Changes In Residual Stress Research Articles

Detectability of residual stress anomalies in railway wheels with different geometries subjected to thermal overload based on back gauge change

Temperature increases of railway wheels due to frictional braking on the running surface (wheel tread) can lead to maintenance challenges such as tread wear and thermal cracking. While heating within the anticipated design range should not adversely affect the structural safety of the wheels, excessive temperature rises resulting from brake system failures can induce tensile residual stresses in the rim, potentially leading to wheel fracture. Detecting wheels with abnormal residual stresses is therefore crucial for railway safety, and monitoring residual displacements in the rim due to changes in circumferential residual stresses is an implementable approach. However, the shape of the wheel web varies, and the displacement response to thermal input differs depending on the wheel geometries. This study aims to explore general deformation behaviours related to wheel shape and elucidate the relationship between shape and heat resistance. The elastic-plastic finite element analysis employing simplified intense thermal input revealed that residual deformation after excessive thermal loading consistently results in back gauge expansion, although the deformation and stress responses differ based on the web geometry. Differences in heat resistance are indicated by the variation in the temperature at which compressive yielding due to thermal stress occurs, depending on the web shape. The residual stress detectability of each wheel is determined based on the principle that greater residual displacement at lower stress indicates higher anomaly detectability.

Counterbalancing effects of bowing in gallium nitride templates by epitaxial growth on pre-strained sapphire substrates

To minimize bowing in a gallium nitride (GaN) template, which is caused by differences in the properties of the GaN film and the sapphire substrate, we studied how to offset bowing by directly growing GaN using the hydride vapor phase epitaxy (HVPE) method on the frontside of a pre-strained sapphire substrate prepared using a backside grinding process. The relationships between the respective thicknesses and stresses of the undamaged sapphire, damaged sapphire, and GaN layers were analyzed by deriving the bow formula, which is a modification of Freund's equation, and the theoretical formula-derived results were compared with experimentally determined values. The bow of the GaN template was measured using a micrometer, and the residual stresses in the GaN and sapphire, carrier mobilities, and GaN crystal qualities were measured using a micro-Raman spectrophotometer. The results confirmed the annealing effect on the damaged sapphire layer, and the introduction of pre-strained GaN templates facilitated easier bow control compared to that afforded by a conventional GaN template. Additionally, we identified trends and optimal conditions for changes in residual stress, carrier mobility, and crystal quality in GaN and the damaged sapphire layer based on layer thickness and stress variations. We explain the mechanisms responsible for changes in bow, stress, carrier mobility, and crystal quality of the GaN template.

A multistrategy differential evolution algorithm combined with Latin hypercube sampling applied to a brain–computer interface to improve the effect of node displacement

Injection molding is a common plastic processing technique that allows melted plastic to be injected into a mold through pressure to form differently shaped plastic parts. In injection molding, in-mold electronics (IME) can include various circuit components, such as sensors, amplifiers, and filters. These components can be injected into the mold to form a whole within the melted plastic and can therefore be very easily integrated into the molded part. The brain–computer interface (BCI) is a direct connection pathway between a human or animal brain and an external device. Through BCIs, individuals can use their own brain signals to control these components, enabling more natural and intuitive interactions. In addition, brain–computer interfaces can also be used to assist in medical treatments, such as controlling prosthetic limbs or helping paralyzed patients regain mobility. Brain–computer interfaces can be realized in two ways: invasively and noninvasively, and in this paper, we adopt a noninvasive approach. First, a helmet model is designed according to head shape, and second, a printed circuit film is made to receive EEG signals and an IME injection mold for the helmet plastic parts. In the electronic film, conductive ink is printed to connect each component. However, improper parameterization during the injection molding process can lead to node displacements and residual stress changes in the molded part, which can damage the circuits in the electronic film and affect its performance. Therefore, in this paper, the use of the BCI molding process to ensure that the node displacement reaches the optimal value is studied. Second, the multistrategy differential evolutionary algorithm is used to optimize the injection molding parameters in the process of brain–computer interface formation. The relationship between the injection molding parameters and the actual target value is investigated through Latin hypercubic sampling, and the optimized parameters are compared with the target parameters to obtain the optimal parameter combination. Under the optimal parameters, the node displacement can be optimized from 0.585 to 0.027 mm, and the optimization rate can reach 95.38%. Ultimately, by detecting whether the voltage difference between the output inputs is within the permissible range, the reliability of the brain–computer interface after node displacement optimization can be evaluated.

Unraveling Changes of Brachial Artery Residual Stress and Its Relationship to Cardiovascular Disease Risk Factors.

Arterial pressure volume index (API) offers a non-invasive measurement of brachial artery residual stress. This study investigated API distribution characteristics and correlations with cardiovascular disease risk (CVD) factors in a large Chinese population sample. This cross-sectional study surveyed a total of 7620 participants. We analyzed the relationships between API and factors influencing CVD, using regression-based stepwise backward selection and restrictive cubic spline models to express relationships as standardized beta values. Multiple linear regression analysis identified many independent factors influencing API including age, sex, body mass index (BMI), pulse pressure (PP), heart rate (HR), hemoglobin, uric acid (UA), estimated glomerular filtration rate (eGFR), triglyceride (TC), and a history of hypertension. Notably, API values increased at 33 and escalated with advancing age. Increases in API were associated with rises in PP and UA increases, particularly when PP reached 60 mmHg and the UA reached 525 units. Conversely, API was found to decrease with elevated HR and eGFR. Furthermore, there was a significant inverted U-shaped relationship between API and BMI. This study was the first to describe API distribution characteristics in a large sample of the Chinese population, providing references for evaluating API changes in the assessment of residual stress variations in diverse diseases. Notably, API displayed a U-shaped relationship with age and was closely related to traditional CVD risk factors, underscoring its potential as a non-invasive tool for risk assessment in vascular health. This research was registered with the China Clinical Trial Registration Center (Registration Number: ChiCTR2000035937).

Evolution of Material Properties and Residual Stress with Increasing Number of Passes in Aluminium Structure Printed via Additive Friction Stir Deposition.

Additive friction stir deposition (AFSD) is an emerging solid-state additive manufacturing process with a high deposition rate. Being a non-fusion additive manufacturing (AM) process, it significantly eliminates problems related to melting such as cracking or high residual stresses. Therefore, it is possible to process reactive materials or high-strength alloys with high susceptibility to cracking. Although the residual stresses are lower in this process than with the other AM processes, depending on the deposition path, geometry, and boundary conditions, residual stresses may lead to undesired deformations and deteriorate the dimensional accuracy. Thermal cycling during layer deposition, which also depends on the geometry of the manufactured component, is expected to affect mechanical properties. To this day, the influence of the deposit geometry on the residual stresses and mechanical properties is not well understood, which presents a barrier for industry uptake of this process for large-scale part manufacturing. In this study, a stepped structure with 4, 7, and 10 passes manufactured via AFSD is used to investigate changes in microstructure, residual stress, and mechanical property as a function of the number of passes. The microstructure and defects are assessed using scanning electron microscopy and electron backscatter diffraction. Hardness maps for each step are created. The residual stress distributions at the centreline of each step are acquired via non-destructive neutron diffraction. The valuable insights presented here are essential for the successful utilisation of AFSD in industrial applications.

Measurement of stress characteristics in flexible multi-thin-film substrates using tomography common optical path interferometry

Flexible displays are lightweight, thin, flexible, and impact-resistant, making them a major trend in the display industry. However, their short lifespan is a significant challenge. Thus, improving process parameters and extending product life through advanced measurement technology is crucial. Therefore, this study proposes using tomography common optical path interferometry (TCOPI) to measure and analyze the tomography stress characteristics of multi-thin-film flexible substrates in the folding direction. For polyethylene terephthalate (PET) and polyimide (PI), three thicknesses of indium tin oxide (ITO) were coated on the PET, graphene/PET, and graphene/PI flexible film substrates, and an automatic sliding-folding test platform was used to fold each flexible film substrate. Moreover, this study used TCOPI to measure and analyze the change in residual stress and the sheet resistance of the samples before and after folding. Additionally, this study conducted inward and outward folding tests on graphene/PET/graphene and graphene/PI/graphene substrates to analyze tomographic stress and sheet resistance in the folding direction. After 11,000 folding tests, the graphene/PET/graphene sample exhibited smaller stress and sheet resistance change rates compared to the graphene/PI/graphene sample, as measured by TCOPI. Consequently, the graphene/PET/graphene sample demonstrated better resistance to folding stress in this batch manufacturing process. Specifically, for the graphene layer of the graphene/PET/graphene sample, the minimum absolute value of the stress change rate before and after folding reached 5%. At the same time, the minimum sheet resistance value change rate was 8%. Based on the tomography stress measurements, suggestions for fine-tuning process parameters are provided to improve the flexible film substrate’s folding endurance.

Research on the Analysis of Residual Stress in Heat Treatment of Bellows Using ABAQUS.

Taking austenitic stainless-steel bellows as the research object, a finite element model for the heat treatment of austenitic stainless-steel bellows was constructed based on ABAQUS CAE 2022. The physical properties of the bellows after the heat treatment were analyzed using experimental and simulated curve processing analysis methods. The changes in residual stress and deformation in relation to the bellows under different cooling times were explored, as well as the distribution of residual stress and deformation at a certain cooling time. The results show that as the cooling time of the heat treatment increases, the residual stress of the bellow decreases significantly, the reduction rate accelerates, and the degree of deformation gradually decreases. When the cooling time of the heat treatment is 900 s, the residual stress of the wave peak in the middle position of the bellow is relatively small, and the residual stress value of the wave valley along the axis direction does not change significantly. The deformation degree of the wave peak and valley axis direction is relatively uniform.

Effect of laser-assisted heat treatment on material removal behavior of sapphire in indentation and scratching

Sapphire is widely used in aerospace, microelectronics and defense applications. Due to its high hardness and low fracture toughness, it is difficult to achieve high efficiency and low damage machining. Laser-assisted machining is an effective method for machining hard and brittle materials and has been explored in many experimental and theoretical studies. In this paper, the mechanical property of sapphire and the variation of the coefficient of friction assisted by different laser powers are investigated in detail. Meanwhile, Raman spectroscopy was employed to reveal the residual stress characteristics in the deformation zone of the scratch grooves, and to analyse the changes in the depth of plastic-brittle transition of sapphire after heat treatment with different laser powers. Comparing the material removal behavior of sapphire in indentation and scratching experiments with and without laser-assisted heat treatment (LAHT), and exploring their material removal mechanisms. Experimental results show that LAHT can improve the ductility and workability of sapphire by reducing the hardness and improving the fracture behavior of the material. Hardness and elasticity modulus decrease with increasing power, and the distribution of residual stress changes from compressive to tensile with increasing power. Laser treated surface was found to possess shorter crack length, no significant localized chipping and spalling in indentation, and its scratch grooves were deeper with no radial cracks observed, the scratching force ratio was higher, the critical load for brittle-plastic transition became larger, and plastic flow lines and lumpy spalling debris appeared in the scratch areas. Nearly zero cracks were observed in material subsurface under the LAHT. With LAHT, the material is removed at a higher rate and in a more plastic way, fracture behavior of the material is improved, surface and subsurface damage is reduced, and the machining efficiency is enhanced. This study has important implications and benefits for the machining of sapphire in ensuring surface quality and achieving high efficiency.

Driving force for enhancing the cold silver sinter joining using time domain-dependent Ag–Au epitaxy and interfacial stress

We reveal the mechanism of the cold silver sinter joining process using time-dependent characteristics of Ag–Au interactions grown in the highly (111) orientation. In the initial (∼15 min) state at 175 °C, the Ag–Au inter-diffusion layers developed strongly in the (001) direction, and with increasing time (∼60 min), they switched epitaxial growth in the (111) orientation. The die-bonding strength was significantly improved from 14.9 MPa to 37.8 MPa when the sintering time increased from 15 min to 60 min. The gradual Ag–Au epitaxial growth behavior with a higher stacking-fault energy (SFE) at 175 °C was the dominant factor linearly increasing the cold silver sinter joining strength and ultimately maximizing energy absorption leading to fracture. The surface finish of Au, which can contribute to the time-dependent growth of Ag–Au inter-diffusion layers, underwent a dramatic transformation from a Cube texture to a γ-fiber texture over time. This change was attributed to the micro/nanoscale shear deformation, and reduction of the twin boundary fraction. This study unveiled the in-depth fundamental mechanism for strengthening and pressureless cold sinter joining of Ag–Au epitaxial layers by comprehensively considering this texture behavior, changes in X-ray residual stress, and mechanical properties.

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

Magnetic needle grinding processing technology is one of the magnetic grinding processing techniques. It possesses the characteristics of micro-cutting removal, small increase in processing temperature, flexible processing, high-quality, and high-precision processing. It is mainly utilized to remove burrs at the edge of the workpiece and the edge of the hole, as well as to finish the surface of the workpiece. It is frequently employed in civil, aerospace, navigation, and other fields. Due to the randomness and complexity of magnetic needle movement in magnetic abrasive finishing, it is difficult to quantify the processing parameters and predict processing effects. Therefore, this paper establishes a simulation model of magnetic needle in magnetic abrasive finishing by the coupling numerical simulation method of fluid dynamics discrete element method (CFD-DEM) to analyze the working state parameters of the magnetic needle. Through the simulation of actual working conditions, the machining process and parameters of magnetic abrasive finishing are quantified and analyzed, and the motion trend of magnetic needles during the machining process is studied. Then, the residual stress of single magnetic needle impact is analyzed with ABAQUS, and the performance enhancement of the workpiece is predicted. Finally, observations of surface morphology and validation of residual stress prediction were conducted through experiments on an aluminum plate. The results show that the residual stress of the aluminum plate is positively correlated with the number of strikes of the magnetic needle. The residual stress changes from tensile stress (+0.1 MPa) to compressive stress (-16.5 MPa). The comparison between simulation results and experimental results is good, indicating that the simulation model can comprehensively consider multiple factors such as magnetic field, particle motion, and fluid flow, and establish a magnetic needle magnetic grinding process model that is suitable for actual working conditions.

Three-Dimensional Thermo-Chemo-Mechanical Coupled Curing Analysis for the Filament Wound Composite Shell.

Carbon fiber resin-based composite materials are widely employed in the manufacturing of composite shells. During the curing process, the temperature gradients and cure degree gradients make it easy to generate thermal strains in both carbon fibers and resin, with the resin experiencing cure shrinkage strain due to the curing reaction, ultimately leading to residual stresses and strains. In this paper, a three-dimensional thermo-chemo-mechanical coupled curing model of the composite shell was established based on a resin test, and the changes of temperature, curing degree, residual stress, and strain during the solidification of the composite shell were investigated. First, the curing property parameters and elastic modulus of HCM-2184 resin were obtained through a curing dynamic test and a tensile test. Then, considering the heat release and shrinkage reaction of solidification, a coupled thermo-chemo-mechanical curing model was developed with the CHILE (α) elastic model, and the curing process of the composite shell was simulated numerically. The results show that the resin used in the test belongs to the autocatalytic reaction. For thin composite shells, the heat accumulation inside the shell during curing is not obvious. During the curing process, the curing shrinkage behavior of the resin is an important factor for the generation of residual stress and residual strain.

Local relaxation of residual stress in high-strength steel welded joints treated by HFMI

This research studies the influence of high-peak loads on local relaxation of residual stress and fatigue damage in high-strength steel welded joints treated by high-frequency mechanical impact (HFMI) treatment. The joint behavior is simulated with elastic–plastic finite element analyses that account for the combined effect of geometry, residual stress, and material properties. This simulation uses two treated geometry models: with or without surface roughness on HFMI groove, and two material properties: S690QL and AH36 structural steels. The results show that surface roughness and load history, including high-peak loads, significantly influence fatigue response. It is revealed that the model neglecting the surface roughness cannot represent the amount of residual stress change and fatigue damage at less than 100 µm depth from the surface. In addition, the local yield strength in the HFMI-treated zone affects the plasticity behavior near the surface imperfection under the high-peak loads, which provides comparatively different fatigue damage between S690QL and AH36 in some cases. As a result, this study provides the further understanding needed to develop a robust modeling approach to the fatigue life estimation of HFMI-treated welds subjected to high-peak loads.

Assessment of Refracturing Potential of Low Permeability Reservoirs Based on Different Development Approaches

The technique of refracturing is an effective method to solve the rapid decline in oil well production caused by factors such as severe reservoir energy loss and fracture failure after the initial hydraulic fracturing of low-permeability reservoirs. The key to designing refracturing lies in establishing a model for evaluating the potential fracturing layers. Based on the geological characteristics of the low-permeability conglomerate reservoir in the Lower Wuerhe area of the Eig District of the Xinjiang Oilfield, this paper studies the influence of different development approaches on the distribution pattern of remaining oil in the reservoir. A coupled model of remaining oil distribution and the in situ stress field is established and discusses the characteristics of the four-dimensional in situ stress field under different development modes. This paper analyzes the influence of geological factors and well network factors on the distribution of residual oil, and analyzes the influence of various factors, such as reservoir properties and injection and extraction parameters, on ground stress. Based on the residual oil distribution and ground stress changes, an evaluation method for screening potential fractured layers in reservoirs with different development modes (water injection development and depletion development) is developed.

Computational investigation of plasma arc welding process for aluminium alloys

Thermal stress is a very common phenomenon that occurs at the welded joint. Determination of the same at the joint is however difficult due to inhomogeneity of the weld joint metals and spreading of heat to the surroundings from the Heat Affected Zone (HAZ). Thermal stress induced at the welded joint changes the microstructure of grains which affects the mechanical properties of the welded material. Due to this, cracks may appear in the joint leading to failure of the weld. In the present study, three-dimensional model of two types of welded joint, i.e., Tee Joint and lap joint of two plates having dimensions 100 mm × 75 mm × 5 mm are prepared using ANSYS Workbench 2020 R2. Hex dominant meshing is chosen in order to have clear picture of the spread of temperature over the entire region. The change of Residual stress with variation of welding current and keeping welding voltage constant is also observed for weld joint made of Aluminium Alloy. In this study, conduct steady-state thermal analysis and structural analysis on an aluminium alloy 6063 to assess von Mises stress, von Mises strain, and deformation distribution induced by heating. Evaluate various welding joints to identify the most effective technique.

Finite element simulation and experiment of residual stress evolution in MEMS structures

The MEMS device structure is usually formed by the combination of thick film and thin film deposition of many different materials, and the residual stress generated in the process of integration/superposition of different materials has a significant impact on the performance and reliability of the device.In this study, a test structure of a multilayer thin film was designed and processed. Based on this, finite element modeling analysis and reliability experiment, analyze the evolution of residual stress and construct the corresponding theoretical analysis model. The finite element modeling analysis can characterize the evolution and distribution laws of residual stress. The reliability experiment is mainly by carrying out the temperature shock experiment, and measuring the resistance value, resonance frequency and the surface morphology of the device, so as to better reflect the change of residual stress. Through this study, the resonant frequency and surface morphology of the device can reflect the residual stress of the device, which provides help for the test and analysis of the residual stress. To a certain extent, it can help reduce the harm caused by the residual stress in the design and manufacturing process, and improve the performance and reliability of MEMS devices.

Minimizing residual stress and fatigue crack propagation rate of FSW joints of AA2024-T3 by transient thermal tensioning: Effect of heater distance

Friction stir welding (FSW) is a solid-state welding process that is suitable for joining hardly weldable metals such as aircraft AA2024-T3 aluminum alloy. Despite FSW owns many advantages, however, some problems still arise, especially welding residual stress which influences the weld fatigue performance. In the present work, in-process transient thermal tensioning (TTT) treatment was applied to the FSW process of AA2024-T3 aluminum alloy by putting two symmetrical heaters at the sides of the weld line at distances of 25 mm, 40 mm, and 55 mm. The FSW was conducted at the tool rotational speed of 1500 rpm and tool traveling speed of 30 mm/min whereas the heating temperature was set at 200 °C. Subsequently, changes in microstructure, strength, hardness, residual stress, and fatigue crack propagation rate under TTT treatment were evaluated. The results showed that the use of TTT generated peaks of tensile residual stress along the heater passage which changed the residual stress distributions. It was found that the best fatigue crack propagation resistance of the weld occurred at the heater distance of 25 mm which was attributable to the compressive residual stresses present in the weld region induced by thermal tensioning combined with re-precipitation during welding.

Simulation Analysis and Parameter Optimization of Residual Film Pickup Process Based on Finite Element Method

The extended duration of mulching in Xinjiang cotton fields leads to a significant decline in the tensile strength of plastic film. When recycling is in operation, the soil and the spring teeth of the machinery used can easily cause secondary damage and fracture the residual film. Establishing appropriate working parameters for recycling is essential to enhance the overall quality of collection efforts. By analyzing the motion process of a chain-tooth residual film pickup device, we identified key working parameters that significantly impact the efficiency of recycling. Employing the finite element method (FEM) and a coupled algorithm incorporating smooth particle hydrodynamics (SPH), we developed a coupled finite element model representing the interaction among spring teeth, soil, and residual film. Through simulation and analysis of the process of inserting the spring teeth into the soil to collect film, we derived the governing rules for residual film stress and deformation changes. Utilizing forward speed, rotational angular velocity, and angle of entry into the soil of the spring teeth as test factors and selecting the residual film stress and the residual film deformation as test indices, we conducted a multi-factor simulation test. We established a mathematical model correlating test factors with test indices, and the influence of each factor on the test index was analyzed. Subsequently, we optimized the working parameters of the spring teeth. The results indicated that the optimal working parameters are forward speed of 1111.11 mm/s, rotational angular velocity of 25 rad/s, and angle of entry into the soil of 30°. At these values, the average peak stress of residual film was 4.51 MPa and the height of residual film pickup was 84.48 mm. To validate the optimized the spring teeth impact on performance, field experiments were conducted with recovery rate and winding rate as test indices. The results demonstrated a 92.1% recovery rate and a 1.1% winding rate under the optimal combination of working parameters. The finite element model presented in this paper serves as a reference for designing and analyzing key components of residual film recycling machines.

Reliability evaluation for shot-peening conditions affecting durability life of automotive suspension coil springs

Shot peening (SP) is a cold working method used to improve the fatigue life and corrosion resistance of metallic materials subjected to repeated loading. However, optimal SP conditions can only be found through experiments with actual operating parts. In addition, studies on the effective SP conditions and ensuring safety for improving the durability of parts are lacking. In this study, SP of various conditions were applied to automobile suspension coil springs (ASCS). Consequently, the process factors, damage assessment, and microstructure were analyzed to determine the factors that exerted a dominant effect on durability life. The durability life of springs applied with stress SP (SSP) was evaluated to be approximately 3.8–4.8 times higher compared to that of springs applied with other SP conditions. In addition, by analyzing the process factors affecting the durability life, the absence of a direct effect of the arc height and Vickers hardness was observed. Moreover, the effect of surface roughness was observed to be small. However, the durability life in response to the change in maximum compressive residual stress (MCRS) exhibited a tendency to change linearly, and this relationship was expressed in an equation through regression analysis. The fracture surface of spring with a high durability life tended to have a large number of spiral shapes, and that of spring with a low durability life tended to have a large number of flat shapes. Before conducting the durability test, a circumferential metal flow was observed in the work-hardened layer below the spring surface upon shot peening. After conducting the durability test, partial crack initiation and propagation and delamination were observed in these areas. Despite the varying SP conditions, the surface microstructure of each spring was observed to be similar before and after the durability test. In this study, it was confirmed that SSP is the most effective method to improve the durability life of ASCS, and it was possible to understand through damage evaluation and microstructure analysis that MCRS affects the durability life by delaying the initiation of cracks in the spring. The analysis method and results of this study are expected to be useful for improving the reliability of not only ASCS but also SP-applied components in the future.

Influence of different wet-blasting pressure on the surface integrity and tool cutting performance of hybrid CVD-TiN/TiCN/α-Al2O3/TiN coated tools

This paper investigates the effect of wet-blasting pressure on the surface integrity and tool cutting performance of hybrid CVD-TiN/TiCN/α-Al2O3/TiN coated tools. The hybrid TiN/MT-TiCN/α-Al2O3/TiN multilayer coating was deposited on the surface of the cemented carbide inserts by chemical vapor deposition (CVD) technique. Then the coated inserts were subjected to wet-blasting by aluminum oxide with varying pressure. The coatings were characterized by scanning electron microscopy, white light surface profiler, and X-ray residual stress diffractometer. The results indicate that the average residual tensile stress of the α-Al2O3 layer on the rake face of CVD-coated inserts gradually decreased with the increase of wet-blasting pressure. When the wet-blasting pressure reached 0.24 MPa, the residual tensile stress was transformed into compressive stress. It was accompanied by increased cutting edge roughness and cutting edge radius, reduced cutting edge coating thickness, and a change in rake face surface roughness. To understand the effect of the surface integrity change on the cutting performance of CVD-coated inserts, a case study designed for AISI 4340 steel machining under continuous and intermittent cutting conditions is performed. When the Al2O3 layer on the cutting edge is not peeled off by wet-blasting, the change of residual stress from tensile to compressive in the rake face of CVD-coated inserts can effectively improve the fracture failure resistance of inserts in continuous and intermittent cutting processes. When the Al2O3 layer on the cutting edge is peeled off by wet-blasting, the fracture failure resistance during intermittent cutting will be significantly reduced.

Numerical Study on the Influence of Polyimide Thickness and Curing Temperature on Wafer Bow in Wafer Level Packaging

In wafer level packaging, polyimide and electroplated copper are dielectric and conducting materials respectively in the so-called redistribution layers. During the wafer fabrication process large amount of stress is generated in those layers due to curing shrinkage of the polyimide and the coefficient of thermal expansion mismatch of both materials to silicon which can lead to severe wafer bow after a high temperature curing. In different applications polyimide can be used either only as passivation layer over electroplated copper, or polyimide is applied before the redistribution layer and then a second polyimide layer is applied as passivation. In the current study the effect of different polyimide integrations is investigated. In-situ wafer bow measurements and finite element method studies were conducted with samples, with and without polyimide below redistribution layer, exposed to different curing temperatures to understand the change in wafer bow and copper residual stress. It is observed that wafers with polyimide before redistribution layer show higher stress relaxation in copper with decreasing curing temperature, resulting therefore in a lower wafer bow. A good agreement is achieved between the experimentally measured and the simulated wafer bow.