Cordierite was adhered to molybdenum using various metallic interlayers of copper, nickel, and chromium. The development of a coating adhesion test methodology was required to choose between interface designs. An indentation method was chosen because of ease in testing and availability of fracture mechanics interpretations of test data. The interfacial fracture toughness was determined from indentation load vs. crack length data by examining the residual stress and critical buckling load of the ceramic coatings. The interfacial fracture toughness values obtained using a slightly different indentation analysis agree with those in the literature. Quantitative chemical analysis of the interface microstructure was used to explain differences in interfacial fracture toughness values for samples with different metallic interlayer designs. The best interface design for adhering cordierite glass-ceramic coatings to molybdenum was found to be molybdenum / 2 μm copper / 4 μm chromium / cordierite. / Master of Science

The development of organic photovoltaics (OPVs) has attracted a lot of attention due to their potential to create a low cost flexible solar cell platform. In general, an OPV is comprised of a number of layers of thin films that include the electrodes, active layers and barrier films. Thus, with all of the interfaces within OPV devices, the potential for failure exists in numerous locations if adhesion at the interface between layers is inherently low or if a loss of adhesion due to device aging is encountered. To date, few studies have focused on the basic properties of adhesion in organic photovoltaics and its implications on device reliability. In this dissertation, we investigated the adhesion between interfaces for a model multilayer barrier film (SiNx/PMMA) used to encapsulate OPVs. The barrier films were manufactured using plasma enhanced chemical vapor deposition (PECVD) and the interfacial fracture toughness (Gc, J/m2) between the SiNx and PMMA were quantified. The fundamentals of the adhesion at these interfaces and methods to increase the adhesion were investigated. In addition, we investigated the adhesive/cohesive behavior of inverted OPVs with different electrode materials and interface treatments. Inverted OPVs were fabricated incorporating different interface modification techniques to understand their impact on adhesion determined through the interfacial fracture toughness (Gc, J/m2). Overall, the goal of this study is to quantify the adhesion at typical interfaces used in inverted OPVs and barrier films, to understand methods that influence the adhesion, and to determine methods to improve the adhesion for the long term mechanical reliability of OPV devices.

The development of organic photovoltaics (OPVs) has attracted a lot of attention due to their potential to create a low cost flexible solar cell platform. In general, an OPV is comprised of a number of layers of thin films that include the electrodes, active layers and barrier films. Thus, with all of the interfaces within OPV devices, the potential for failure exists in numerous locations if adhesion at the interface between layers is inherently low or if a loss of adhesion due to device aging is encountered. To date, few studies have focused on the basic properties of adhesion in organic photovoltaics and its implications on device reliability. In this dissertation, we investigated the adhesion between interfaces for a model multilayer barrier film (SiNx/PMMA) used to encapsulate OPVs. The barrier films were manufactured using plasma enhanced chemical vapor deposition (PECVD) and the interfacial fracture toughness (Gc, J/m2) between the SiNx and PMMA were quantified. The fundamentals of the adhesion at these interfaces and methods to increase the adhesion were investigated. In addition, we investigated the adhesive/cohesive behavior of inverted OPVs with different electrode materials and interface treatments. Inverted OPVs were fabricated incorporating different interface modification techniques to understand their impact on adhesion determined through the interfacial fracture toughness (Gc, J/m2). Overall, the goal of this study is to quantify the adhesion at typical interfaces used in inverted OPVs and barrier films, to understand methods that influence the adhesion, and to determine methods to improve the adhesion for the long term mechanical reliability of OPV devices.

The goal of this research was to develop new experimental techniques to quantitatively study the interfacial fracture of micro-contact thin film interconnects used in microelectronic applications under monotonic and cyclic loadings. The micro-contact spring is a new technology that is based on physical vapor deposited thin film cantilevers with a purposely-imposed stress gradient through the thickness of the film. These "springs" have the promise of being the solution to address near-term wafer level probing and long-term high-density chip-to-next level microelectronic packaging challenges, as outlined by the International Technology Roadmap for Semiconductors. The success of this technology is, in part, dependent on the ability to understand the failure mechanism under monotonic and cyclic loadings. This research proposes two experimental methods to understand the interfacial fracture under such monotonic and fatigue loading conditions. To understand interfacial fracture under monotonic loading, a fixtureless superlayer-based delamination test has been developed. Using stress-engineered Cr layer and a release layer with varying width, this test can be used to measure interfacial fracture toughness under a wide range of mode mixity. This test uses common IC fabrication techniques and overcomes the shortcomings of available methods. The developed test has been used to measure the interfacial fracture toughness for Ti/Si interface. It was found that for low mode mixity Ti/Si thin film interfaces, the fracture toughness approaches the work of adhesion which is essentially the Ti-Si bond energy for a given bond density. In addition to the monotonic decohesion test, a fixtureless fatigue test is developed to investigate the interfacial crack propagation. Using a ferromagnetic material deposited on the micro-contact spring, this test employs an external magnetic field to be able to drive the interfacial crack. Fatigue crack growth can be monitored by E-beam lithography patterned metal traces that are 10 to 40nm wide and 1 to a few µm in spacing. The crack initiation and propagation can be monitored through electrical resistance measurement. In the conducted experiments, it is seen that the interfacial delamination does not occur under fatigue loading, and that the micro-contact springs are robust against interfacial fracture for probing and packaging applications.

The target of the ‘Green Overlays’ research was a cost effective, minimal disruption, sustainable and environmentally friendly alternative to the wholesale demolition, removal and complete reconstruction of the existing structural concrete pavement. The important problem of flexural resistance for strengthening concrete pavements with structural overlays has been scrutinised. A new mix design method for steel fibre reinforced, roller compacted, polymer modified, bonded concrete overlay has been proposed. The mixes developed were characterized of high flexural strength and high bond strength with the old concrete substrate. ‘Placeability’ and ‘compactability’ of the mix were two dominant issues during laboratory investigation. An innovative approach for establishing the relationship between Stress and Crack Face Opening Displacement for steel fibre reinforced concrete beams under flexure was developed. In addition, a new and simple method for calculating the interfacial Strain Energy Release Rate of both, a two-dimensional specimen and a three-dimensional model of the overlay pavement system were developed. This method can be readily and easily used by practicing engineers. Finally, a new test specimen and its loading configuration for measuring interfacial fracture toughness for concrete overlay pavements were established. The interfacial fracture toughness of a composite concrete beam, consisted of steel fibre-reinforced roller compacted polymer modified concrete bonded on conventional concrete and undergoing flexure, was assessed. In summary, this thesis presents four key findings: A new mix design method for steel fibre-reinforced roller compacted polymer modified concrete bonded on conventional concrete. A new method for establishing the fibre bridging law by an inverse analysis approach. A new, simplified method for calculating strain energy release rate at the interface of a composite beam. A new, innovative technique for calculating strain energy release rate at the interface of an overlaid pavement. The thesis contains a plethora of graphs, data-tables, examples and formulae, suitable for future researchers.