A review of extreme condition effects on solder joint reliability:Understanding failure mechanisms

Solder joint,crucial component in electronic systems,face significant challenges when exposed to extreme conditions during applications.The solder joint reliability involving microstructure and mechanical properties will be affected by extreme conditions.Understanding the behaviour of solder joints under extreme conditions is vital to determine the durability and reliability of solder joint.This review paper aims to comprehensively explore the underlying failure mechanism affecting solder joint reliability under extreme conditions.This study covers an in-depth analysis of effect extreme temperature,mechanical stress,and radiation conditions towards solder joint.Impact of each condition to the microstructure including solder matrix and intermetallic compound layer,and mechanical properties such as fatigue,shear strength,creep,and hardness was thoroughly discussed.The failure mechanisms were illustrated in graphical diagrams to ensure clarity and understanding.Furthermore,the paper highlighted mitigation strategies that enhancing solder joint reliability under challenging operating conditions.The findings offer valuable guidance for researchers,engineers,and practitioners involved in electronics,engineering,and related fields,fostering advancements in solder joint reliability and performance.

Energy evolution and structural health monitoring of coal under different failure modes:An experimental study

Structural instability in underground engineering,especially in coal-rock structures,poses significant safety risks.Thus,the development of an accurate monitoring method for the health of coal-rock bodies is crucial.The focus of this work is on understanding energy evolution patterns in coal-rock bodies under complex conditions by using shear,splitting,and uniaxial compression tests.We examine the changes in energy parameters during various loading stages and the effects of various failure modes,resulting in an innovative energy dissipation-based health evaluation technique for coal.Key results show that coal bodies go through transitions between strain hardening and softening mechanisms during loading,indicated by fluctuations in elastic energy and dissipation energy density.For tensile failure,the energy profile of coal shows a pattern of “high dissipation and low accumulation” before peak stress.On the other hand,shear failure is described by “high accumulation and low dissipation” in energy trends.Different failure modes correlate with an accelerated increase in the dissipation energy before destabilization,and a significant positive correlation is present between the energy dissipation rate and the stress state of the coal samples.A novel mathematical and statistical approach is developed,establishing a dissipation energy anomaly index,W,which categorizes the structural health of coal into different danger levels.This method provides a quantitative standard for early warning systems and is adaptable for monitoring structural health in complex underground engineering environments,contributing to the development of structural health monitoring technology.

Reliability analysis of supporting pressure in tunnels based on three-dimensional failure mechanism

Based on nonlinear failure criterion,a three-dimensional failure mechanism of the possible collapse of deep tunnel is presented with limit analysis theory.Support pressure is taken into consideration in the virtual work equation performed under the upper bound theorem.It is necessary to point out that the properties of surrounding rock mass plays a vital role in the shape of collapsing rock mass.The first order reliability method and Monte Carlo simulation method are then employed to analyze the stability of presented mechanism.Different rock parameters are considered random variables to value the corresponding reliability index with an increasing applied support pressure.The reliability indexes calculated by two methods are in good agreement.Sensitivity analysis was performed and the influence of coefficient variation of rock parameters was discussed.It is shown that the tensile strength plays a much more important role in reliability index than dimensionless parameter,and that small changes occurring in the coefficient of variation would make great influence of reliability index.Thus,significant attention should be paid to the properties of surrounding rock mass and the applied support pressure to maintain the stability of tunnel can be determined for a given reliability index.

Numerical investigations on mechanical characteristics and failure mechanism of outwash deposits based on random meso-structures using discrete element method

Outwash deposit is a unique type of geological materials, and its features such as heterogeneity, discontinuity and nonlinearity determine the complexity of mechanical characteristics and failure mechanism. In this work, random meso-structure of outwash deposits was constructed by the technique of computer random simulation based on characteristics of its meso-structure in the statistical sense and some simplifications, and a series of large direct shear tests on numerical samples of outwash deposits with stone contents of 15%, 30%, 45% and 60% were conducted using the discrete element method to further investigate its mechanical characteristics and failure mechanism under external load. The results show that the deformation characteristics and shear strength of outwash deposits are to some extent improved with the increase of stone content, and the shear stress–shear displacement curves of outwash deposits show great differences at the post-peak stage due to the random spatial distribution and content of stones. From the mesoscopic view, normal directions of contacts between "soil" and "stone" particles undergo apparent deflection as the shear displacement continues during the shearing process, accompanying redistribution of the magnitude of contact forces during the shearing process. For outwash deposits, the shear zone formed after shear failure is an irregular stripe due to the movements of stones near the shear zone, and it expands gradually with the increase of stone content. In addition, there is an approximately linear relation between the mean increment of internal friction angle and the stone content lying between 30% and 60%, and a concave nonlinear relation between the mean increment of cohesion and stone content, which are in good agreement with the existing research results.

RELIABILITY ANALYSIS OF FRP LAMINATED PLATES WITH CONSIDERATION OF BOTH INITIAL IMPERFECTION AND FAILURE SEQUENCE

A probabilistic progressive failure analyzing method is applied to estimating the reliability of a simply supported laminated composite plate with an initial imperfection under bi-axial compression load. The initial imperfection and the strength parameters are considered as random variables. Ply-level failure probability is evaluated by the first order reliability method (FORM) together with the Tsai-Wu strength criterion and Tan criterion. Current stresses in the laminated structure are calculated by the classical lamination theory with the stiffness modified based on the last step ply failure. Probabilistically dominant ply-level failure sequences leading to overall system failure are identified, based on which the system failure probability is estimated. A numerical example is presented to demonstrate the methodology proposed. Through parameter studies it is shown that the deviation of the initial imperfection and some of the strength parameters largely influence the system reliability.

Improved Reliability Analysis Method Based on the Failure Assessment Diagram

With the uncertainties related to operating conditions,in-service non-destructive testing（NDT） measurements and material properties considered in the structural integrity assessment,probabilistic analysis based on the failure assessment diagram（FAD） approach has recently become an important concern.However,the point density revealing the probabilistic distribution characteristics of the assessment points is usually ignored.To obtain more detailed and direct knowledge from the reliability analysis,an improved probabilistic fracture mechanics（PFM） assessment method is proposed.By integrating 2D kernel density estimation（KDE） technology into the traditional probabilistic assessment,the probabilistic density of the randomly distributed assessment points is visualized in the assessment diagram.Moreover,a modified interval sensitivity analysis is implemented and compared with probabilistic sensitivity analysis.The improved reliability analysis method is applied to the assessment of a high pressure pipe containing an axial internal semi-elliptical surface crack.The results indicate that these two methods can give consistent sensitivities of input parameters,but the interval sensitivity analysis is computationally more efficient.Meanwhile,the point density distribution and its contour are plotted in the FAD,thereby better revealing the characteristics of PFM assessment.This study provides a powerful tool for the reliability analysis of critical structures.

Strength Reliability Analysis of Stiffened Cylindrical Shells Considering Failure Correlation

The stiffened cylindrical shell is commonly used for the pressure hull of submersibles and the legs of offshore platforms. There are various failure modes because of uncertainty with the structural size and material properties, uncertainty of the calculation model and machining errors. Correlations among failure modes must be considered with the structural reliability of stiffened cylindrical shells. However, the traditional method cannot consider the correlations effectively. The aim of this study is to present a method of reliability analysis for stiffened cylindrical shells which considers the correlations among failure modes. Firstly, the joint failure probability calculation formula of two related failure modes is derived through use of the 2D joint probability density function. Secondly, the full probability formula of the tandem structural system is given with consideration to the correlations among failure modes. At last, the accuracy of the system reliability calculation is verified through use of the Monte Carlo simulation. Result of the analysis shows the failure probability of stiffened cylindrical shells can be gained through adding the failure probability of each mode.

Failure mechanism and control technology of water-immersed roadway in high-stress and soft rock in a deep mine

Aiming at soft rock ground support issues under conditions of high stress and long-term water immersion, the ground failure mechanism is revealed by taking the deep-water sumps of Jiulong Mine as the engineering background and employing field investigation, tests of rock structure, mechanical properties and mineral composition. The main factors leading to the surrounding rock failure include the high and complex stress state of the water sumps, high-clay content and water-weakened rock, and the unreasonable support design. In this paper, the broken and fractured rock mass near roadway opening is considered as ground small-structure, and deep stable rock mass as ground large-structure. A support technology focusing on cutting off the water, strengthening the small structure of the rock and transferring the large structure of the rock is proposed. The proposed support technology of interconnecting the large and small structures, based on high-strength bolts, high-stiffness shotcrete layer plugging water,strengthening the small structure with deep-hole grouting and shallow-hole grouting, highpretensioned cables tensioned twice to make the large and small structures bearing the pressure evenly,channel-steel and high-pretensioned cables are used to control floor heave. The numerical simulation and field test show that this support system can control the rock deformation of the water sumps and provide technical support to similar roadway support designs.

Study on interface failure of shape memory alloy(SMA)reinforced smart structure with damages

Shape memory alloy （SMA） reinforced smart structure can be used to make structural shape and strength selfadapted and structural damage self-restrained. Although SMA smart structures without damages were extensively studied, researches on SMA smart structures with damages have rarely been reported thus far. In this paper, thermo-mechanical behaviors of SMA fiber reinforced smart structures with damages are analyzed through a shear lag model and the variational principle, Mathematical expressions of the meso-displacement field and the stress-strain field of a typical element with damages are obtained, and a failure criterion for interface failure between SMA fibers and matrix is established, which is applied to an example. Results presented herein may provide a theoretical foundation for further studies on integrity of SMA smart structures.

Structural reliability analysis using a hybrid HDMR-ANN method

A new hybrid method is proposed to estimate the failure probability of a structure subject to random parameters. The high dimensional model representation(HDMR) combined with artificial neural network(ANN) is used to approximate implicit limit state functions in structural reliability analysis. HDMR facilitates the lower dimensional approximation of the original limit states function. For evaluating the failure probability, a first-order HDMR approximation is constructed by deploying sampling points along each random variable axis and hence obtaining the structural responses. To reduce the computational effort of the evaluation of limit state function, an ANN surrogate is trained based on the sampling points from HDMR. The component of the approximated function in HDMR can be regarded as the input of the ANN and the response of limit state function can be regarded as the target for training an ANN surrogate. This trained ANN surrogate is used to obtain structural outputs instead of directly calling the numerical model of a structure. After generating the ANN surrogate, Monte Carlo simulation(MCS) is performed to obtain the failure probability, based on the trained ANN surrogate. Three numerical examples are used to illustrate the accuracy and efficiency of the proposed method.

Analytical and numerical solutions for shear mechanical behaviors of structural plane

The original descriptive model of shear stress and shear displacement only reflects the stress deformation characteristics of plastic structural plane.The index model was revised and piecewise index model was built to describe the stress deformation characteristics of plastic structural plane and brittle structural plane.The relation of stress and strain to the failure mode of structural plane considering the effect of its shape was investigated,and a model which could reflect the relation between undulate angle and shear strength was built.The result indicates that structural plane presents nonlinear characteristics,specifically,the value of undulate angle,as well as corresponding shear strength,becomes larger as the normal stress decreases.

Structural Reliability Assessment by a Modified Spectral Stochastic Meshless Local Petrov-Galerkin Method

This study presents a new tool for solving stochastic boundary-value problems. This tool is created by modify the previous spectral stochastic meshless local Petrov-Galerkin method using the MLPG5 scheme. This modified spectral stochastic meshless local Petrov-Galerkin method is selectively applied to predict the structural failure probability with the uncertainty in the spatial variability of mechanical properties. Except for the MLPG5 scheme, deriving the proposed spectral stochastic meshless local Petrov-Galerkin formulation adopts generalized polynomial chaos expansions of random mechanical properties. Predicting the structural failure probability is based on the first-order reliability method. Further comparing the spectral stochastic finite element-based and meshless local Petrov-Galerkin-based predicted structural failure probabilities indicates that the proposed spectral stochastic meshless local Petrov-Galerkin method predicts the more accurate structural failure probability than the spectral stochastic finite element method does. In addition, generating spectral stochastic meshless local Petrov-Galerkin results are considerably time-saving than generating Monte-Carlo simulation results does. In conclusion, the spectral stochastic meshless local Petrov-Galerkin method serves as a time-saving tool for solving stochastic boundary-value problems sufficiently accurately.

An Energy Model of a Failure Mechanism and its Application

The energy expression is presented for a failure mechanism, and it is appliedin an Accelerated Life Test (ALT) and an Accelerated Reliability Growth Test (ARGT). The conditionsof the common failure mechanism are obtained. The essential relationship between the conditions andthe Accelerated Factor (A_f) is proposed by using the energy model.

Fatigue reliability analysis of fixed offshore structures:A first passage problem approach

This paper describes a methodology for computation of reliability of members of fixed offshore platform structures, with respect to fatigue. Failure criteria were formulated using fracture mechanics principle. The problem is coined as a “first passage problem”. The method was illustrated through application to a typical plane frame structure. The fatigue reliability degradation curve established can be used for planning in-service inspection of offshore platforms. A very limited parametric study was carried out to obtain insight into the effect of important variables on the fatigue reliability.

Numerical analysis of the failure process of soil-rock mixtures through computed tomography and PFC3D models

Soil-rock mixture （SRM） is a unique type of geomaterial characterized by a heterogeneous composition and a complicated structure. It is intractable for the continuum-based soil and rock mechanics theories to accurately characterize and predict the SRM＇s mechanical properties. This study reports a novel numerical method incorporating microfocus computed tomography and PFC3D codes to probe the deformation and failure processes of SRM. The three-dimensional （3D） PFC models that represent the SRM＇s complex structures were built. By simulating the entire failure process in PFC3D, the SRM＇s strength, elastic modulus and crack growth were obtained. The influence of rock ratios on the SRM＇s strength, deformation and failure processes, as well as its internal mesoscale mechanism, were analyzed. By comparing simulation results with experimental data, it was verified that the 3D PFC models were in good agreement with SRM＇s real structure and the SRM＇s compression process, deformation and failure patterns; its intrinsic mesomechanism can be effectively analyzed based on such 3D PFC models.

Damage and deterioration mechanism and curing technique of concrete structure in main coal cleaning plants

Concrete structures in main coal cleaning plants have been rebuilt and reinforced in the coal mines of the Shanghai Datun Energy Sources Co. Ltd., the first colliery of the Pingdingshan Coal Co. Ltd. and the Sanhejian mine of the Xuzhou Mining Group Co. Ltd. In these projects, the operating environment and reliability of concrete structures in the main plants of the three companies were investigated and the safety of the structures inspected. Qualitative and quantitative analyses were made on the special natural, technological and mechanical environments around the structures. On the basis of these analyses, we discuss the long-term, combined actions of the harsh natural (corrosive gases, liquids and solids) and mechanical environments on concrete structures and further investigated the damage and deteriorating mechanisms and curing techniques of concrete structures in the main coal cleaning plants. Our study can provide a theoretical basis for ensuring the reliability of concrete structures in main coal cleaning plants.

A Review of Structural Health Monitoring Techniques as Applied to Composite Structures

Structural Health Monitoring(SHM)is the process of collecting,interpreting and analysing data from structures in order to determine its health status and the remaining life span.Composite materials have been extensively use in recent years in several industries with the aim at reducing the total weight of structures while improving their mechanical properties.However,composite materials are prone to develop damage when subjected to low to medium impacts(i.e.1-10 m/s and 11-30 m/s respectively).Hence,the need to use SHM techniques to detect damage at the incipient initiation in composite materials is of high importance.Despite the availability of several SHM methods for the damage identification in composite structures,no single technique has proven suitable for all circumstances.It must be noted that the amount of techniques available nowadays is too extensive to be comprehensively reviewed in a single paper.Therefore,the focus will be on techniques that can serve as a starting point for studies focusing on damage detection,localisation,assessment and prognosis on certain kinds of structures.Thus,the line of thought behind the search and the structure of this review is a result of objectives beyond the scope of the paper itself.Nevertheless,it was considered that,once the above was understood,an updated synopsis such as this could also be useful for other researchers in the same field.

Analysis and Prevention for Oscillation Failure of Capacitive Micro-accelerometers

As actuator of the force-rebalanced servo loop, the electrostatic force generator of the micro-accelerometer shows high nonlinearity while the interpole of the micro-electro-mechanical system（MEMS） sensor is far away from its balance position. The control system cannot rebalance itself with the limited bandwidth after an external long overload, because the characteristics of the force generator differ from normal case. Although for similar problems, solutions with cascading lead-lag blocks, with the anti-windup（AW） technology, or with the sliding-mode control, are widely reported, the problems such as performance loss or difficulty to synthesize a digital controller still remain. Based on existing researches, remedies are developed by analyzing the characteristic of the system not only near the balance position, but also corresponding to the whole moveable range of the interpole, and a new controller is proposed. The solution is compared with the common solutions of cascading lead-lag blocks method, AW methods, and sliding mode methods. Comparison results show that the proposed solution avoid performance loss, compared to cascading lead-lag blocks solution; the proposed solution is easily synthesized and implemented in the analog servo loop of the micro-accelerometer, compared to digital AW methods; at the same time, the proposed solution avoids suffering the chattering effect problem but just utilize it, compared to the sliding-mode control solution. Nevertheless, comparison results show the solution is lack of commonality, since the solution is only more suitable to micro electrostatic force-rebalance system. The SIMULINK models with and without the proposed solution, taking typical micro-accelerometer parameters, have been set up for simulation; corresponding experiments utilizing electrometric method are also conducted after the successful simulations. Simulation and experiment results verify that the micro-accelerometer will reliably return to normal operation after external long overload with the proposed solution. Therefore, it is expected to design the analog servo loop of high performance micro electrostatic force-rebalance system so as to ensure the rebalance after long overload without performance loss.

MESO-MECHANICAL ANALYSIS OF SHAPE MEMORY ALLOY REINFORCED SMART STRUCTURE WITH DAMAGE

The mechanical behaviors of shape memory alloy （SMA） wires reinforced smart structure with damage were analyzed through the variational principle, a governing equation for the structure was derived, mathematical expressions for the meso-displacement field, stressstrain field of typical element with damage were presented, and a failure criterion for interface failure between SMA wires and matrix was established under two kinds of actuation which are dead-load and temperature, where the temperature is included in effective free restoring strain. In addition, there are some other composing factors in the failure criterion such as the interface properties, dynamical properties of SMA, initial debonding length L - l etc. The results are significant to understand structural strength self-adapted control and failure mechanism of SMA wires reinforced smart structure with damage.

Comparison of large deformation failure control method in a deep gob-side roadway: A theoretical analysis and field investigation

Under the dual influence of the mining disturbance of the previous working face and the advanced mining of the working face,the roadway is prone to large deformation,failure,and rockburst.Roadway stabilization has always significantly influenced deep mining safety.In this article we used the research background of the large deformation failure roadway of Fa-er Coal Mine in Guizhou Province of China to propose two control methods:bolt-cable-mesh+concrete blocks+directional energy-gathering blasting(BCM-CBDE method)and 1st Generation-Negative Poisson’s Ratio(1G NPR)cable+directional energy-gathering blasting+dynamic pressure stage support(πgirder+single hydraulic prop+retractable U steel)(NPR-DEDP method).Meantime,we compared the validity of the large deformation failure control method in a deep gob-side roadway based on theoretical analysis,numerical simulations,and field experiments.The results show that directional energy-gathering blasting can weaken the pressure acting on the concrete blocks.However,the vertical stress of the surrounding rock of the roadway is still concentrated in the entity coal side and the concrete blocks,showing a’bimodal’distribution.BCM-CBDE method cannot effectively control the stability of the roadway.NPR-DEDP method removed the concrete blocks.It shows using the 1G NPR cable with periodic slipping-sticking characteristics can adapt to repeated mining disturbances.The peak value of the vertical stress of the roadway is reduced and transferred to the deep part of the surrounding rock mass,which promotes the collapse of the gangue in the goaf and fills the goaf.The pressure of the roadway roof is reduced,and the gob-side roadway is fundamentally protected.Meantime,the dynamic pressure stage support method withπgirder+single hydraulic prop+retractable U steel as the core effectively protects the roadway from dynamic pressure impact when the main roof is periodically broken.After the on-site implementation of NPR-DEDP method,the deformation of the roadway is reduced by more than 45%,and the deformation rate is reduced by more than 50%.