The objective of this study was to evaluate and gain a better understanding of the short-term impact performance and the long-term durability of electrically conductive adhesives for electronic interconnection applications. Three model conductive adhesives, designated as ECA1, ECA2 and ECA3, supplied by Emerson & Cuming, were investigated, in conjunction with printed circuit board (PCB) substrates with metallizations of Au/Ni/Cu and Cu, manufactured by Triad Circuit Inc. Effects of environmental aging on the durability of conductive adhesives and their joints were evaluated. All the samples for both mechanical tests and thermal tests were aged at 85%, 100%RH for periods of up to 50 days. Studies of bulk conductive adhesives suggested that both plasticization, which is reversible and further crosslinking and thermal degradation, which are irreversible, might have occurred upon exposure of ECAs to the hot/wet environment. The durability of electrically conductive adhesive joints was then investigated utilizing the double cantilever beam (DCB) test. It was observed that the conductive adhesive joint was significantly weakened following hydrothermal aging, and there was a transition from cohesive failure to interfacial failure as aging continued. A comparative study of the durability of different conductive adhesive and substrate metallization combinations suggested that the resistance of the adhesive joints to moisture attack is related to the adhesive properties, as well as the substrate metallizations. It was noted that the gold/adhesive interface had better resistance to moisture attack than the copper/adhesive interface. A reasonable explanation of this phenomenon was given based upon the concept of surface free energy and interfacial free energy. XPS analysis was performed on the fractured surfaces of DCB samples. For adhesive joints with copper metallization, copper oxide was detected on the failed surfaces upon exposure of the conductive adhesive joints following aging. XPS analysis on the fractured surfaces of adhesive joints with Au metallization suggested that diffusion of Cu to the Au surface might have happened on the Au/Ni/Cu plated PCB substrates during aging. The impact performance of conductive adhesives was quantitatively determined using a falling wedge test. This unique impact resistance testing method could serve as a useful tool to screen conductive adhesives at the materials level for bonding purpose. Moreover, this test could also provide some useful information for conductive adhesive development. This study revealed that the viscoelastic energy, which is a result of the internal friction created by chain motions within the adhesive material, played an important role in the impact fracture behavior of the conductive adhesives. This study also demonstrated that the loss factor, evaluated at the impact environment conditions, is a good indicator of a conductive adhesive's ability to withstand impact loading. / Ph. D.

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<p>Extrusion Deposition Additive Manufacturing (EDAM) is a process in which fiber-filled thermoplastic polymers pellets get molten in the extruder and deposited onto a build plate in a layer-by-layer basis. The use of short fiber composite for EDAM has enabled large-scale 3D printing structures and tools for traditional composite manufacturing processes. Successful EDAM production critically depends on the understanding of the process-structure-property relationship. Especially on the bonding between the beads which is of paramount importance in additive manufacturing since it affects primarily the fracture and strength characteristics of the printed part. Bonding is influenced mainly by the temperature history and the contact between the beads. Both of which is dependent on the fiber orientation within the bead induced by the flow deformation that occurs according to the printing parameters. This study aims to investigate and model the complex relationship between the printing conditions and inter-bead bonding in the lateral direction.</p> <p>A framework was developed to facilitate this aim, and it contains a fusion bonding model that couples the time-temperature history and the bead-to-bead contact interface. Four deposition parameters were studied: the nozzle height, ratio of the print velocity to extrudate velocity, bead-to-bead spacing, and layer time. First, a deposition flow model was developed, utilizing the anisotropic viscous flow model and smooth particle hydrodynamic finite element formulation, to predict the fiber orientation state across the deposited bead and the bead-to-bead interface for the given set of deposition parameters. Next, the effect of printing conditions on the temperature history of the bead was discovered by utilizing the heat transfer process simulation in ADDITIVE3D. Third, the experimental characterization procedure for mode I fracture toughness in the lateral direction was developed, and the fracture toughness was characterized using linear elastic fracture mechanics principles. Lastly, the phenomenological model for non-isothermal lateral fusion bonding was characterized using the bead contact interface, temperature history, and fracture toughness properties. This work showed a comprehensive effort in fusion bonding modeling while also presented a valuable process-structure-property-performance relationship in EDAM.  Guidance on the selection of printing conditions and strategy can be made using the developed model to print higher-strength parts.  </p>

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High strength low alloy (HSLA) steels have been developed to simultaneously have high yield strength and high fracture toughness. However, in practical applications steel must be welded. Traditional arc welding has proven detrimental to the fracture toughness of HSLA steels. Friction stir welding has recently shown mixed results in welding HSLA steels. The range of welding parameters used in these recent studies however has been very limited. With only a few welding parameters tested, the effect of spindle speed, travel speed, and heat input on the fracture toughness of friction stir welded HSLA steel remains unknown. To understand how the friction stir welding process parameters affect fracture toughness, double sided welds in API X80 were performed and analyzed. Results show that at room temperature friction stir welded API X80 exceeded industry minimum fracture toughness requirements in both the API Standard 1104 and DNV-OS-F101 by 143% and 62%, respectively. The process parameters of spindle speed and HI have been shown to effectively control the fracture toughness of the stir zone. Relationships have been established that show that fracture toughness increased by 85% when spindle speed decreased by 59% and heat input decreased by 46%.

Solid Oxide Fuel Cells (SOFCs) are emerging as a potential breakthrough energy conversion technology for clean and efficient production of electricity and heat from hydrogen and hydrocarbon fuels. Sc0.1Ce0.01ZrO2 electrolytes for Solid Oxide Fuel Cells are very promising materials because their high ionic conductivity in the intermediate temperature range 700°C-800°C. The vibration response of cubic and rhombohedral (β) 10 mol%Sc2O3 - 1 mol%CeO2 - ZrO2(Sc0.1Ce0.01ZrO2 ) both at room and high-temperatures is reported. The in-situ heating experiments and ex-situ indentation experiments were performed to characterize the vibrational behavior of these important materials. A temperature and stress-assisted phase transition from cubic to rhombohedral phase was detected during in-situ Raman spectroscopy experiments. While heating and indentation experiments performed separately did not cause the transition of the cubic phase into the rhombohedral structure under the performed experimental conditions and only broadened or strained peaks of the cubic phase could be detected, the heating of the indented (strained) surface leaded to the formation of the rhombohedral Sc0.1Ce0.01ZrO2. Both temperature range and strained zone were estimated by in situ heating and 2D mapping, where a formation of rhombohedral or retention of cubic phase has been promoted. The mechanical properties, such as Young’s modulus, Vickers hardness, indentation fracture resistance, room and high temperature four point bending strength and SEVNB fracture toughness along with the stress – strain deformation behavior in compression, of 10 mol% Sc2O3 – 1 mol % CeO2 - ZrO2 (ScCeZrO2) ceramics have been studied. The chosen composition of the ScCeZrO2 has very high ionic conductivity and, therefore, is very promising oxygen ion conducting electrolyte for the intermediate temperature Solid Oxide Fuel Cells. Therefore, its mechanical behavior is of importance and is presented in this study.

The goal of this research is to investigate the combined effects of glass fibre reinforcement and molecular orientation in polypropylene-short glass fibre composites. Specimens have been fabricated using the injection moulding process and drawn using a small die drawing rig. The effects of die drawing on the fibre composites are complex, with the drawing process orienting both the polymer molecules and the glass fibres. This may be accompanied by the creation of voids in the polymer matrix and their destruction in the compressive stress field thus restoring the interfacial contact area between fibre and matrix. Unfilled and short glass fibre filled polypropylene specimens, with fibre content 7% wt, 13%wt, 27%wt, and 55%wt, were injection moulded prior to the die drawing process. An experimental program of die drawing within an oven at elevated temperature was conducted for polypropylene filled to various levels and at different strain rates. The specimens drew to draw ratios in the range ¿=1.41 to ¿=5.6. Mechanical characterization of the test materials has been conducted by examining the tensile stress strain and fracture behaviour under uniaxial conditions. The influence of glass fibre content and drawing conditions (draw ratio) on the fracture toughness and crack propagation was investigated using the double edge notched fracture test. The notch lengths ranged from 1.5 to 2.5 mm for 10 mm wide specimens. The critical stress intensity factor increased as the fibre content increased up to a limiting filler level. The fracture toughness of both unfilled and fibre filled polypropylene were found to be highly dependent on draw ratio. The results were analysed to find out the optimal draw ratio and fibre content that yielded the maximum modulus, strength and fracture toughness. Data showed that, at a given draw ratio, modulus, strength and fracture toughness increased with increasing fibre content to a maximum and then decreased. The optimum material was obtained at a draw ratio of 2.5 and filler loading 13wt%.

Transparent trä biokompositer (TW) är en ny attraktiv klass av biokomposit. De är uppbyggda av delignifierat trä som impregnerats med en polymer med matchande brytningsindexet.  TW kan skräddarsys för inom ett brett spektrum av funktionella, optiska och mekaniska egenskaper. Eftersom de är biobaserade ses de dessutom som ett möjligt material som kan ersätta andra, mer miljöpåverkande material, inom olika sektorer, däribland byggnadsindustrin. Till skillnad från de funktionella egenskaperna har det mekaniska beteendet hos dessa biokompositer dock inte undersökts särskilt ingående. Syftet med denna avhandling är därför att utöka den nuvarande kunskapen om det mekaniska beteendet av dessa material genom att använda två olika mekanisk karakterisering metoder av TW och vanligt trä som referensmaterial. TW framställdes genom impregnering av delignifierade björkfaner med PMMA. Den mekaniska karakteriseringen utfördes med hjälp av olika metoder. Elastiska modulen och böjhållfastheten i tvärriktningen studerades med hjälp av fyrpunktsböjningprov. Resultaten visade en förbättring för båda egenskaperna jämfört med vanligt björkträ. Brottet vinkelrätt mot fibern (TR-systemet) undersöktes genom att utföra in situ fyrpunktsböjningstester på prover med en kant-spricka i ett svepelektronmikroskop för att observera hur sprickorna fortplantar sig i den komplexa mikrostrukturen. En anmärkningsvärd förbättring (cirka 175 procent) av brottsstyrkan konstaterades jämfört med vanligt trä. Dessutom användes DIC-teknik (digital image correlation) på fyrpunktsböjningstesterna, med kant-spricka, för att studera spänningsfältet under spricktillväxten, särskilt bildandet av brottprocesszonen (FPZ) runt sprickspetsen. Därefter föreslogs en ekvation som beskriver kohesionslagen för båda materialen baserat på experimentella observationer som i slutändan kan användas för sprickmekaniska simuleringar. Slutligen visades kort hur man kan använda de uppmätta mekaniska egenskaperna hos den nya TW för materialval för tekniska tillämpningar. / Transparent wood (TW) biocomposites are a new attractive class of materials. They are based on a delignified wood template impregnated by a refractive index-matching polymer.  TWs can be tailored in order to show a wide range of functional, optical, and mechanical properties. Moreover, being biobased, they are seen as a possible key material to replace more environmentally impactful materials in various sectors including the construction industry. However, unlike the functional properties, the mechanical behaviour of this class of materials has been poorly investigated. Therefore, in this thesis, the aim was to extend the current knowledge about the mechanical response of these materials by using a two-step mechanical characterization on TW and native wood as reference material. The analysed TW biocomposite was prepared by impregnation of delignified birch veneers by PMMA. The mechanical characterization was carried out using different techniques. The Young’s modulus and the flexural strength along the transverse direction were studied by four-point bending tests. The results showed an improvement for both properties compared to native birch wood. The fracture perpendicular to the grain (TR system) was investigated by performing in situ single-edge-notched four-point bending tests onto a scanning electron microscope to observe how the cracks propagate in this complex microstructure. A remarkable improvement (about 175 percent) in fracture toughness was found compared to the native wood. Furthermore, the in situ single-edge-notched four-point bending test was also applied, together with the digital image correlation (DIC) technique, to study the strain field during the crack growth, specifically the formation of the fracture process zone (FPZ) around the crack tip. Then, an equation describing the cohesive law was proposed for both materials based on experimental observations that can be ultimately used for fracture mechanics simulations. Finally, it was briefly shown how to make use of the measured mechanical properties of the novel TW for material selection for engineering applications.