Growth Of Microvoids Research Articles

Optimizing Transformation-Induced Plasticity to Resist Microvoid Softening

Many high-performance steels that are critical for energy-efficient, lightweight designs rely on transformation-induced plasticity (TRIP) to achieve superior combinations of strength and ductility/toughness. Further development of these alloys will require greater optimization of the metastable (retained) austenite phase responsible for TRIP. Considering the complex nature of TRIP and its effects on ductile fracture, an integrated computational materials engineering (ICME) approach to materials optimization is desired. In this work, we report the results of a large series of micromechanical finite element calculations that probe the interaction of TRIP and void-mediated ductile fracture mechanisms. The simulations identify the optimal austenite stability for maximizing the benefit of TRIP across a wide range of stress states. The applied stress triaxiality significantly influences the microvoid growth rate and the computationally determined optimal stability. The simulation results are compared with existing experimental data, demonstrating good agreement.

Implementation of a finite element framework coupling chemo‐mechanics and the Gurson‐Tvergaard‐Needleman model

AbstractHydrogen embrittlement in ductile metals, such as steel, is a significant concern, for instance, in the safety assessment of existing pipeline infrastructure intended for hydrogen transport. The ductile damage mechanism in steels is characterized by the nucleation, growth, and coalescence of microvoids, which is further enhanced by the presence of hydrogen. This leads to material damage and premature failure in components. Mechanisms contributing to hydrogen‐induced reduction of strength in steels include hydrogen‐enhanced decohesion (HEDE), hydrogen‐enhanced local plasticity (HELP), and hydrogen‐enhanced strain‐induced vacancies (HESIV). The HEDE mechanism leads to a principal stress‐controlled brittle failure mode. Conversely, the HELP and the HESIV mechanisms, which are dominated by plastic deformation, alter the ductile damage behavior as they lead to accelerated void growth and coalescence. Furthermore, interstitial diffusion of hydrogen leading to lattice expansion, commonly referred to as swelling, also contributes to hydrogen‐induced embrittlement. Hydrogen embrittlement is therefore a stress‐diffusion process that involves chemo‐mechanical coupling, where hydrogen atoms primarily diffuse toward areas with high hydrostatic stress. In this regard, we propose a framework using the finite element method and combining coupled chemo‐mechanics and the well‐known Gurson‐Tvergaard‐Needleman (GTN) damage model. The framework is motivated by mixed rate‐type potentials, that account for the influence of hydrogen concentration on the damage behavior. An additional dependence of the fracture strain and evolution of the void volume fraction on hydrogen is included. A comparison of the fully‐coupled model to simplified versions is conducted to individually assess the role of hydrogen concentration on damage evolution and the stress state on diffusion.

Creep rupture properties of dissimilar welded joint of ferritic/martensitic P92 steel and Inconel 617 alloy

The dissimilar welded joint (DWJ) comprising P92 steel and Inconel 617 (IN617) is frequently utilized in advanced ultra-supercritical (AUSC) boilers. In present work the creep rupture behaviour, rupture mechanism and microstructure evolution of DWJ of P92 steel and IN617 with Ni-based ERNiCrCoMo-1 filler, were examined at 650 °C under the stress range of 120–200 MPa. The results of the creep test indicated that the location of creep rupture varied across different testing conditions, encompassing areas such as P92 base metal and the fine-grained heat-affected zone (FGHAZ). The creep tested specimens within the stress range of 180–200 MPa exhibited failure originating from P92 base metal, predominantly influenced by plastic deformation. The failure manifested in a transgranular mode, driven by the formation, growth, and eventually coalescence of microvoids. The creep tested specimens within the stress range of 120–150 MPa displayed the characteristic ofType IV failure, primarily attributed to matrix softening and the absence of adequate precipitates to pin the PAGBs. Microstructural characterization unveiled the presence of microvoids along the PAGBs, facilitating microvoid nucleation primarily owing to the existence of the coarse brittle carbide phase. The growth of these microvoids over a period of time during tertiary stage of creep which lead to their coalescence and the formation of microcracks, ultimately resulting in premature intergranular failure. The specimen creep exposed at 650 °C under the lower stress of 120 MPa exhibited higher creep rupture life for 432 h. The SEM/EDS study of the crept sample of 120 MPa is also confirmed the presence of intermetallic laves phases in regions near the fracture tip and in the heat-affected zones (HAZs). Although the creep tested specimens at 150 MPa and 120 MPa exhibited failure in the FGHAZ and their elemental SEM/EDS analysis confirmed the presence of an oxide layer and notch formation near the interface of P92 base metal and ErNiCrCoMo-1 filler weld. The FESEM study revealed the growth of the oxide layer in the notch region, and it also showed the presence of multiple cracks and microvoids in the oxide layer. The formation and propagation of the oxide notch mainly led to the interfacial failure. The crept specimens subjected to 180 MPa and 200 MPa did not exhibit any cracks or microvoids in HAZs. However, specimens that failed under applied stresses of 120 MPa and 150 MPa revealed the presence of a high density of microvoids in the FGHAZ, inter-critical heat-affected zone (ICHAZ), and in the region of the coarse-grained heat-affected zone (CGHAZ) adjacent to the interface attached with an oxide layer.

Improving UV aging resistance by loading PDA on the surface of PBO fibers via Fe (III) coordination

Poly(p-phenylene-2,6-benzobisoxazole) (PBO) fiber is currently one of the best-performing organic fibers; however, its low UV aging resistance limits its use. To improve the UV aging performance of PBO fibers, a novel PBO-Fe-PDA fiber was created by depositing a biomimetic structure of polydopamine (PDA) on the surface of PBO fibers with the transition metal ion Fe3+ as the active center. The surface morphology and elemental composition of PBO-Fe-PDA fibers were investigated. It was revealed that Fe3+ formed a coordination bond structure with the oxazole ring, and PDA was successfully loaded onto the surface of PBO-Fe fibers. After UV aging, the crystallinity and crystallographic orientation of PBO fibers significantly decrease, microcrystals inside the fibers slip, and the size of microvoids in the fibers rises. As a result, the strength of PBO fibers was significantly decreased after UV aging. The anti-UV aging capacity of PBO-Fe-PDA fibers, on the other hand, has been enhanced, as evidenced by a slight drop in crystallinity and crystallographic orientation and a significant decrease in the size growth of internal microvoids in the fibers after UV aging. The tensile strength retention of PBO-Fe-PDA fibers after UV aging increased by 93.13% when compared to PBO fibers without altering the fibers’ initial strength. The testing results show that this surface modification method is simple to employ and extends the service life of PBO fibers significantly.

Analysis of Hot Tensile Fracture and Flow Behaviors of Inconel 625 Superalloy.

In this work, Inconel 625 alloy is explored regarding high-temperature tensile deformation and fracture behaviors at a strain rate of 0.005-0.01 s-1 under a deformation temperature ranging from 700-800 °C. The subsequent analysis focuses on the impact of deformation parameters on flow and fracture characteristics. The fractured surface reveals that ductile fracture is dominated by the nucleation, growth, and coalescence of microvoids as the primary failure mechanisms. The elevated deformation temperature and reduced strain rate stimulate the level of dynamically recrystallized (DRX) structures, resulting in intergranular fractures. The Arrhenius model and the particle swarm optimization-artificial neural network (PSO-ANN) model are developed to predict the hot tensile behavior of the superalloy. It indicates that the PSO-ANN model exhibits a correlation coefficient (R) as high as 0.9967, surpassing the corresponding coefficient of 0.9344 for the Arrhenius model. Furthermore, the relative absolute error of 9.13% (Arrhenius) and 1.85% (PSO-ANN model) are recorded. The developed PSO-ANN model accurately characterizes the flow features of the Inconel 625 superalloy with high precision and reliability.

Extreme load analysis of flexible wave energy converters utilising nonlocal continuum damage mechanics

In recent years, there has been a notable increase in interest towards Flexible Wave Energy Converters (FlexWECs). These flexible energy harvesters solve structural design challenges faced by rigid-body WECs by responding to external loading by changing shapes. Typically, the structures are made from rubber-like materials which pose few challenges from a material modelling point of view. Firstly, the material is in the finite strain regime requiring a hyperelastic modelling approach, but more critically the material response is expected to change during the operational lifetime. There is softening from both time-dependent viscoelasticity and micro-void growth caused by fatigue loading. The goal of this paper is to understand the latter mechanism and how it manifests within a membrane. To account for this damage accumulation, the gradient-enhanced nonlocal damage model is coupled to a hyperelastic Neo-Hookean constitutive law. The framework has been implemented in the commercial finite element software ABAQUS by exploiting its fully coupled thermo-mechanical formulation. A parametric study is performed on two FlexWEC archetypes: a submerged pressure differential and a floating bulge wave attenuator. The performance evaluation of these devices is carried out by analysing the evolution of the pressure–volume relation and pressure-stretch relation, respectively. The results show that the nonlocal aspects of damage in the pressure differential FlexWECs are small due to membrane action, but the saturation of damage does affect the pressure–volume function of each membrane. However, in the case of attenuator, the damage regularisation plays a crucial role in its behaviour due to the steep stress gradient from the crest of the wave. The outcomes from these analyses suggest FlexWEC design is advantageous from a fatigue loading perspective as it always reaches an equilibrium state which minimises the stress-differential, reducing the likelihood of localised crack growth.

A novel defect-related cyclic damage model driven by strain energy density for LPBF titanium alloy

The unavoidable defects in additive manufacturing (AM) material have an impact on the deformation behavior and fatigue lifetime. In this study, a series of experiments on Laser powder bed fusion (LPBF) Ti-6Al-4 V under symmetrical tension–compression cyclic loading were conducted, and the corresponding damage mechanism was then investigated. It is revealed that due to the nucleation, growth, and coalescence of micro-voids, LPBF Ti-6Al-4 V exhibits accelerated softening behavior after reaching cyclic stability. Based on the physical mechanism, a cyclic damage model with a critical initiation criterion was developed using fracture mechanics principles, in which plastic strain energy as the driving parameter is introduced to describe the defect evolution, and the void’s closure effect during the tension–compression cycle is considered. Experimental validation has demonstrated that the damage model can accurately predict the cyclic stress–strain curves for LPBF Ti-6Al-4 V vertical and horizontal specimens, with errors in predicting crack initiation and growth lifetime falling within the ± 1.6 and ± 2.5 scatter bands.

Degradation and anisotropy characteristics of fracture toughness in Ni-based superalloys after phase coarsening

The effect of phase coarsening on the crack propagation characteristics and the corresponding fracture toughness in Ni-based superalloys is investigated by integrating with the finite element method simulations and related mechanism analysis, and the relationship between the macroscopic mechanical properties of alloys and the evolution in their microstructures are discussed in detail. Related analysis shows that the fracture toughness of alloys degraded considerably with phase coarsening. Moreover, the fracture toughness also demonstrates an anisotropic characteristic. Specifically, when the volume fraction of precipitate is low or the degree of phase coarsening is relatively low, the fracture toughness of alloys increases first and then decreases gradually along with increasing the loading angle, showing an inverted "V" shape. In comparison, in the case of a higher volume fraction of precipitate or higher degree of phase coarsening, the fracture toughness displays an opposite variation trend, and reaches the minimum value at the loading direction of 45°. The corresponding variation characteristics of fracture toughness are correlated with the evolutions of precipitate shape, size, and distribution within the alloys. The change in the microstructure or that in the loading direction affects remarkably the initiation and growth of micro-voids within the alloys, and it further affects the crack propagation characteristics, resulting in the degradation and anisotropy characteristics of macroscopic fracture toughness in the alloys. Related work is of great significance for the structure design of Ni-based superalloys components, the mechanical property evaluation and the life prediction during their service process.

A shear modified GTN model based on stress degradation method for predicting ductile fracture

The Gurson–Tvergaard–Needleman (GTN) model has provided a powerful description of the nucleation growth and coalescence of micro voids, but it has limitations in simulating shear fracture due to the absence of a description of shear localization behavior. A shear improvement method is proposed for simulating the ductile fracture of materials under different stress states. The modified model not only allows for strain hardening of the matrix material, but also accounts for the stress degradation caused by shear. The strength equation of the material is described by both the shear stress state function and a decay function, making it easier for materials under shear stress state to experience material softening and further inducing shear fracture. The modified GTN model is developed by incorporating the shear stress degradation factor into the yield function, while taking into account both void growth and shear failure mechanisms. By carefully calibrating the model’s parameters, the deformation and fracture processes of tensile, plane strain, notch tensile, and compression specimens in the 7A52 aluminum alloy are simulated. The damage evolution behavior of the material under different stress states is analyzed. The results indicate that the damage include void growth mechanism and void shear mechanism. The proportions of these two mechanisms vary under different levels of stress triaxiality. Upon localizing material deformation, the shear stress state intensifies, and the shear damage mechanism assumes a critical role in fracture. The modified GTN model accurately predicts the load-displacement response and fracture path of the 7A52 aluminum alloy under a wide range of stress states.

On the predictive capabilities of non‐local models for ductile crack propagation under different levels of stress triaxiality

AbstractDuctile materials are used in many applications such as hydrogen storage and transport, energy plants and additively manufactured components. High safety standards are vital for such applications, which underline the necessity of thoroughly investigating ductile failure to ensure safety and increase components efficiency. Ductile failure is mainly prompted by the evolution of the so‐called ductile damage, characterized by the nucleation, growth and coalescence of microvoids due to plastic deformation. Moreover, the plastic zones formed at the crack tip of ductile materials exhibit high sensitivity to the stress triaxiality level, which in turn distinctly depends on the geometry of the considered component. The quantification of the stress triaxiality at the crack tip is therefore essential to better understand and predict ductile crack propagation and failure. For that reason, a non‐local ductile damage model is employed in this work to simulate the ductile crack propagation under different stress triaxiality conditions. Different geometries are considered, such as constrained geometries of notched bending specimens and unconstrained geometries of center cracked tension specimens, which characterize the different triaxiality levels. To address the effects of thickness and initial crack length, three‐dimensional geometries are simulated, which account for the out‐of‐plane crack‐tip constraints. Finally, to evaluate the prediction quality of the simulations, corresponding experiments have been carried out and direct comparisons are conducted, with respect to the crack length, ductile crack propagation and resistance curves.

Influence of boron segregation on the hot ductility of T23 steel CGHAZ

Boron segregates in a non-equilibrium segregation mode at lath, packet, block boundaries as well as prior austenite grain boundaries (PAGBs) in 2.25Cr1.6WVNb steel coarse grain heat-affected zone (CGHAZ) during the thermal cycle, and tends to segregate only at PAGBs in the same mode during the high-temperature tensile test. Boron segregation along PAGB increases GB plasticity but not inter-granular strength. This is because the boron segregation at PAGBs occupies the vacancies and other defect positions, which inhibits the nucleation and growth of micro-voids, and reduces plasticity consumption. As a result, the hot ductility of CGHAZ is enhanced.

A Micro-Macro mixed GTN-MMC model to study plasticity and fracture of AISI 4340 steel

Experimental and numerical studies were conducted to study the plastic and fracture behaviors of AISI 4340 steel (with three different heat treatments) under multiaxial stress loading conditions, including axial symmetric and plane strain loadings. The classical Gurson-Tvergaard-Needleman (GTN) plasticity model was extended and calibrated to consider Lode angle dependence on the material's matrix plastic strength especially needed for plane strain loadings. The 3D fracture loci of AISI 4340 steels were previously calibrated by the Modified Mohr-Coulomb (MMC) model. Considering the microvoid growth and nucleation mechanisms, GTN model is combined with MMC model to derive a new analytical solution of microvoid volume fraction at fracture (ff) under general loading conditions. The ff should NOT be a constant, and it depends on different stress states. The modified GTN-MMC model was implemented using VMAT in Abaqus, and it gives a very good correlation between experimental data and finite element simulations.

Fatigue crack growth: Validation of the Kmax-ΔK approach using the GTN damage model

Considering cyclic plastic deformation as the single damage mechanism behind the fatigue crack growth (FCG), the effect of the mean stress is null in the absence of crack closure. In this study, an additional damage mechanism was introduced, predicting the effects of the growth, nucleation and coalescence of micro-voids. Using a non-local damage model, the reverse plastic zone was identified as the fatigue process zone, allowing to establish a relation to calculate its size. Considering aluminium alloy 2024-T351, the predictions are in close agreement with the experimental da/dN-ΔK curves, for distinct stress ratios. The results highlight that the effect of Kmax on the FCG rate is small in the absence of crack closure. On the other hand, modelling the contact between the crack flanks, the effect of Kmax on the FCG rate is amplified, i.e. the ΔK-Kmax plots for a given da/dN presented a Kmax dominance zone. The developed model suggests a three-parameter approach: ΔKeff -ΔK-Kmax.

Crystallographic texture effect on statistical microvoid growth in heterogeneous polycrystals

Polycrystalline materials usually exhibit obvious preferred grain orientations (i.e., crystallographic texture) after rolling and heat treatments, leading to a certain crystalline anisotropy. However, most previous studies on microvoid growth generally treated the material as homogeneous isotropic matrix, ignoring the influence of crystallographic texture. In the present work, four typical crystallographic textures of face-centered cubic crystal are considered, including the Cube, Goss, Brass and Copper textures. Afterwards, the texture effect on microvoid growth is systematically studied by crystal plasticity finite element simulation, from a statistical point of view. In addition, the role of loading mode (i.e., uniaxial or biaxial tension) in the texture effect on microvoid growth has also been explored. The results indicate that the crystallographic texture evidently affects the statistical void growth in heterogeneous polycrystals, regardless of the loading mode. Meanwhile, it has been found that the statistical void growth of Cube (resp. Brass) texture is always slower (resp. faster) than that of random grain-orientation case. Furthermore, it is interestingly concluded that for the four considered textures, the trend of statistical void growth (from fast to slow) is well consistent with that of average flow stress (from high to low) at any given strain level, which cannot be captured by the classical Rice-Tracey model. Finally, based on the statistical characteristics of void growth for different textures, a statistical Rice-Tracey model incorporating the texture effect is established. It is demonstrated that this statistical model can well envelop all the dispersed void growth results of different textures for the uniaxial tensile loading.

Quantification of damage evolution in stainless steel 316L based on 3D ex-situ X-ray CT and micro-damage model

Quantifying damage to improve the constitutive models that better account for damage prediction is of great importance in metal forming process. In this study, high-resolution micro-focus X-ray Computed tomography (CT) system, together with loading-unloading tensile test, were employed to quantify the 3D interactions of micro-voids evolution in the biocompatible alloy stainless steel 316L (SS316L). The specimen material was tensile deformed and interrupted at several strain intervals prior to failure, X-ray CT was then performed to quantify the damage evolution via the detected changing in size, number, distribution, and volume fraction of micro-voids (VFMV) after each specified strain increment. Thereby the nature of ductile damage, which involved the dynamic evolution mechanism of the nucleation, growth and coalescence of micro-voids, was revealed. Furthermore, an improved micromechanics-based damage (micro-damage) model considering large deformation condition was implemented into finite element (FE) package ABAQUS for the damage prediction. The damage of the specimen under tensile deformation with a wide range of stress states was predicted and a good agreement with experimental data was achieved in terms of damage distribution and evolution. It is concluded that the findings of this study not only reveal the dynamic evolution mechanism of the micro-voids in the damage process intuitively from the experimental point of view, but also provide more accurate material parameters for the theoretical damage modelling, so as to obtain more convincible damage prediction results in the metal forming process.

Hydrogen Embrittlement Mechanism of Ultrafine-grained Iron with Different Grain Sizes

To investigate the effect of grain sizes on hydrogen embrittlement of 4N-purity iron, miniature tensile tests were conducted after hydrogen charging for the ultrafine-grained specimens produced by high-pressure torsion and subsequent annealing. Hydrogen embrittlement indexes defined from reduction of area were increased with decreasing grain size, and shear-type fracture occurred with fine dimples on the fracture surface of the diagonally raptured tensile specimen with a smaller grain size. The formation and growth of microvoids at triple junctions of grain boundaries ahead of propagated cracks were responsible for such earlier shear-type fracture because necking between adjacent microvoids more likely and extensively occurred. In the specimens with larger grain sizes or without hydrogen charging, on the other hand, local coalescence and growth of microvoids were predominant due to longer distances between triple junctions, resulting in void coalescence-type fracture with coarser dimple patterns. Therefore, hydrogen atoms introduced by hydrogen charging are considered to enhance the formation of deformation-induced vacancies in ultrafine-grained iron, resulting in shear-type fracture with finer dimple patterns.

The modified GTN model for fracture of nickel-based superalloys considering size effect and healing effect in pulsed current assisted deformation

Gurson-Tvergaard-Needleman (GTN) model is one of the most famous and classical criterions widely used in modelling the ductile fracture process of metal. However, the existence of grain size effect affects the ductile fracture prediction in micro-scaled plastic deformation of nickel-based superalloy ultrathin sheet. In the pulsed current assisted (Pca) forming process, the current has a healing effect on the micro-void of metal due to the existence of local Joule heat, yet the strain has a promotion on the micro-void growth, and the coupled effect between grain size and electrical field is complicated, which makes it difficult to predict the fracture for the traditional GTN model in Pca forming process. To solve this problem, the authors added pulsed current parameters to the GTN model to describe the healing effect of pulsed current on the voids in the material. The parameters of the GTN model were calibrated by the finite element inverse identification method. The modified GTN model was embedded into Abaqus by VUMAT, and the Backward Euler algorithm was employed to integrate the constitutive equation. The validity of the model was verified by comparing the true stress-strain curves with the simulation results and comparing the void volume fraction (VVF) measured by three-dimensional X-ray computerized tomography (3DCT). The model provides a new method for ductile fracture prediction of multiphase alloys under a discontinuous energy field. Meanwhile, it is confirmed that the behaviour of fracture and necking in the Pca forming process is affected by the coupling effect of pulsed current and grain size effect, which provides a new idea for studying the Pca forming process.

Super-Tough PLA-Based Blends with Excellent Stiffness and Greatly Improved Thermal Resistance via Interphase Engineering.

Super-tough poly(lactic acid)/polycarbonate (PLA/PC) (50/50) blends with an excellent balance of stiffness, toughness, and thermal stability were systematically designed and characterized. Poly(methyl methacrylate) (PMMA) was utilized as a novel, highly effective nonreactive interphase to promote PLA-PC phase compatibility. Partial miscibility of PMMA with both PLA and PC produced strong molecular entanglements across the PLA-PC phase boundary followed by an excellent phase adhesion. This was predicted from interfacial energy measurements and supported by dynamic mechanical thermal analysis, morphological observations, and mechanical tests. Ternary PLA/PC/PMMA blends exhibited an exceptional set of stiffness, tensile and flexural strength, tensile and flexural ductility, and thermal stability together with improved impact strength compared with neat PLA and uncompatibilized PLA/PC blends. Addition of nonreactive polybutadiene-g-styrene-co-acrylonitrile (PB-g-SAN) impact modifier to the compatibilized blend resulted in further dramatic improvements in the dispersion state of PC and PMMA phase domains followed by the development of an interconnected structure of PC, PMMA, and PB-g-SAN domains in the PLA matrix. Such a network-like morphology, with rubbery particles percolated at the interface between the dispersed structures and surrounding PLA matrix, produced a tremendous increase in impact resistance (≈700 J/m) and tensile ductility (≈200% strain) while maintaining excellent stiffness (≥2.1 GPa). The combined effects of interfacial localization of impact modifier particles, network-like morphology (extended over the entire volume of the blend), and strong phase interactions between the components (due to mutual miscibility) are described to be responsible for super-tough behavior. The role of PMMA as an efficient interphase adhesion promoter in the toughened quaternary blends is also clarified. Impact fractography revealed multiple void formations, plastic growth of microvoids, and the formation of void-fibrillar structures around as well as inside the dispersed structures as the main micromechanical deformation processes responsible for massive shear yielding and plastic deformation of blends. Blends designed in this work offer remarkable improvements in tensile and flexural ductility, impact resistance, and heat deflection temperature compared with neat PLA resin. The overall characteristics of these blend systems are comparable and/or superior to those of several commercial thermoplastic resins.

Numerical modelling of the delamination in multi-layered ceramic capacitor during the thermal reflow process

Purpose This paper aims to study the interfacial delamination found in the boundary of the copper/copper-epoxy layers of a multi-layer ceramic capacitor. Design/methodology/approach The thermal reflow process of the capacitor assembly and the crack propagation from the initial micro voids presented in the boundary, and later manifested into delamination, were numerically simulated. Besides, the cross section of the capacitor assembly was inspected for delamination cracks and voids using a scanning electronic microscope. Findings Interfacial delamination in the boundary of copper/copper-epoxy layers was caused by the thermal mismatch and growth of micro voids during the thermal reflow process. The maximum deformation on the capacitor during reflow was 2.370 µm. It was found that a larger void would induce higher vicinity stress, mode I stress intensity factor, and crack elongation rate. Moreover, the crack extension increased with the exerted deformation until 0.3 µm, before saturating at the peak crack extension of around 0.078 µm. Practical implications The root cause of interfacial delamination issues in capacitors due to thermal reflow has been identified, and viable solutions proposed. These can eliminate the additional manufacturing cost and lead time incurred in identifying and tackling the issues; as well as benefit end-users, by promoting the electronic device reliability and performance. Originality/value To the best of the authors’ knowledge, the mechanism of delamination occurrence in a capacitor during has not been reported to date. The parametric variation analysis of the void size and deformation on the crack growth has never been conducted.

Size-dependent microvoid growth in heterogeneous polycrystals

Microvoid growth involves a strong size effect, i.e., smaller microvoid presents a lower growth rate. In polycrystalline materials, the size ratio between microvoids and grains may also affect microvoid growth behavior. However, most previous studies treated material matrix surrounding microvoids as homogeneous. It turned out that such treatment cannot effectively depict the influence of the abovementioned void-grain size ratio on damage evolution. In the present study, both classical local and non-local strain-gradient crystal plasticity finite element simulations are performed to study size-dependent microvoid growth in heterogeneous polycrystals. The results indicate that both void-grain size ratio and absolute microvoid size influence microvoid growth significantly, referred to as first (induced by grain-scale heterogeneous deformation) and second kinds of (induced by plastic strain gradient) size effects, respectively. Besides, macroscopic stress triaxiality T has a significant influence on the size effect of microvoid growth, while Lode parameter L exhibits a negligible effect. Due to random grain-orientation distribution and grain-geometric characteristic, a smaller microvoid within polycrystalline environments may even grow faster than a larger one, implying that the size effect of microvoid growth should be understood from a statistical point of view in polycrystalline environments. The present study provides a fundamental understanding on the intrinsic mechanism of the size-dependent microvoid growth in heterogeneous polycrystals.