiC content was observed.     

Fabrication of an electronic package box of SiCP/Al composites with high volume SiCP

In this paper, a SiC_P preform was prepared by Powder Injection Molding (PIM), and the melting aluminum was injected into the SiC_P preform by the pressure infiltration method to manufacture an electronic package box of SiC_P (65%)/Al composites. SiC_P (65%)/Al composite prepared by pressure infiltration has full density and a homogeneous microstructure. The relative density of the composite is higher than 99%, the thermal expansion coefficient and thermal conductivity of the composite are 8.0×10⁻⁶/K and nearly 130 W/(m · K) at room temperature, respectively, which meet the requirements of electronic packaging. Translated from Journal of Acta Materiae Compositae Sinica, 2006, 23(6): 109–113 (in Chinese)     

Study on microstructures and mechanical properties of short-carbon-fiber-reinforced SiC composites prepared by hot-pressing

Short-carbon-fiber-reinforced silicon carbide composites were prepared by hot-pressing with SiC powder, Polycarbosilane as precursor polymer and MgO–Al₂O₃–Y₂O₃ as sintering additives. The phase composition, microstructure and mechanical properties of the composites with different Polycarbosilane content were investigated. The results showed that, dense composites could be prepared at a relatively low temperature of 1800 °C via the liquid-phase-sintering mechanism and the highest mechanical property was obtained for the composites with 20 wt.% PCS and 8 wt.% sintering additives. The amorphous interphase formed during sintering process in the composites not only contributed to the densification of the composites, but also improved the fiber–matrix bonding. The nano-silicon carbide derived from Polycarbosilane, could also play a role of improving the relative density of the composites.     

The dynamic properties of SiCp/Al composites fabricated by spark plasma sintering with powders prepared by mechanical alloying process

The dynamic compressive properties of SiC particle reinforced pure Al matrix composites, fabricated by spark plasma sintering technique with mixture powders prepared by mechanical alloying process, were tested in this paper. Two different average SiC particle sizes of 12 μm and 45 μm were adopted, and the compressive tests of these composites at strain rates ranging from 800/s to 5200/s were conducted by split Hopkinson pressure bar. The damage mechanism of the SiC_p/Al composites was analyzed through the microstructural observations and high-precision density measurements. Results show that the dynamic properties and damage accumulation of these composites are significantly affected by the particle distribution, size, particle cracking, particle/matrix interface debonding and adiabatic heat softening. The composites containing smaller SiC particles exhibit higher flow stress, lower strain rate sensitivity, and less damage at high strain rate deformation.     

Corrosion behavior of SiC p /6061 Al metal matrix composites in chloride solutions

The corrosion behavior of silicon carbide particulates-aluminum metal matrix composites was studied in chloride solution by means of electrochemical techniques, scanning electron microscope (SEM), transmission electron microscope (TEM) and optical microscope. The materials under investigation were compocasting processed 6061 Al reinforced with increasing amounts of SiC particulates. Electrochemical tests such as potentiostatic polarization were done in 0.1 kmol·m^–3 NaCl solutions that were aerated and deaerated to observe overall corrosion behavior. In addition, pit morphology was observed after immersion tests. It was seen that the pitting potentials did not vary greatly or show definite trends in relation to the amounts of SiC _p reinforcement. However, the degree of corrosion increased with increasing SiC _p content; probably mainly due to galvanic couple. No intermetallics layer was found at the SiC _p /Al interface. Based on pitting potentials of Al-Si alloys, a pitting process around SiC particulate was proposed.Abbreviations SiC _p (silicon carbide particulates) - SiC _f (silicon carbide fibers) - SiC _w (silicon carbide whiskers) - E_pit (pitting potential) - E_prot (protection potential) - E _corr (corrosion potential) - i _galv (galvanic current density) - E _galv (galvanic potential)     

Extrusion textures in Al, 6061 alloy and 6061/SiCp nanocomposites

The 6061 alloy matrix composites reinforced with 10 wt.% and 15 wt.% of SiC nanoparticles with an average diameter of ~ 500 nm were hot extruded in strip shape from ball milled powders. The microstructures and textures of the hot extruded nanocomposites have been investigated by means of three dimensional orientation distribution functions and electron backscatter diffraction (EBSD) techniques. Pure Al and 6061 alloy extruded strips from atomised powders have been produced for comparison purposes. The results show that the non-deformable SiC particulates have a strong influence on the formation of extrusion textures in the matrix. Pure Al and 6061 alloy develop a typical β fibre texture after extrusion in strip shape. For 6061/SiC_p nanocomposites, the intensities of major texture components decrease with increasing amount of SiC particles. The total intensities of Brass, Dillamore and S components have decreased by 19% for 6061/10 wt.% SiC_p and 40% for 6061/15 wt.% SiC_p composites when compared with the 6061 alloy. EBSD analysis on local grain orientations shows limited Al grain rotations in SiC rich zones and decreased texture intensities.