Development Of Residual Stresses Research Articles

Residual stress, distortion, and porosity analysis of LED heat sink printed by SLM process using machine learning

In recent years, Light-emitting diodes (LEDs) are dominating the traditional lighting system. Besides mercury-free, they have small size, good break resistance and long life. Although LEDs are cool to touch, they generate a lot of unnecessary heat inside the gadgets. It is important to remove the heat using efficient thermal management component such as heat sink. Instead of using a conventional manufacturing process, selective laser melting (SLM) process is used to manufacture the heat sink. The quick solidification and various thermal regimes of the material during the SLM process lead to the development of residual stresses that cause the part distortion and harm the mechanical properties of the component. The objective of the current study is to find the optimum value of laser power, scanning speed, and hatch spacing to bring down the residual stress and distortion in the SLM process to an acceptable range. Residual stress and distortion values of the heat sink are simulated using MSC Simufact additive and ANSYS Additive software. The conflicting nature between residual stress and porosity was observed. Hence, grey relation analysis was used to convert residual stress & porosity into a single objective. Optimum process parameters obtained were, laser power 80 (W), scanning speed 950 (mm s−1), and hatch spacing of 70 The values of residual stress and porosity at optimum parameters were found to be 385.58 MPa and 12.21%. Multiple regressions algorithm of machine learning was used to form a relationship between residual stresses and porosity. It was also observed that the magnitude of residual stress and distortion were low at lower energy densities and high at higher energy densities and the residual stress and porosities were high in the z-direction.

Simulation of transient heat transfer and phase transformation in laser beam welding for low alloy steel and studying its influences on the welding residual stresses

The welding process causes high local heat input on the material, which leads to microstructural changes in the base material, followed by the development of residual stresses in the welded components. This has a significant impact on the performance of the welding joint. Therefore, it is crucial to effectively predict the effect of temperature, metallurgical and structural changes on the component, which can be achieved by numerical simulation.The main goal of this work is to mathematically investigate the influence of thermo-metallurgical phase transformations on the welding residual stresses which was induced by laser beam welding in low alloy steel (S235JR). In this study, two separate numerical simulation models were analyzed using the software Abaqus CAE. One numerical model describes the thermo-mechanical behavior and the other describes the thermo-metallurgical-mechanical behavior of the system which was realized using UEXPAN user subroutine. In this user subroutine, the kinematics of phase transformation was computed using the modified Johnson-Mehl-Avrami and Kolomogorov while considering a nucleation and growth process that controls the dissolution of the initial microstructure. The generation of martensitic transformation has been accounted by the Koistinen-Marburger equation. In the next step, the phase transformation subroutine has been integrated with a structural model along with a special temperature step function to realize the effect of thermal strain and the strain caused by phase transformation on the welding residual stresses. The computed residual stresses of both the models were compared with the experimentally measured residual stresses using the hole drilling method. These results show that the inclusion of phase transformations has a significant effect on the residual stresses of the welded component.

Microstructure and residual stress evolution in nanocrystalline Cu-Zr thin films

Grazing incidence X-ray diffraction (GIXRD) and scanning transmission electron microscopy (STEM) combined with energy dispersive X-ray spectroscopy (EDS) were employed to study the microstructure evolution and stress development in the nanocrystalline Cu100−X-ZrX (2.5 at% ≤ x ≤ 5.5 at%) alloy thin films. Small Zr additions to Cu led to significant lattice parameter anisotropy in the as-deposited Cu-Zr thin films both due to macroscopic lattice strain and stacking faults in the Cu matrix. Strain free lattice parameters obtained after the XRD stress analysis of Cu-Zr thin films confirmed formation of a supersaturated substitutional Cu-Zr solid solution. For the first time, the study of film microstructure by XRD line profile analysis (XLPA) confirmed progressive generation of dislocations and planar faults with increasing Zr composition in Cu-Zr alloy films. These microstructural changes led to the generation of tensile stresses in the thin films along with considerable stress gradients across the films thicknesses which are quantified by the traditional dψhkl−Sin2ψ and GIXRD stress measurement methods. The origin of tensile stresses and stress gradients in the Cu-Zr film are discussed on the basis of film growth and heterogeneous microstructure with changing Zr composition.

Evolution of structure, residual stress, thermal stability and wear resistance of nanocrystalline multilayered Al0.7Cr0.3N-Al0.67Ti0.33N coatings

The fundamental understanding of the relation between the architecture and the development of structure and residual stress in multilayer coatings is a challenging task. In this work, cross-sectional X-ray nanodiffraction with a spatial resolution of 50 nm, performed at the cross-section of a Al 0.7 Cr 0.3 N/Al 0.67 Ti 0.33 N multilayer coating was used to investigate its depth gradients of the phase composition and residual stress. It could be demonstrated that the cubic structure can be stabilized in a substrate bias range between −100 and −200 V developing stress values above −5 GPa. Below −100 V and above −200 V a dual phase microstructure developed with reduced stress values compared to the pure cubic regime. Based on the results of the cross-sectional X-ray nanodiffraction investigation, five multilayer architectures, differing in the sublayer thickness, interface design and microstructure were developed to test the wear resistance by ball-on-disc experiments at temperatures up to 700 °C. It could be demonstrated that a sublayer thickness between 70 and 100 nm has been proven to be an ideal thickness for such an Al 0.7 Cr 0.3 N/Al 0.67 Ti 0.33 N multilayer to decrease the wear rate by a factor of 10 at 600 °C compared to their monolithic counterparts. • Cross-sectional X-ray nanodiffraction with a spatial resolution of 50 nm • Investigation of depth gradients of the microstructure and residual stress • Demonstration of various approaches to (de)stabilize the metastable cubic phase • Increase in wear resistance due to bi-layer and substrate bias voltage variations

Enabling High-Performance Surfaces of Biodegradable Magnesium Alloys via Femtosecond Laser Shock Peening with Ultralow Pulse Energy.

The fast degradation rate and poor wear resistance of magnesium (Mg) alloys in physiological environments have limited their potential usage as next-generation biodegradable orthopedic implant materials. In this work, femtosecond laser shock peening (fs-LSP) was successfully applied to simultaneously improve the surface mechanical, corrosion, and tribocorrosion properties of WE43 Mg alloys in blood bank buffered saline solution at body temperature. Specifically, the treated surfaces of WE43 Mg alloys via fs-LSP with ultralow pulse energy were investigated under different power densities, confining mediums, and absorbent materials. It was found that the combination of a black tape and a quartz layer gave the optimum peening effect under a power density of 28 GW/cm2, which simultaneously strengthened the surface and reduced the corrosion kinetics. In addition, a rapid self-repassivation was observed in fs-LSP-treated WE43 surfaces during tribocorrosion, promising sustained corrosion resistance under mechanical loading, critical to the reliability of load-bearing implants. Finally, the subsurface microstructural evolution and residual stress development in WE43 after fs-LSP were discussed based on the results from transmission electron microscopy analysis and finite element simulations.

Multi-scale residual stress prediction for selective laser melting of high strength steel considering solid-state phase transformation

The complex metallurgical processes of high strength steel making it difficult to accurately predict the residual stress in laser additive manufacturing, especially for part scale parts. To solve this problem, a multi-scale model considering solid-state phase transformation (SSPT) is proposed to predict thermal, residual stress evolution and distribution for the selective laser melting (SLM) process of high strength tool steel. In 3D finite-element-method thermo-metallurgical-mechanical model, the Kamamoto equation and Koistinen-Marburger equation are used to predict the austenite and martensite phase transformation, respectively. The temperature cycle and thermal behavior are analyzed, and the effects of phase properties transition, transformation-induced volume change and plasticity on residual stress are discussed in detail. The residual stress spatial distribution of multi-layer is obtained. Simulations show that the SSPT has a significant effect on the residual stress evolution in the SLM of high strength steel, considering the influence of phase transformation can effectively reduce tensile residual stress. The thermo-metallurgical-mechanical model is then applied to obtain the inherent strain. The inherent strain method is used to predict the residual stress of the part scale models. Compared with the experimental data, the simulated residual stress shows the same variation trend, which indicates that the proposed multi-scale model can predict residual stress in SLM of high strength steel more accurately and efficiently.

Understanding residual stress in thin films: Analyzing wafer curvature measurements for Ag, Cu, Ni, Fe, Ti, and Cr with a kinetic model

An analytical model for the evolution of residual stress in polycrystalline thin films is used to analyze numerous previously reported wafer curvature measurements obtained for a variety of materials and processing conditions. The model, which has been described in previous publications, considers stress-generating mechanisms that occur at the grain boundary as it forms between adjacent grains and stress due to the subsurface grain growth in layers that have already been deposited. Current work extends the model to include different types of microstructural evolutions. A set of parameters for each dataset is obtained by non-linear least square fitting. Model parameters that are not expected to depend on the processing conditions are constrained to have a common value when fitting the multiple datasets for each material. The dependence of the fitting parameters on the material and process conditions is evaluated and compared with the physical mechanisms implemented in the model.

Structural and mechanical modifications of GaN thin films by swift heavy ion irradiation

The structural modifications and the evolution of mechanical behavior of gallium nitride (GaN) thin films irradiated by 92 MeV 129Xe23+ at different fluences have been investigated. The modifications induced by irradiation in GaN have been studied using a combination of high resolution X-ray diffraction and Transmission Electron Microscopy observations coupled to nanoindentation. The crystalline lattice of the GaN is modified by irradiation, with an extension of the lattice along the c-direction parallel to the ion path, leading to the development of residual stresses. Correlated to the crystallographic disorder, modification of the deformation mechanisms of the material is observed: damaged areas (highly disordered zones near the surface and black dots deeper in the bulk) hinder the dislocation motion, such as after irradiation, dislocation slip occurs only along the basal plane, and no more prismatic or pyramidal slip is observed. This results in increasing the dislocation loop density, with a subsequent increase in hardness of the GaN film. At higher fluence, the overlapping of the latent tracks created by swift heavy ions results in a significant decrease in the mechanical characteristics of the thin film, and an amorphous-like material behavior.

Experimental and Simulation Analysis of the Evolution of Residual Stress Due to Expansion via CMAS Infiltration in Thermal Barrier Coatings

The failure behavior of thermal barrier coatings (TBCs) involves multilayered systems infiltrated with calcium–magnesium–alumino-silicates (CMAS). The metastable tetragonal phase is mainly composed of 7YSZ (7 mol.% Y2O3-stabilized ZrO2), and it destabilizes into the Y-lean tetragonal phase, which may be induced by CMAS infiltration, and transforms into a monoclinic phase during cooling. The phase transformation leads to volume expansion around the CMAS-rich layer. Furthermore, it is shown that the spalling of the coating system emerges when the surface of the coating system is subjected to significant residual stress. In this study, a double-cantilever beam model is established to describe the macroscopic phenomenon of thermal buckling induced via CMAS. The result of the buckle height is used to demonstrate the consistency of the experiment and finite element simulation. The experimental parameters are imported into a multilayer cantilever beam model to analyze the interfacial stresses due to CMAS infiltration. The finite element results indicate that the phase transformation leads to damage in the coating system wherein the interfacial stresses due to phase transformation are 27% higher than those in the model without phase transformation.

Effect of autofrettage on the ultimate behavior of thick cylindrical pressure vessels

Major applications of thick cylinders are in the defense sector. Stress distributions especially under elastic-plastic conditions are more complex in thick cylinders. Though the cylinder may not be strained to ultimate in service, assessment of factor of safety is essential. Simulating elastic-plastic material behavior of cylinders using the uni-axial test data is more dependable and the finite element analysis (FEA) software has got this capability. A procedure using a suitable material model is demonstrated in this study utilizing the FEA software Ansys. The instability criterion followed in Svensson's pressure expansion relationship is used in the process of FEA. The predicted failure pressure is very close to the literature test data as well as few theories that have been highlighted. Moreover, thick cylinders are mostly subjected to autofrettage in applications like gun barrels to enhance service pressure and fatigue life. Hence it is attempted to simulate the development of residual stress due to autofrettage and its effect on the ultimate behavior on the pressure vessels. The residual stress developed is superimposed on the stresses due to internal pressure which causes the redistribution of stresses throughout the thickness. There is a marginal increase in burst pressure due to autofrettage. Though the effect could be made significant by increasing the autofrettage pressure, it gives detrimental effects on the other side by developing tensile residual stresses on the external surface. Hence, with the permissible extent of autofrettage, the effects are found to be marginal and this knowledge helps assess the safe loading limits.

A comprehensive analytical-computational model of laser directed energy deposition to predict deposition geometry and integrity for sustainable repair

Laser directed energy deposition (DED) is an innovative additive manufacturing technology with tremendous potential for remanufacturing and repairing critical components. For sustainable repair, it is necessary to control the deposition geometry and integrity in terms of residual stresses and dilution. Obtuse contact angles and inadequate dilution can lead to inter-track porosity and cracks at the edge of the deposition-substrate interface. In addition, the fatigue life of the restored part is compromised if tensile residual stresses are induced in the deposited layer. A comprehensive modeling approach presented in this paper integrates analytical formulations for the laser-powder interaction and the powder entrapment in the melt pool, with the finite element models for determining the melt pool characteristics and the residual stresses. This model captures the physics of the key phenomena in DED, namely, power attenuation due to laser-particle interaction, melt-pool formation, powder catchment in the melt pool, and the residual stress evolution due to differential thermal contraction and metallurgical transformations. The model predictions have been experimentally validated for residual stresses, dilutions, catchment efficiencies, powder flux, and deposition geometries for crucible particle metallurgy (CPM 9V) steel powder on H13 tool steel. CPM 9V is a preferred material for repairing H-13 molds. Extensive simulations have been carried out using the comprehensive analytical-computational model to develop data-driven expressions for deposition geometry, normalized dilution, and residual stress as a function of process parameters (laser power, scan speed, and powder feed rate). For identifying the preferred deposition regime, these relations are employed to bifurcate the entire operating space into obtuse and acute contact angle, insufficient and sufficient dilution, tensile and compressive residual stress. Higher Pv/m˙ values yield depositions with the desired acute contact angles and higher specific energies (P/vd) induce favorable compressive longitudinal residual stress in the depositions.

Evolution of Residual Stresses and Fracture in Thermomechanically Loaded Particle-Reinforced Metal Matrix Composites

Evolution of Residual Stresses and Fracture in Thermomechanically Loaded Particle-Reinforced Metal Matrix Composites

Evolution of residual stress, microstructure and cyclic performance of the equiatomic high-entropy alloy CoCrFeMnNi after deep rolling

High-cycle fatigue tests were performed on differently deep rolled conditions of the equiatomic high-entropy alloy (HEA) CoCrFeMnNi. Twinning in the near-surface layer of specimens deep rolled at cryogenic temperature is revealed by electron-backscatter diffraction. As internal failure mode and similar fatigue lives are found irrespective of the deep rolling temperature, these twins are not expected to significantly contribute to the fatigue properties of the surface treated HEA. S-N curves of the initial state and deep rolled conditions revealed a point of intersection at low stress amplitudes. This unexpected behaviour is explained based on the interplay of several characteristics of the near-surface layers.

Simulation Study of Hatch Spacing and Layer Thickness Effects on Microstructure in Laser Powder Bed Fusion Additive Manufacturing using a Texture-Aware Solidification Potts Model

Microstructure control in the laser powder bed fusion additive manufacturing processes is a topic of major interest because of the submillimeter length scale at which the manufacturing process occurs. The ability to control the process at the melt pool scale allows for microstructure control that few other manufacturing techniques can match. The majority of work on microstructure control has focused on altering laser parameters to control solidification conditions (Ref (R.R. Dehoff, M.M. Kirka, W.J. Sames, H. Bilheux, A.S. Tremsin, L.E. Lowe, and S.S. Babu, Site Specific Control of Crystallographic Grain Orientation through Electron Beam Additive Manufacturing, Mater. Sci. Technol., 2014, 31(8), p 931–938. R. Shi, S.A. Khairallah, T.T. Roehling, T.W. Heo, J.T. McKeown, and M.J. Matthews, Microstructural Control in Metal Laser Powder Bed Fusion Additive Manufacturing Using Laser Beam Shaping Strategy, Acta Mater., 2020, 184, p 284–305, https://doi.org/10.1016/j.actamat.2019.11.053.)). Other machine parameters, besides the laser parameters, have also been shown to affect the microstructure of AM parts (Ref (N. Nadammal, S. Cabeza, T. Mishurova, T. Thiede, A. Kromm, C. Seyfert, L. Farahbod, C. Haberland, J.A. Schneider, P.D. Portella, and G. Bruno, Effect of Hatch Length on the Development of Microstructure, Texture and Residual Stresses in Selective Laser Melted Superalloy Inconel 718, Mater. Des., 2017, 134, p 139–150, https://doi.org/10.1016/j.matdes.2017.08.049. F. Geiger, K. Kunze, and T. Etter, Tailoring the Texture of IN738LC Processed by Selective Laser Melting (SLM) by Specific Scanning Strategies, Mater. Sci. Eng. A, 2016, 661, p 240–246, https://doi.org/10.1016/j.msea.2016.03.036.)). We propose an investigation of the effects of hatch spacing and layer thickness on microstructure development in laser powder bed fusion additive manufacturing. A Monte Carlo Potts model with textured solidification capabilities is used to study the effects of these parameters on a unidirectional scan strategy. The simulation results reveal substantial changes in grain morphology as well as texture. Additionally, EVP-FFT crystal plasticity simulations were performed to evaluate the effect of the microstructural shifts on mechanical response. The conclusions from this work elucidate the effects of these parameters on part microstructure as predicted by the texture-aware solidification Potts model and inform understanding of how bulk texture is predicted by the simulation approach.

Study of the Contact Thermal Compression Behavior of Copper using Scanning Contact Potentiometry Method and Finite Element Analysis

The issue of tracking residual stresses initiation in welding copper under various affected conditions is essential in increasing safety through improving the welding quality in particular, in the nuclear industry. This study investigated the behavior of welded copper numerically and experimentally under contact-heating compression test with constant clamping force. The scanning contact potentiometry (SCP) method was used to track the initiation and development of residual stresses within the weld zone. Furthermore, the finite element analysis (FEA) method was used to simulate and study the effect of thermal variations, with a constant compressive force, on mechanical factors that contribute to residual stresses formation within the weld zone. Additionally, scanning electron microscope (SEM) and energy-dispersive X-ray spectroscopy (EDS) were used to get further information about the topography and composition of the specimen's surface. SCP results show that residual stress initiated from within the volume after 200 °C, and with further oxidation, its formation began on the surface after 250 °C. Using the relationship between maximum values of linearized von Mises stresses and maximum values of ADS at high SLS = 4.523, it was found that residual stresses generation began after 150 °C within the weld zone, and thermal stresses linearly increase with temperature due to further thermal expansion, which is associated with variation in linearized von Mises stresses and ADS maximum values. Comparison between potentiograms after 300 °C and FEA results have shown that the distribution of von Mises stress, normal stress, and total deformation are matching those in the distribution of ADS and are localized within the weld zone.
 HIGHLIGHTS
 
 The behavior of welded copper under compression at medium-low temperature range
 Residual stresses detection at an early stage localized within weldment zone
 Residual stresses increase with increased oxidation at copper surface
 Matched the SCP Experimental and FEA simulation results
 
 GRAPHICAL ABSTRACT

Molecular design of polymer coatings capable of photo‐triggered stress relaxation via dynamic covalent bond exchange

AbstractPolymer coatings are frequently used to modify surface properties of inorganic substrates. However, the disparity in physical properties between polymer film and substrate often leads to residual stress development, which can be deleterious to the overall performance of coated materials. This work reports the molecular design of polymer films that dissipate stress upon irradiation with ultraviolet (UV) light. These polymers are synthesized by post‐polymerization modification of the reactive polymer, poly(2‐vinyl‐4,4‐dimethyl azlactone), to introduce dynamic crosslinks capable of light‐initiated addition transfer fragmentation chemistry. Using a custom‐built optical cantilever, contrasting film stress responses are observed between films containing dynamic bonds and analogous control films after UV light irradiation, which indicate successful stress relaxation. Further experiments demonstrate the complete relaxation of residual stress in dynamic films after an extended exposure, thereby generating a “stress‐free” film. Films fabricated using this approach can be easily tailored to incorporate additional moieties to introduce desired surface properties for future application in a wide array of coatings.

Thermal field and residual stress analyses of similar and dissimilar weldments joined by constant and pulsed current TIG welding techniques

ABSTRACT Higher heat input rates and uneven thermal cycles involved in fusion welding processes effect HAZ properties and causes to develop residual stress across fusion zones. These thermal stresses reduce the service life of welded structures. To understand the thermal cycles, In-Situ peak temperatures and their distribution over the weld surface of similar and dissimilar combinations of Monel 400 and AISI 316 base plates joined by constant and pulsed current TIG welding processes are measured with Infrared thermography technique at different time intervals. After welding the joints, thermal stresses developed across the joints were measured using X-ray diffraction technique. The stress measurements were made on weld surfaces of fusion zone and HAZ on either side of base metals. Higher temperature values were recorded during constant welding technique than the pulsed welding technique. Also, the heat affected area was more in weldments of constant welding technique. The maximum temperatures of 1657 0C, 1711 0C and 1748 0C were recorded in CCGTAW process during pass-1, pass-2 and pass-3 welding, respectively. Whereas, in PCGTAW process, maximum temperatures of 1434 0C, 1509 0C and 1634 0C were recorded during pass-1, pass-2 and pass-3 welding, respectively. The overall reduction in temperatures in PCGTAW process was 10.6%, which could affect the cooling cycles during solidification. Both the welding techniques have exhibited development of compressive natured residual stresses in dissimilar joints. The heat concentration at fusion area was reduced in pulsed technique that resulted in lower residual stresses.

Investigation on residual stress evolution in nickel-based alloy affected by multiple cutting operations

Machining-induced residual stresses in a part can significantly influence its performance and service time. It is common that the final surface of the part is produced after multiple cuts in the machining process. In multiple cuts, the previous cuts could often generate accumulated strain/stress and temperature on the part surface. These accumulated strain/stress and temperature will be brought to the subsequent cut or final cut and continuously affect the cutting forces, process temperatures, deformation zones, etc. in subsequent cut, and eventually affect the final residual stresses on the part. This paper reports on a joint experimental and numerical investigation to explore the influence of previous cuts on surface residual stresses with consideration of cutting parameters, cutting procedure, and tool geometries in multiple cut of Inconel 718 alloy. Coupled Eulerian and Lagrangian (CEL) formulation is used in a two/three-cuts numerical model. The loading cycles of the selected material nodes are characterised based on isotropic constitutive model (Johnson-Cook model) to analyse the underlying mechanism of residual stress evolution during cutting sequences. The results show that accumulated stress/strain induced by previous cuts lead to a more curled chip morphology, a slight decrease in cutting force and a slight increase in feed force in the subsequent cut. An increased magnitude and depth of compressive residual stresses in the finished workpiece are generated owing to the influence of previous cuts, and this is more obvious when the previous cut is implemented at a larger uncut chip thickness, using a more negative rake angle or a larger edge radius tool. The residual stress level might be controlled by optimizing the previous cuts to get the desired surface integrity.

The influence of the technological cycle of production on the change in the physical and mechanical characteristics of bimetal with a butt welded joint in the cladding layer

The goal of the study is to consider the effect of explosion welding, heat treatment and cold straightening (gagging) in production of 09G2S + 08Kh13 bimetal with a butt welded joint in the cladding layer on the evolution of residual internal stresses. The impact of technological operations on the change in the level of residual stresses in a bimetallic material with a welded butt joint in the cladding layer was carried out using a non-destructive method of the magnetic memory of metals (MMM). This method is based on the use of the intrinsic stray magnetic field formed in the zones of increased dislocation density. The results revealed the special features of the location of zones with maximum values of the stress field gradient (dH/dx) and their evolution upon production of 09G2S + 08Kh13 bimetal with a butt welded joint in the cladding layer. An increase in the level of residual stresses in the cladding layer occurs after manual electric arc welding of 2 parts of the cladding layer made of 08Kh13 steel. It is shown that after explosion welding the level of residual stresses change. The stress relaxation occurs in the zone of weld in the cladding layer. At the same time, an increase in the level of residual stresses is observed in the main and cladding layer of the bimetal. To reduce the high level of residual stresses, we used the subsequent heat treatment of the obtained bimetallic samples in two different modes. The optimal heat treatment mode (heating to 720 ± 20°C, holding for 2 h, cooling with a furnace) which excluded the crack formation in the cladding layer upon mechanical straightening of bimetal was specified for 09G2S + 08Kh13 bimetal sample with a butt welded joint in the cladding layer.

Analysis of micro-cracks evolution in silicon cell during entire solar photovoltaic module manufacturing process

The crack growth behaviour of silicon cell during entire solar photovoltaic module manufacturing process is numerically studied in this work using finite element analysis. In this investigation, the inherently present micro-cracks in the silicon cells are introduced systematically in the finite element model by considering their influencing parameters such as location, length and origination. The cracks in the silicon cell near the solder region are found to be more critical ones through mode-I stress intensity factor. The critical micro-cracks initiate the fracture even during the PV module manufacturing process, when the stress intensity factor reaches the critical value called the fracture toughness of the silicon cell. To substantiate the findings from this work, the residual stress evolution without cracks in the silicon cell is also numerically simulated and correlated with the experimental observations reported. Finally, the extended finite element method is employed further to confirm the fracture phenomena in the silicon cell for critical lengths and locations.