Structural integrity in electronics

With continuing miniaturisation, increased performance demands and the requirement to remove lead from solder alloys, the challenges to structural integrity and reliability of electronic equipment are substantial and increasing. This paper outlines typical features in electronic equipment of which the structural integrity community may be generally unaware. Potential failure modes in service are described, and the problems of scale and material characteristics are considered. Progress in the application of fracture mechanics to the life prediction of interconnections is reviewed. The limited evidence available suggests that the crack growth resistance of silver‐containing lead‐free solders is superior to that of the traditional Sn‐37Pb under cycle‐controlled conditions but there is no difference when time‐dependent conditions prevail. In several respects, it is contended that the electronics sector is faced with challenges at least equivalent to those encountered in gas turbines and nuclear power generation.     

Tensile fracture and failure behavior of technical flax fibers

The apparent tensile strength of technical flax fibers was determined in single‐fiber tests at various clamping lengths (20, 40, and 80 mm) and the outcome was compared with literature data. It was demonstrated that the strength of flax at each clamping length obeyed the two‐parameter Weibull model. The failure mode and sequence were studied in situ (i.e., during loading) by SEM and acoustic emission (AE). The failure sequence (axial splitting of the technical fiber along its elementary constituents, radial cracking of the elementary fibers, multiple fracture of the elementary fibers) concluded reflected the hierarchical build‐up of the flax bast fibers. To the above failure events AE amplitude ranges were assigned. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 3638–3645, 2003     

非均匀材料破坏过程数值模拟的边界元法研究

用格子模型和统计分布模拟非均匀材料性质的初始分布,针对二维非均匀材料格子模型建立了重复多子域边界元法求解方程。通过把各行子域集成为亚子域,然后对链状排列的亚子域应用域转移矩阵法进行求解。由于使用的域转移矩阵法对内存的要求仅略大于一个亚子域的求解,以及重复多子域法只需要进行一次系数矩阵积分,因而可以大大提高求解的规模和效率。在此基础上,对非均匀脆性材料在简单载荷作用下的破坏过程进行了数值模拟。采用重复多子域法和域转移矩阵法,可以得到子域内高精度的连续应力分布,为进一步研究非均匀材料裂纹萌生、扩展和破坏过程提供了基础。     

Stress Heterogeneity Effect on the Strength of Silicon Nitride

The experiments reported in this paper demonstrate the causes of the failure of monolithic ceramics. The specimens are made of silicon nitride and tested at room temperature. The stress field within the specimen is different for each of four series of tests that have been conducted. Fractographic observations have also been made to identify the causes of the failures. A size effect analysis is performed.     

Possibilities and extension of XRD material response analysis in failure research for the advanced evaluation of the damage level of Hertzian loaded components

Due to clearly distinguishable damage symptoms, it is differentiated between the surface and sub‐surface failure mode of rolling bearings. Material states red out by X‐ray diffraction (XRD) residual stress measurements point to a variety of loading conditions especially at raceway surfaces that are associated with several competing failure mechanisms. The corresponding lifetime reduction can range from the lower fatigue strength region to material ratcheting in extreme cases. Relevant position of the microstructural changes and nature of the failure mechanisms are characterized. The time alteration of the XRD material parameters measured at or near the surface and at the depth of the maximum equivalent stress correlates, in a different manner, with the statistical parameter of the 10 % bearing life. Both failure modes are illustrated by concrete examples. Contaminated lubricant and boundary lubrication, which represent practically important surface‐induced failures, are discussed in more detail. Gray staining, i.e. shallow pitting, often occurs without distinct indication of global material aging by means of XRD characteristics. Here, scanning electron microscopy observations and electron microprobe analyses point to corrosion fatigue as acting surface failure mechanism. The interaction between material and lubricant under complex loading regimes particularly of mixed friction and corrosion opens further failure research areas in the field of tribology.     

Evaluation of Slow Crack Growth Resistance in Ceramics for High-Temperature Applications

The slow (subcritical) crack growth (SCG) resistance of Si₃N₄ and SiC ceramics has been evaluated by a stepwise loading test on bending bars precracked by Vickers indentation. Three highly refractory materials were selected for the evaluation: i.e., (1) high-purity Si₃N₄ sintered by hot isostatic pressing (HIP) without additives and (2,3) α - and β - SiC pressureless sintered with B and C addition. Under the hypothesis of linear elastic behavior at high temperature, which was found satisfied in the present materials, the SCG resistance was expressed in terms of initial stress intensity factor critical for SCG failure within a predetermined lifetime. The present method was found useful in shortening the testing time and consistent with other traditional fatigue tests (e.g., static-fatigue test): It is recommended as a screening test for materials under research and development. Among the materials tested in the present study, the highest SCG resistance up to 1440°C was found in the high-purity Si₃N₄ without additives.     

A simple correlation for gas bubbles rising in power‐law fluids

Recently, the author (Rodrigue, 2001 a, b) proposed a generalized correlation for the steady rise of gas bubbles in uncontaminated viscous Newtonian fluids of infinite extent. It is the purpose of this note to show that this model can be modified for inelastic non‐Newtonian power‐law fluids. Using data taken from six different studies, it is shown that the modified model can predict quite nicely the bubble velocity for these non‐Newtonian inelastic fluids.     

弹簧钢棒线材质量投诉的分析研究

为分析研究某特钢厂用户投诉的原因及存在的问题，统计了其两年间的弹簧钢棒线材用户质量投诉，从缺陷类型及生产过程控制进行了分析，重点对多起断裂原因不明的投诉进行了深入的失效研究。结果表明，弹簧钢生产厂在设备工艺、过程控制和管理中存在很多不足，加上用户的使用工艺、材料的内外质量和规格等综合因素导致了材料的断裂失效。     

VCM压缩机曲轴断裂失效分析

介绍了锦化化工(集团)有限责任公司出现的VCM压缩机曲轴断裂事故，并从断口的部位、形貌特征，断轴的几何状态、受力状态及树料性能等方面分析了曲轴断裂的根本原因。     

SIMILARITY LAW OF FLUCTUATING PRESSURE WITHIN HYDRAULIC JUMP AREA

Through a series of model tests of five scales for 2-D free hydraulic jump, the da-ta of fluctuating pressure acting on the floor level within the hydraulic jump were obtained. Dur-ing the experiments, Froude number varied from 2.94 to 8.61, and Reynolds number rangedfrom 2×10~4 to 6×10~5. Experiment results indicate that the amplitude scale of fluctuating pres-sure is the length scale of model, i. e. P'=L, which agrees with gravity similarity law: Thefrequency scale of the fluctuating pressure is a unity i. e., f=1, which does not satisfy thegravity similarity law.