Preventing formation of intermetallic compounds in ultrasonic-assisted Sn soldering of Mg/Al alloys through pre-plating a Ni coating layer on the Mg substrate

Magnesium and aluminum alloys are widely used in various industries because of their excellent properties,and their reliable connection may increase application of materials.Intermetallic compounds(IMCs)affect the joint performance of Mg/Al.In this study,AZ31 Mg alloy with/without a nickel(Ni)coating layer and 6061 Al alloy were joined by ultrasonic-assisted soldering with Sn-3.0Ag-0.5Cu(SAC)filler.The effects of the Ni coating layer on the microstructure and mechanical properties of Mg/Al joints were systematically investigated.The Ni coating layer had a significant effect on formation of the Mg_(2)Sn IMC and the mechanical properties of Mg/Al joints.The blocky Mg_(2)Sn IMC formed in the Mg/SAC/Al joints without a Ni coating layer.The content of the Mg_(2)Sn IMC increased with increasing soldering temperature,but the joint strength decreased.The joint without a Ni coating layer fractured at the blocky Mg_(2)Sn IMC in the solder,and the maximum shear strength was 32.2 MPa.By pre-plating Ni on the Mg substrate,formation of the blocky Mg_(2)Sn IMC was inhibited in the soldering temperature range 240–280℃and the joint strength increased.However,when the soldering temperature increased to 310℃,the blocky Mg_(2)Sn IMC precipitated again in the solder.Transmission electron microscopy showed that some nano-sized Mg_(2)Sn IMC and the(Cu,Ni)_(6)Sn_(5)phase formed in the Mg(Ni)/SAC/Al joint soldered at 280℃,indicating that the Ni coating layer could no longer prevent diffusion of Mg into the solder when the soldering temperature was higher than 280℃.The maximum shear strength of the Mg(Ni)/SAC/Al joint was 58.2 MPa for a soldering temperature of 280℃,which was 80.7%higher than that of the Mg/SAC/Al joint,and the joint was broken at the Mg(Ni)/SAC interface.Pre-plating Ni is a feasible way to inhibit formation of IMCs when joining dissimilar metals.

Numerical Analysis of a Spiral-groove Dry-gas Seal Considering Micro-scale Effects

A dry-gas seal system is a non-contact seal technology that is widely used in different industrial applications.Spiral-groove dry-gas seal utilizes fluid dynamic pressure effects to realize the seal and lubrication processes,while forming a high pressure gas film between two sealing faces due to the deceleration of the gas pumped in or out.There is little research into the effects and the influence on seal performance,if the grooves and the gas film are at the micro-scale.This paper investigates the micro-scale effects on spiral-groove dry-gas seal performance in a numerical solution of a corrected Reynolds equation.The Reynolds equation is discretized by means of the finite difference method with the second order scheme and solved by the successive-over-relaxation（SOR） iterative method.The Knudsen number of the flow in the sealing gas film is changed from 0.005 to 0.120 with a variation of film depth and sealing pressure.The numerical results show that the average pressure in the gas film and the sealed gas leakage increase due to micro-scale effects.The open force is enlarged,while the gas film stiffness is significantly decreased due to micro-scale effects.The friction torque and power consumption remain constant,even in low sealing pressure and spin speed conditions.In this paper,the seal performance at different rotor face spin speeds is also described.The proposed research clarifies the micro-scale effects in a spiral-groove dry-gas seal and their influence on seal performance,which is expected to be useful for the improvement of the design of dry-gas seal systems operating in the slip flow regime.

Discharge characteristics of a needle-to-plate electrode at a micro-scale gap

To understand the discharge characteristics under a gap of micrometers,the breakdown voltage and current–voltage curve are measured experimentally in a needle-to-plate electrode at a microscale gap of 3–50 μm in air.The effect of the needle radius and the gas pressure on the discharge characteristics are tested.The results show that when the gap is larger than 10 μm,the relation between the breakdown voltage and the gap looks like the Paschen curve;while below 10 μm,the breakdown voltage is nearly constant in the range of the tested gap.However,at the same gap distance,the breakdown voltage is still affected by the pressure and shows a trend similar to Paschen＇s law.The current–voltage characteristic in all the gaps is similar and follows the trend of a typical Townsend-to-glow discharge.A simple model is used to explain the non-normality of breakdown in the micro-gaps.The Townsend mechanism is suggested to control the breakdown process in this configuration before the gap reduces much smaller in air.

Recent Advances in Computational Simulation of Macro-,Meso-,and Micro-Scale Biomimetics Related Fluid Flow Problems

Over the last decade, computational methods have been intensively applied to a variety of scientific researches and engineering designs. Although the computational fluid dynamics （CFD） method has played a dominant role in studying and simulating transport phenomena involving fluid flow and heat and mass transfers, in recent years, other numerical methods for the simulations at meso- and micro-scales have also been actively applied to solve the physics of complex flow and fluid-interface interactions. This paper presents a review of recent advances in multi-scale computational simulation of biomimetics related fluid flow problems. The state-of-the-art numerical techniques, such as lattice Boltzmann method （LBM）, molecular dynamics （MD）, and conventional CFD, applied to different problems such as fish flow, electro-osmosis effect of earthworm motion, and self-cleaning hydrophobic surface, and the numerical approaches are introduced. The new challenging of modelling biomimetics problems in developing the physical conditions of self-clean hydrophobic surfaces is discussed.

Fabrication of micro-scale gratings for moiré method with a femtosecond laser

Fabrication of micro gratings using a femtosecond laser exposure system is experimentally investigated for the electron moire method. Micro holes and lines are firstly etched for parameter study. Grating profile is theoretically optimized to form high quality moire patterns. For a demonstration, a parallel grating is fabricated on a specimen of quartz glass. The minimum line width and the distance between two adjacent lines are both set to be 1 μm, and the frequency of grating is 500 lines/ram. The experimental results indicate that the quality of gratings is good and the relative error of the gratings pitch is about 1.5%. Based on molte method, scanning electron microscope （SEM） moire patterns are observed clearly, which manifests that gratings fabricated with the femtosecond laser exposure is suitable for micro scale deformation measurement.

Micro-scale Dispersion of Air Pollutants over an Urban Setup in a Coastal Region

The dispersion is mainly governed by wind field and depends on the planetary boundary layer (PBL) dynamics. Accurate representation of the meteorological weather fields would improve the dispersion assessments. In urban areas representation of wind around the obstacles is not possible for the pollution dispersion studies using Gaussian based modeling studies. It is widely accepted that computational fluid dynamics (CFD) tools would provide reasonably good solution to produce the wind fields around the complex structures and other land scale elements. By keeping in view of the requirement for the micro-scale dispersion, a commercial CFD model PANACHE with PANEPR developed by Fluidyn is implemented to study the micro-scale dispersion of air pollution over an urban setup at Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam a coastal station in the east coast of India under stable atmospheric conditions. Meso-scale module of the PANACHE model is integrated with the data generated at the site by IGCAR under RRE (Round Robin Exercise) program to develop the flow fields. Using this flow fields, CFD model is integrated to study the micro-scale dispersion. Various pollution dispersion scenarios are developed using hypothetical emission inventory during stably stratified conditions to understand the micro-scale dispersion over different locations of coastal urban set up in the IGCAR region of Kalpakkam.

Micro-scale FEM Calculation of Concrete Temperature during Production and Casting

A micro-scale finite element method(FEM) was proposed to precisely calculate the heat conduction between mortar and aggregate, and thus to accurately predict the non-uniformity of concrete pouring temperature. The concrete temperature field during vibration was also precisely calculated by accurate description of heat absorption characteristics of different parts of concrete when vibration. Based on the above method, the prediction model was used to predict the pouring temperature of a practical engineering. The comparison between actual results and simulated values shows that this method can be adopted to accurately predict the non-uniformity of concrete pouring temperature and the influence of mechanized vibration on concrete pouring temperature, and thus accurately predict pouring temperature. The control of casting temperature is crucial for preventing concrete fracture. The study provides a new method for predicting the pouring temperature of concrete structures, which has great practical value in engineering application.

Micro-Scale Motion Precision Simulation Method for a New-Type 6-DOF Micro-Manipulation Robot

A new 6-DOF micro-manipulation robot based on 3-PPTTRS parallel mechanisms in combination with flexure hinges is proposed. The design principle of the mechanism is introduced, and the kinematics analysis method based on differentiation is used to get the (inverse) kinematics equations. Then a micro-scale motion precision simulation method is proposed according to finite element analysis (FEA), and the prediction of robot’s motion precision in design phase is realized. The simulation result indicates that the 6-DOF micro-manipulation robot can meet the design specification.

Response of revegetation to climate change with meso- and micro-scale remote sensing in an arid desert of China

The revegetation protection system(VPS)on the edge of the Tengger Desert can be referred to as a successful model of sand control technology in China and even the world,and there has been a substantial amount of research on revegetation stability.However,it is unclear how meso-and micro-scale revegetation activity has responded to climatic change over the past decades.To evaluate the relative influence of climatic variables on revegetation activities in a restored desert ecosystem,we analysed the trend of revegetation change from 2002 to 2015 using a satellite-derived normalized difference vegetation index(NDVI)dataset.The time series of the NDVI data were decomposed into trend,seasonal,and random components using a segmented regression method.The results of the segmented regression model indicate a changing trend in the NDVI in the VPS,changing from a decrease(−7×10−3/month)before 2005 to an increase(0.3×10−3/month)after 2005.We found that precipitation was the most important climatic factor influencing the growing season NDVI(P<0.05),while vegetation growth sensitivity to water and heat varied significantly in different seasons.In the case of precipitation reduction and warming in the study area,the NDVI of the VPS could still maintain an overall slow upward trend(0.04×10−3/month),indicating that the ecosystem is sustainable.Our findings suggest that the VPS has been successful in maintaining stability and sustainability under current climate change conditions and that it is possible to introduce the VPS in similar areas as a template for resistance to sand and drought hazards.

A novel strategy of smart manipulation by micro-scale oscillatory networks of the reactionary zones for enhanced extreme thrust control of the next-generation solid propulsion systems

The main aim of this research is to get a better knowledge and understanding of the micro-scale oscillatory networks behavior in the solid propellants reactionary zones. Fundamental understanding of the micro-and nano-scale combustion mechanisms is essential to the development and further improvement of the next-generation technologies for extreme control of the solid propellant thrust. Both experiments and theory confirm that the micro-and nano-scale oscillatory networks excitation in the solid propellants reactionary zones is a rather universal phenomenon. In accordance with our concept,the micro-and nano-scale structures form both the fractal and self-organized wave patterns in the solid propellants reactionary zones. Control by the shape, the sizes and spacial orientation of the wave patterns allows manipulate by the energy exchange and release in the reactionary zones. A novel strategy for enhanced extreme thrust control in solid propulsion systems are based on manipulation by selforganization of the micro-and nano-scale oscillatory networks and self-organized patterns formation in the reactionary zones with use of the system of acoustic waves and electro-magnetic fields, generated by special kind of ring-shaped electric discharges along with resonance laser radiation. Application of special kind of the ring-shaped electric discharges demands the minimum expenses of energy and opens prospects for almost inertia-free control by combustion processes. Nano-sized additives will enhance self-organizing and self-synchronization of the micro-and nano-scale oscillatory networks on the nanometer scale. Suggested novel strategy opens the door for completely new ways for enhanced extreme thrust control of the solid propulsion systems.

A review of soldering by localized heating

In recent years,the rapid development of the new energy industry has driven continuous upgrading of high-density and high-power devices.In the packaging and assembly process,the problem of differentiation of the thermal needs of different modules has become increasingly prominent,especially for small-size solder joints with high heat dissipation in high-power devices.Localized soldering is con-sidered a suitable choice to selectively heat the desired target while not affecting other heat-sensitive chips.This paper reviews several local-ized soldering processes,focusing on the size of solder joints,soldering materials,and current state of the technique.Each localized solder-ing process was discovered to have unique characteristics.The requirements for small-size solder joints are met by laser soldering,microres-istance soldering,and self-propagating soldering;however,laser soldering has difficulty meeting the requirements for large heat dissipation,microresistance soldering requires the application of pressure to joints,and self-propagating soldering requires ignition materials.However,for small-size solder junctions,selective wave soldering,microwave soldering,and ultrasonic soldering are not appropriate.Because the magnetic field can be focused on a tiny area and the output energy of induction heating is large,induction soldering can be employed as a significant trend in future research.

Interfacial reaction behavior and mechanical properties of 5A06 Al alloy soldered with Sn-1Ti-xGa solders at a low temperature

Active soldering of 5A06 Al alloy was performed at 300 ℃ by using Sn-1Ti and Sn-1Ti-0.3Ga active solders, respectively. Theeffects of soldering time on the microstructure and mechanical properties of the joints were investigated. The results showed that the Sn-1Tisolder broke the oxide film on the surface of the Al substrate and induced intergranular diffusion in the Al substrate. When Ga was added tothe solder, severe dissolution pits appeared in the Al substrate due to the action of Sn-1Ti-0.3Ga solder, and many Al particles were flakedfrom the matrix into the solder seam. Under thermal stress and the Ti adsorption effect, the oxide film cracked. With increasing solderingtime, the shear strength of 5A06 Al alloy joints soldered with Sn-1Ti and Sn-1Ti-0.3Ga active solders increased. When soldered for 90 min,the joint soldered with Sn-1Ti-0.3Ga solder had a higher shear strength of 22.12 MPa when compared to Sn-1Ti solder.

Research Progress on the Solder Joint Reliability of Electronics Using in Deep Space Exploration

The spacecraft for deep space exploration missions will face extreme environments,including cryogenic temperature,intense radiation,wide-range temperature variations and even the combination of conditions mentioned above.Harsh environments will lead to solder joints degradation or even failure,resulting in damage to onboard electronics.The research activities on high reliability solder joints using in extreme environments can not only reduce the use of onboard protection devices,but effectively improve the overall reliability of spacecraft,which is of great significance to the aviation industry.In this paper,we review the reliability research on SnPb solder alloys,Sn-based lead-free solder alloys and In-based solder alloys in extreme environments,and try to provide some suggestions for the follow-up studies,which focus on solder joint reliability under extreme environments.

Effect of Strain Rate on Tensile Behavior of Sn-9Zn-xAg-ySb;{(x, y) = (0.2, 0.6), (0.2, 0.8), (0.6, 0.2), (0.8, 0.2)} Lead-Free Solder Alloys

The tensile properties of Sn-9Zn-xAg-ySb;{(x, y) = (0.2, 0.6), (0.2, 0.8), (0.6, 0.2), (0.8, 0.2)} lead-free solders were investigated. All the test samples were annealed at 150°C for 1 hour. The tests are carried out at room temperature at the strain rate of 4.17 × 10-3 s-1, 20.85 × 10-3 s-1, and 208.5 × 10-3 s-1. It is seen that the tensile strength increases and the ductility decrease with increasing the strain rate over the investigated range. From the strain rate change test results, the strain sensitivity values are found in the range of 0.0831 to 0.1455 due to the addition of different alloying elements.

大尺寸AlN活性金属焊接覆铜基板的界面结合机理

基于190 mm×139 mm×0.635 mm的大尺寸AlN表面活性金属钎焊(AMB)覆铜板工艺制程,开展其界面显微组织、物相组成等的研究,确定钎焊界面结合机理,为制备大尺寸、低气孔、高剥离强度AlN-AMB覆铜板提供支持。结果表明,在大尺寸AlN-AMB覆铜板钎焊过程中,Ag-Cu-Ti合金钎料中的Ag-Cu合金与Cu箔扩散溶合,形成强的冶金结合界面。同时,钎料中的活性Ti原子向AlN基板表面扩散,并与其反应,生成厚度为0.5~1μm的TiN反应层,形成强的反应结合界面。此外,钎料熔体难以填充基板的AlN晶界和凹坑,其中的Ti原子也不与Y-Al-O第二相颗粒反应,导致AlN基板表面TiN反应层不连续分布,形成气孔,降低大尺寸AlN-AMB覆铜板的界面结合强度及可靠性。

SnAgCu/SnBi混装焊点的热循环可靠性研究

Sn-Bi和Sn-Ag-Cu混装焊点是利用低熔点的Sn-58Bi锡膏将高熔点的Sn-3.0Ag-0.5Cu(SAC305)的小球回流焊接在印制电路板(PCB)上,从而实现高温芯片的低温焊接工艺.文中研究了SnAgCu/SnBi混装焊点在热循环条件下的可靠性并通过有限元模拟揭示了混装焊点热循环可靠性的应变演变行为.热循环试验发现混装焊点的寿命要优于SAC305无铅焊点.有限元计算表明,结构混装焊点内SnBi钎料层的添加能够减小最大非弹性应变范围,从而提升混装焊点的热循环可靠性.

PCB中耐高温有机可焊保护剂成膜机理及性能研究

印制电路板铜焊盘表面生成耐高温有机可焊保护剂(HT-OSP)膜是克服无铅高温回流焊工艺并获得良好焊点的关键。选用2-[(2,4-二氯苯基)甲基]-1H-苯并咪唑(C_(14)H_(10)Cl_(2)N_(2))作为成膜剂,在铜层表面生成了HT-OSP膜。理论计算结合对比实验,研究C_(14)H_(10)Cl_(2)N_(2)分子与Cu原子反应生成HT-OSP膜机理。基于量子化学密度泛函理论,模拟C_(14)H_(10)Cl_(2)N_(2)分子与Cu^(+)之间的络合反应;利用红外光谱对HT-OSP膜中的特征官能团进行表征;借助X射线光电子能谱测试HT-OSP膜中Cu元素的化合价;设计对比实验分析Cu^(2+)对生成HT-OSP膜的影响。结果表明:HT-OSP膜生成机理是C_(14)H_(10)Cl_(2)N_(2)分子与Cu原子发生反应生成HT-OSP膜并沉积在铜层表面,Cu^(2+)通过络合反应促进HT-OSP膜生长。另外,HT-OSP膜的分解温度高达531℃,HT-OSP膜保护的铜层放置在自然环境中180天没有被氧化,证明HT-OSP膜具有优异的耐热性和抗氧化性。

基于度量学习的电路焊点缺陷检测方法

针对目前电路焊点缺陷检测方法效率低、准确度差、焊点图像样本量小的问题,提出了一种基于度量学习的快速识别焊点缺陷的方法.首先利用工业相机搭配远心镜头获取焊点图像.通过挖掘焊点图像特征,设计交点检测法来分割焊接单元图像,制作焊点缺陷数据集.在此基础上,设计焊点图像全局特征与局部表征提取方法来对焊点的两类特征进行融合,并对注意力机制进行改进,加入到全局特征提取模块中.对焊点缺陷的检测实验结果表明该方法最终实现了准确率达到98.4%,满足焊点缺陷检测的实际生产要求.

基于双目结构光的三维立体电路板焊点定位

三维立体电路将传统二维集成电路拓展至三维,在提高了电路板形状设计柔性的同时,也提升了电路板上元器件焊点定位的复杂度.为了降低三维立体电路加工过程中的人力成本,提高加工效率,设计了一种用于焊接机床对三维立体电路板焊点定位的双目结构光系统,并针对双目结构光系统在与焊接机床结合应用过程中存在的坐标转换、焊点识别困难等问题,从硬件与算法层面提出了解决方案.在软硬件的配合下,可以简单快速地完成双目结构光系统与焊接机床之间的坐标转换,并对电路板焊点完成定位与坐标计算,代替了人工对三维立体电路板焊点测量定位的复杂流程.实验表明,提出的方案具有较高的精度,能够满足机床焊接元器件过程中对焊点的定位需求.

基于波峰焊桥连改善的设计优化研究

波峰焊是一种常见的电装工艺焊接方式,而桥连是波峰焊工艺最为常见的焊接缺陷之一。介绍了波峰焊接桥连产生的机理,并分析了焊盘间距过近、引脚出脚长度过长,以及器件布局方向不当三种典型可制造性设计引起桥连的原因,并探讨了有助于波峰焊接桥连改善的可制造性设计优化方案。