Moussa Karama

Reliability of lead-free solder in power module with stochastic uncertainty

Abstract The weak point for Insulated-Gate Bipolar Transistor (IGBT) modules in terms of reliability is thermal fatigue in solder joints due to the thermal stress induced by constitutive materials with different coefficients of thermal expansion (CTE). Now, many researches aimed to define accurate finite element simulation with constitutive equations of material behavior and fatigue failure relation connecting the inelastic strain and the number of cycles before failure. Even when these relations are clearly identified, the validation of the finite element model is difficult due to the scatter of input data. In fact, fatigue life of solder joints strongly depends on geometric shape, solders behavior (due to the process) and applied load. The aim of this article is to estimate the probability of failure of power module with structural reliability methods by considering geometric, material and loading variables as random variables. Since in a non-linear context, the finite element calls are expensive in terms of computer run time, an FE strategy is proposed here to replace conventional 3D mesh of layer by 3D-shell. To reduce computation time, response surface method, which approximates the output strain with respect to input random variable (RV) with the design of experiment (DOE) procedure, is used to perform reliability analysis. This reponse surface allows at the end to perform Monte Carlo random simulation process for fitting Weibull and fatigue life distribution on the output inelastic strain.

Lifetime and Reliability Assessment of AlN Substrates Used in Harsh Aeronautic Environments Power Switch Modules

This paper presents a Finite Elements Modelling (FEM) based methodology dedicated to the evaluation of the lifetime and the reliability of assemblies involving brittle materials under cyclic loading. It focuses on the particular case of metal bonded Aluminium Nitride (AlN) substrates used in power electronic switch modules. The ceramic fracture criterion was formulated according to the weakest link concept, under Weibulls approach. The materials parameters were determined by running three points bending tests. In order to check the relevancy of the proposed methodology, a non linear thermomechanical Finite Elements Model allowed computing the number of thermal cycles before substrate brittle fracture within a test vehicle, which was then compared to experimental results. Once validated, the methodology was applied to two different configurations of a power switch module, designed for harsh environment aeronautic applications. The corresponding external loading profile was considered to compute and monitor the evolution of the maximal principal stresses within the ceramic substrates whole volumes. Their lifetimes and reliabilities was finally assessed and compared to the applications requirements.

An investigation into the reliability of power modules considering baseplate solders thermal fatigue in aeronautical applications

Abstract This work examines the thermal fatigue effects on different configurations of power modules used in harsh aeronautical environment. They are used in various applications where the temperature cycling due to the working environment is the most limiting fact. In this case, it is highlighted that the topology assembly choice is a critical point to reach the lifetime required for the final application. In addition, it is proposed to correlate the probabilistic finite elements calculus to the experimental accelerated ageing tests on test vehicle, in order to determine the best configuration of assembling stack consisting of baseplate/RoHS solder/metallized substrate.

Analysis of Sandwich Composite Beams with a New Transverse Shear Stress Continuity Model

This work presents a new composite beam model based on discrete layer theory. It enables the automatic verification of the continuity of transverse shear stresses by taking into account the Heaviside step function. The transverse shear is represented by a sine function which improves the accuracy of the results on the transverse shear stress. The membrane refinement cosine function improves the warping of the straight section in bending deformations. In order to validate the proposed model, several problems in bending and free vibration are presented. For sandwich composite beams, the proposed new model satisfies exactly and automatically the continuity conditions of displacements and stresses at the interfaces, as well as the boundary conditions.

Anisotropic unilateral damage with initial orthotropy: A micromechanics-based approach

A micromechanics-based damage model able to describe the brittle response of initially anisotropic materials is presented. A special emphasis is put on the account of damage-induced anisotropy and unilateral behaviour related to microcracks closure effects. These both features clearly influence the inelastic deformation of microcracked materials and lead to even more complex consequences in the context of initial anisotropy. The aim of this work is then to derive a new strain-based formulation which allows representing the related interactions between all these phenomena. This is achieved through a recent two-dimensional energy-based micromechanical analysis that accounts for the fully anisotropic multilinear response of orthotropic materials weakened by arbitrarily oriented microcracks. On the other hand, the thermodynamics framework gives a standard procedure for the development of the damage evolution law. Throughout the paper, attention is put on the mathematical and thermodynamical consistency of the model to avoid difficulties usually associated to the simultaneous description of damage-induced anisotropy and unilateral effects. In addition to elastic constants, the model requires the identification of only two parameters related to damage evolution. The model has been implemented within the commercial finite-element code ABAQUS, and various numerical simulations are presented to illustrate its capabilities. Especially, evolution of the material symmetry and influence of opening-closure states of microcracks on the damage process are illustrated in the case of brittle matrix composites subjected to different loading cases (axis and off-axis loads, tension and compression, tension followed by compression).

Edge Effects on Sandwich Composite by Analytical, Finite Element, and Experimental Approach

Knowledge of edge effects in composite with honeycomb cores is essential for the design of sandwich structures. This paper deals with the measurement of strain by the application of reflection photoelasticity. Because of the geometry of honeycomb cores a classical method by strain gages is inaccurate and unsuitable. The measurements by photoelasticity is compared to an analytical and numerical results. The final aim of this work is to determine the behavior of such structures by the exact knowledge of its mechanical properties deduced in part from edge effect results.

Experimental characterization of the mechanical behavior of two solder alloys for high temperature power electronics applications

An experimental investigation of two potential candidate materials for the diamond die attachment is presented in this framework. These efforts are motivated by the need of developing a power electronic packaging for the diamond chip. The performance of the designed packaging relies particularly on the specific choice of the solder alloys for the die/substrate junction. To implement a high temperature junction, AuGe and AlSi eutectic alloys were chosen as die attachment and characterized experimentally. The choice of the AlSi alloy is motivated by its high melting temperature Tm (577°C), its practical elaboration process and the restrictions of hazardous substances (RoHS) inter alia. The AuGe eutectic solder alloy has a melting temperature (356°C) and it is investigated here for comparison purposes with AlSi. The paper presents experimental results such as SEM observations of failure facies which are obtained from mechanical shear as well as cyclic nano-indentation results for the mechanical hardening/softening evaluation under cyclic loading paths.

Residual Stresses in Ceramic Metal Assembly after Brazing Process

The framework of this study is the thermo-mechanical analysis of the brazing process of ceramic metal assemblies. The thermal expansion gradient between ceramic and metallic materials leads to the development of residual stresses during the cooling phase of the brazing process which induce consequently an important reduction of the strength of these composite structures. In the present work, numerical simulations are performed in order first to predict the residual stresses distribution after the brazing process and in a second step, to study their influence on the tensile strength of metallized ceramic seals. Results obtained are compared with experimental tests.

Shear Test on CFRP Full-Field Measurement and Finite Element Analysis

The purpose of this work is to study the Iosipescu shear test and more precisely its ability to characterize the shear modulus of a carbone/epoxy composite material. The parameters influencing this identification are the fibre orientation, the geometry of the notch and the boundary conditions. Initially these parameters were studied through the finite element analysis of the shear test. Then, the measurement of the shear strains was carried out by traditional methods of measurement (strain gauges) but also by optical methods. These optical methods: the digital image correlation and the electronic speckle pattern interferometry (ESPI); allow for various levels of loading, to reach a full-field measurement of the shear strain. This enabled us to study the strain distribution on the section between the two notches. The finite element model enabled us to study the parameters influencing the calculation of the shear modulus in comparison with strain gauges, image correlation and ESPI. This work makes it possible to conclude on optimal parameters for the Iosipescu test.

Thermo-mechanical behaviour of ceramic metal brazed assemblies

This study investigates the effects of residual stresses developed during brazing on the performance of brazed ceramic metal joints. The thermal expansion gradient between ceramic and metallic materials leads to the development of such stresses during the cooling phase of the brazing process, which consequently reduce the strength of these composite structures. Here, the objective is to compare the failure behaviour of various assemblies observed during experimental tests and obtained through numerical simulations. In order to get a representation consistent with the physical mechanisms involved, these simulations must account for the brazing phase giving rise to residual stresses before applying in use solicitations to brazed joints. This paper focuses on the tensile strength of ceramic metal joints, for which two brittle failure modes (within the ceramic or at the interface) are observed during the experimental tests.