Electrochemical migration behavior and mechanism of PCB-ImAg and PCB-HASL under adsorbed thin liquid films

The electrochemical migration（ECM） behavior and mechanism of immersion silver processing circuit board（PCB-ImAg）and hot air solder leveling circuit board（PCB-HASL） under the 0.1 mol/L Na2SO4 absorbed thin liquid films with different thicknesses were investigated using stereo microscopy and scanning electron microscopy（SEM）.Meanwhile,the corrosion tendency and kinetics rule of metal plates after bias application were analyzed with the aid of electrochemical impedance spectroscopy（EIS）and scanning Kelvin probe（SKP）.Results showed that under different humidity conditions,the amount of migrating corrosion products of silver for PCB-ImAg was limited,while on PCB-HASL both copper dendrites and precipitates such as sulfate and metal oxides of copper/tin were found under a high humidity condition（exceeding 85%）.SKP results indicated that the cathode plate of two kinds of PCB materials had a higher corrosion tendency after bias application.An ECM model involving multi-metal reactions was proposed and the differences of ECM behaviors for two kinds of PCB materials were compared.

Electrochemical migration behavior of Ag-plated Cu-filled electrically conductive adhesives

The electrochemical migration (ECM) behavior of the electrically conductive adhesives (ECAs) filled with pure Ag powder or Ag-plated Cu composite powder with varied Ag:Cu ratios was investigated under the condition of applying constant voltage and distilled water environment.ECM resistance was determined from the current-time curves.The microstructure and composition of ECM dendrite products were analyzed by SEM/EDS and XRD.It was found that the ECM resistance of Ag-plated Cu composite powder-filled ECAs was evidently higher than that of pure Ag powder-filled ECAs.The Ag:Cu ratio of composite powder in ECAs had notable influence on ECM resistance,which was enhanced with the decrease of Ag:Cu ratios.The composition of dendrites formed between cathode and anode during ECM process was not uniform for Ag-plated Cu-filled ECAs.An ECM inhibiting mechanism of Ag-plated Cu composite powder was proposed according to analysis of the electrochemical impedance spectroscopy,Tafel plot and dendrite composition.

Dissolution Characteristics of New Titanium Alloys in Electrochemical Machining

We focus on the electrochemical dissolution characteristics of new titanium alloys such as near-αtitanium alloy Ti60,α+βtitanium alloy TC4andβtitanium alloy Ti40 which are often used for aerospace industry.The experiments are carried out by electrochemical machining tool,and the surface morphology of the specimens is observed by the scanning electron microscope(SEM)and three-dimensional video microscope(DVM).The appropriate electrolyte is selected and the relationships between surface roughness and current density are achieved.The results show that the single-phase titanium alloy Ti40 has a better surface roughness after ECM compared with theα+βtitanium alloy TC4 and the near-αtitanium alloy Ti60.The best surface roughness is Ra 0.28μm when the current density is 75A/cm2.Furthermore,the surface roughness of the near-αtitanium alloy Ti60 is the most sensitive with the current density because of the different electrochemical equivalents of substitutional elements and larger grains than TC4.Finally,the suitable current density for each titanium alloy is achieved.

Electrochemical Machining Analysis on Grid Cathode Composed of Square Cells

During the electrochemical machining (ECM), the cathodes designed by the existing methods are mainly unitary cathodes, which can be only used to produce the workpieces with the same shapes. However, there are few researches on designing cathodes for machining the different workpieces with the different surfaces. This paper presents the grid cathode composed of the square cells to produce the workpieces with different shapes. Three types of the square cells, 2.5 mm′2.5 mm, 3 mm′3 mm, and 4 mm′4 mm, are utilized to construct the plane, the slant, and the blade cathode. The material of the cathode and the anode is CrNi 18 Ti 9 , and the ingredient of electrolyte is 15% NaCl and 15% NaNO 3 . The machining equilibrium machining current and time are acquired and analyzed, the machining process and the workpiece quality are compared between using the grid cathode and the unitary cathode. Moreover, the machining errors on the workpiece surface are measured and analyzed, and the error reasons are traced and discussed to obtain the better surface quality of the workpiece. The experiment and analysis results show that the grid cathode can be used to manufacture the workpieces with complex shapes in certain range of the error. The workpiece quality improves with the size of the square cell being reduced, and if the square element is small enough, the workpiece quality is almost equal to the one machined by the unitary cathode. The proposed research realizes a single cathode machining the different workpieces with the different surfaces.

ELECTROCHEMICAL MEASUREMENT OF FLOW PARAMETERS IN DILUTE SOLUTION

A new theoretical method is proposed in the electrochemical measurement to obtain therelationship between flow parameter and the electrode current under the existence of ion migration ef-fect.In this way the measurement of local mass transfer coefficient,wall shear stress and liquid veloc-ity are presented and the experiment results are also described.

Aviation-oriented Micromachining Technology—Micro-ECM in Pure Water

This article proposes a precise and ecofriendly micromachining technology for aerospace application called electrochemical machining in pure water （PW-ECM）. On the basis of the principles of water dissociation, a series of test setups and tests are devised and performed under different conditions. These tests explain the need for technological conditions realizing PW-ECM, and further explore the technological principles. The results from the tests demonstrate a successful removal of electrolytic slime by means of ultrasonic vibration of the workpiece. To ensure the stability and reliability of PW-ECM process, a new combined machining method of PW-ECM assisted with ultrasonic vibration （PW-ECM/USV） is devised. Trilateral and square cavities and holes as well as a group of English alphabets are worked out on a stainless steel plate. It is confirmed that PW-ECM will be probably an efficient new aviation precision machining method.

用细胞跟踪系统确定在外细胞间质(ECMs)上的细胞迁移(英文)

大部分哺乳动物具有细胞迁移容量.细胞迁移对于生命中的许多生物学现象有重要作用.在胚胎形成中,细胞迁移是在重要的形态形成过程中重复出现的主题.在成年人的组织中、在正常的生理学以及病理学中,细胞迁移都有其重要性.在炎症反应中,白血球迁移到受伤区域,在哪里它们进行吞噬细胞和实现免疫功能.虽然在现在已有创伤愈合细胞迁移测定等几种方法,但是这些细胞迁移的测定方法对于各类问题并不是总有效的[1-6].我们发展了一种由计算机辅助的时间流逝显示微观复制系统,它包括影象形成过程软件,其程序编制含有自动影象分析和自设计CO2微小细胞培育器,它的功能是在一个倒置显微镜平台上对于细胞迁移进行迅速而精确的分析从而形成细胞的培育.我们运用这一计算机辅助系统计算了外细胞间质(ECMs)覆盖表面的细胞迁移.

Electrochemical Migration Behaviors of Lead-Free 64Sn-35Bi-1Ag Solder on FR-4 PCB Board Plated with Cu

Electrochemical migration （ECM） characteristic is a new reliability failure. A parallel surfacial electrode system coupling with scanning electron microscope （SEM）, energy dispersive X-ray analysis （EDAX）, and X-ray Diffraction （XRD） technologies is designed to research ECM behavior of 64Sn-35BilAg （SBA） solder in 3.5 g/L NaCl solution and compare to that of Sn37Pb and Sn-3.0Ag-O.5Cu （SAC） solders. Results show that SBA solder is more susceptible to ECM failure than Sn37Pb solder, which is more difficult than SAC solder. The affected factors of ECM are given as follows： the solder compositions, the loaded electric field, ECM time, etc. The electrochemical reaction mechanism of ECM process is achieved. EDAX and XRD analyses show that the main contents on dendrites of SBA solder after ECM test are Sn, hardly any Bi, a little Ag, which illustrates that the order of ion migration capacity is shown as follows： Sn 〉 Ag 〉Bi.

工件振动辅助管电极电解加工方孔仿真与试验研究

为解决管电极电解加工方孔过程中因流场分布不均造成加工质量差等问题,提出一种工件振动辅助管电极电解加工方孔的方法。流场仿真结果表明,工件振动辅助电解加工能够在加工间隙内不同位置产生明显的脉动流场,改善加工间隙内的电解液流动状态,有效消除传统电解加工方孔中加工间隙内存在的“死水”区,从而有利于电解产物的排出,提升电解加工的稳定性。同时开展试验研究,结果表明,采用工件振动辅助管电极电解加工可以提升方孔加工的轮廓精度和表面质量,并且采用脉冲电流可以进一步提升方孔的加工质量。最终采用振幅0.04 mm、振频20Hz、脉冲占空比80%、脉冲频率5000 Hz、进给速度1.5 mm/min,加工出平均宽度1.218 mm、宽度标准偏差0.026 mm、侧壁表面粗糙度0.703μm的方孔。

表面织构电解加工技术研究进展

表面织构在能源、光学、电子、信息技术、生物和摩擦学等领域具有重要应用,其加工工艺是制造技术研究的重要内容。由于所加工表面织构具有无毛刺、翻边等优点,电解加工成为表面织构的重要制造技术方法和技术研究热点,故详细介绍了五种典型表面织构电解加工技术在方法创新、材料去除机制、加工过程建模及加工工艺等方面的研究进展,给出了电解加工表面织构的典型结构和材料,指出提高加工效率和加工自动化程度是未来表面织构电解加工技术的发展趋势。

复杂型腔电解加工成形规律分析及试验研究

电解加工适用于包含复杂型腔的难加工材料整体构件的高效加工,但复杂型腔电解加工时加工余量的分布需进一步深入研究。针对阴极曲面上各点法向与进给方向夹角不同时工件成形过程存在差异的问题,对阴极建立特定夹角处加工间隙的微分方程,模拟不同法向与进给方向夹角,并采用规则形状阴极开展直流电解加工和脉冲振动耦合电解加工工艺对比试验,以优选合适的微分方程模拟复杂型腔在上述加工模式下的成形过程。研究成果已应用于闭式整体叶盘叶间流道的电解加工。

电解放电复合加工技术现状与展望

电解放电复合加工是实现电加工技术创新和突破的重要途径,可通过耦合放电与电解能场,利用其时/空协同效应实现在可加工性、加工精度及表面质量等方面的提升,故在介绍电解放电复合加工技术概念和原理分类的基础上,着重概述该领域近十年来的关键性研究进展和新技术创新,对除电火花-电解组合加工和电弧复合加工之外的各类电解放电复合加工技术的未来发展方向进行了展望,指出该技术的规模化工程应用仍需在性能突破、精确建模、加工过程智能控制、复合加工装备等方面取得突破性进展。

深小孔电解加工阴极侧壁绝缘层制备及试验

航空发动机零部件中存在大量深小孔,不仅孔径小、深径比大,而且要求孔表面没有再铸层,这些特点给孔的加工带来了很多困难。电解加工是一种有效的加工方法,针对大深径比小孔电解加工所用的阴极侧壁绝缘层制备困难,且使用过程中容易损坏的问题,尝试了多种材料、多种方式的绝缘层制备方法,并对其在加工过程中的性能稳定性进行了试验研究,最终提出了一种基于弹性石英毛细管的新型多层复合绝缘层制备方法,并借助该方法制作管阴极,在不锈钢材料上成功加工出直径1.1 mm、深径比达181的深小孔。

等效电路模型法预测动态工况下微型直接甲醇燃料电池剩余使用寿命

微型直接甲醇燃料电池(μDMFC)具有能量密度高、可便携使用、快速补能以及环境友好等优点.然而,由于膜电极在电化学反应中会退化,μDMFC的有效使用寿命有限,所以需要对其健康状态与剩余使用寿命进行评估,为燃料电池改性和控制策略提供决策支持.在结合数据驱动和机理模型预测方法的基础上,针对动态运行工况,提出一种基于等效电路模型(ECM)的μDMFC剩余使用寿命预测方法.在燃料电池的性能退化指标中,电池输出电压可以被实时监测从而获得电池的退化趋势,但这一指标无法单独提供精确的预测结果.通过测量电化学阻抗谱并结合ECM可以得到电池内部阻抗等深层信息,但这些深层信息不易被实时监测,通常只能低频离线测量.此外,燃料电池在实际应用中多处于变工况状态,其退化趋势和使用寿命受工作环境影响,传统基于电压退化趋势回归的预测方法无法应对工况的动态变化.因此,可通过定期离线获取内部退化参量建立预测模型.实验结果表明:与传统数据驱动的方法相比,基于内部退化参量的预测方法能更好地适应变工况环境,在燃料电池剩余使用寿命预测中具有更好的性能.

Design method and experimental study of a cathode tool with an extremely high leveling ratio for electrochemical machining of blisk

To obtain final parts with the desired dimensional accuracy and repeatability via electrochemical machining(ECM), the machining process must enter an ECM balanced state. However,for the ECM processing of blisk, a key component of aerospace engines, the surface of the blade blank often has an uneven allowance distribution due to the narrow passage of the cascade. It is difficult to remedy this issue in subsequent processing steps, which is necessary to ensure the dimensional accuracy and repeatability of the final blade profile. To solve this problem, electrolytic machining must be preceded by electrolytic shaping, which requires cathode tools with large leveling ratios to quickly homogenize the blank surface of the blade. In this study, to obtain a cathode tool with an extremely high leveling ratio, a design method based on the variation in the electrode gap in the non-equilibrium electrolytic state is proposed, and a dissolution model based on the nonequilibrium state is established. In this design method, the allowance on the blank to be machined is first divided into many discrete allowances with the normal direction. The initial machining clearance, feed rate, and total machining time are then calculated using classical ECM equilibrium state theory based on the maximum allowance. Meanwhile, the point coordinates of the cathode tool at maximum allowance can be determined. The non-equilibrium model can then be used to calculate the relative coordinate positions corresponding to the remaining discrete allowances. Finally, the entire cathode tool profile is designed. Simulations, fundamental experiments, and blisk unit workpiece experiments were carried out to validate the design approach. In the simulated processing of the plane workpiece, the leveling ratio of the cathode tool designed by the proposed method(0.77)was 83% higher than that of the cathode tool designed using the traditional method. The simulation results were confirmed by processing experiments. In the machining of blisk unit workpieces with complex curved surfaces, the leveling ratios of the convex and concave parts of the blade machined using the proposed cathode tool respectively reached 0.75 and 0.54, which are 75% and 38% higher than those obtained using the traditional method. This new cathode design method and machining technology can significantly improve the surface allowance distribution of blank before electrolytic finishing. It is helpful for finishing machine to enter electrolytic equilibrium state. Finally, the final blade profile accuracy can be guaranteed and repeated errors can be reduced.

高压蒸煮试验下镀锡引脚腐蚀行为及机理研究

引脚金属镀层化学腐蚀是一种典型的封装缺陷,通常在高温、高压、高湿条件下容易出现,并对产品的可靠性和使用寿命造成严重影响。为研究镀锡引脚在高压蒸煮试验下的腐蚀情况,通过金相分析、扫描电镜分析、X射线光电子能谱等分析手段,对高压蒸煮条件下的镀锡引脚化学腐蚀情况进行了研究。结果表明,引脚上化学腐蚀主要是由于锡层-铜层-薄液膜之间的电化学反应造成的,镀锡层表面形貌粗糙会加剧腐蚀的形成。对此,提出了相应的改善措施,对于提高镀层的耐腐蚀性能具有重要的参考意义。

多层挠性印制电路板的CAF失效分析方法探讨

随着电子产品向高密度、小型化的发展,使得由印制电路板(PCB)产生的导电性阳极丝(CAF)现象成为影响产品可靠性的一个重要因素。介绍挠性印制电路板(FPCB)的CAF分析思路和方法,通过聚焦离子束(FIB)、扫描电子显微镜(SEM)等工具找到多层FPCB的CAF失效模式及失效现象,同时结合傅里叶红外光谱仪(FTIR)、X射线荧光光谱仪(XRF),以及电磁场仿真结果确定了CAF失效原因,为多层FPCB产品CAF问题的分析改善提供了解决思路。

三头进给电解加工叶片流场特性

为合理利用流场因素对叶片电解加工的影响,提高叶片电解加工的精度和表面质量,结合自行研制的新型三头进给叶片电解加工机床,建立电解加工流场的数学模型,设计新的'双向进液'的流动形式及适应该流动形式的电解加工夹具,分析气泡率、温度、压力、流速等因素对电解加工的影响。进行叶片电解加工试验,试验表明,流场设计合理,有利于保证加工的稳定性,提高叶片加工质量,并可实现叶片叶身、缘板的全方位电解加工。

镍基高温合金GH4169电解加工ηω—i曲线测定

对GH4169电解加工ηω—i内在规律进行了试验研究,通过测量和计算,得到了准确的ηω及ηω—i的特性曲线。

叶片电化学加工过程多场耦合仿真

针对叶片电化学加工过程难以预测、实验参数修正周期长的问题,建立与温度相关的叶片多场耦合仿真模型,基于COMSOL Multiphysics平台对叶片电化学加工过程进行多场耦合仿真,仿真分析了不同加工电压和不同进液流量对法向平衡间隙的影响。结果表明:加工电压越大,间隙也相应增大,且间隙分布越不均匀;进液流量越大,间隙分布越均匀。采用其中一组仿真参数进行工艺实验,仿真与实验的对比结果表明,叶片轮廓曲率变化缓慢处的仿真结果和实验结果比较贴合,而轮廓曲率变化较快处的仿真值与实验值差别相对较大,但两者的变化趋势相同。