Cycle Thermal Fatigue Research Articles

Thermo-mechanical coupling failure mechanisms of reusable SiCf/SiC composites with PyC interphase

The extreme and repeated aerothermal environments working on reusable launch vehicles bring challenges for the design of hot structure. Due to the outstanding high-temperature resistant, SiCf/SiC composite is an excellent candidate material for hot structures in re-entry vehicles. In this paper, the thermo-mechanical coupling failure mechanisms of SiCf/SiC composite are investigated comprehensively. Experimental results reveal different failure mechanisms of SiCf/SiC composites subjected to monotonic quasi-static tension at room temperature and high temperature, cyclic thermal fatigue and thermo-mechanical coupling fatigue. Cyclic thermal environment causing oxidation of interphase layer and embrittlement of fiber plays a significant role in decrease of load bearing capacity of SiCf/SiC composites. The long-term periodic fatigue load that is superimposed on the cyclic thermal condition would further deteriorate the performance of materials. To better understand the damage evolution process, a thermo-mechanical coupling fatigue model is proposed to describe the degradation of SiCf/SiC composites for different stress levels. The service life of SiCf/SiC composites is obtained, which could be used to evaluate the reusable performance of SiCf/SiC hot structure. The results of this study provide novel insights into the design of SiCf/SiC composites for reusable launch vehicles under prolonged and repeated service environment.

Synthesis and thermophysical properties of rare-earth tantalate ZrO2-Dy3TaO7 ceramics

Abstract Thermal Barrier Coatings (TBCs) are of major concern to researchers because of their outstanding properties, such as high-temperature resistance, compressive resistance, hardness, and toughness. Its applications are wide-ranging and critical. Examples include hypersonic vehicles, aero-engines, and service in high-temperature and high-impact extreme environments. This work focuses on the preparation, thermal properties (coefficient of thermal expansion, thermal conductivity), and performance evaluation (thermal shock resistance, thermal shock resistance, and bonding) of ZrO2-Dy3TaO7 rare earth tantalate ceramic coating materials. The results show that ZrO2-Dy3TaO7 possesses a low thermal conductivity (1.25-1.50 W K−1 m−1, 900°C), a high thermal expansion coefficient (10.80-11.14×10-6 K−1, 1200°C), which is about half of the value of the thermal conductivity of 7YSZ (2.8-2.2 W K−1m−1). It is better than that of the 7YSZ (10.04×10−6 K−1, 1200°C), which meets the performance requirements of the new thermal barrier coating. In addition, ZrO2-Dy3TaO7 can achieve more than 6, 000 thermal fatigue cycles at 1200°C, and the ideal number of thermal shock cycles is 4, 040 cycles at the same temperature. These outstanding test results demonstrate that the ceramic coating can effectively protect the substrate material and provide long-term service in high-temperature copper liquid. This research lays the theoretical foundation for the development of next-generation coating materials, particularly for thermal barrier/environmental barrier integrated coating materials.

Effects of aircraft operating fluids and environmental thermal fatigue on fly ash and steel slag based cementitious composites

This paper investigates the performance of concrete incorporating high-volume fly ash (HVFA) and steel slag aggregates against the detrimental effects of combined cycles of environmental thermal fatigue and exposure to leaked aircraft fluids. A total of 128 cubes and 90 prisms were cast for five mixes and exposed to 60, 120, 180, 240 and 300 combined cycles. The results demonstrate the positive effect of utilization of HVFA which reduces the total amount of portlandite available in the system. The SS aggregates demonstrate a strong interlocking with the surrounding matrix and supply the necessary portlandite for continued pozzolanic reaction. However, their reaction with aircraft fluids causes significant degradation to flexural strength initially, which is redeemed by pozzolanic reaction at a later stage. Hybrid basalt and polypropylene fibres were successful in enhancing the flexural strength and reducing the cracking. The mercury intrusion porosimetry revealed a reduction in pore volume because of HVFA. Scanning electron microscopy and differential scanning calorimetry were also employed to uncover the underlying mechanisms of damage and assess the performance of the cementitious composite.

Performance of Atmospheric Plasma-Sprayed Thermal Barrier Coatings on Additively Manufactured Super Alloy Substrates

This work represents a preliminary study of atmospheric plasma-sprayed (APS) Yttria-Stabilized Zirconia (YSZ)-based thermal barrier coatings (TBCs) deposited on forged and additive manufactured (AM) HAYNES®282® (H282) superalloy substrates. The effect of different feedstock morphologies and spray gun designs with radial and axial injection on APS-deposited YSZ layer characteristics such as microstructure, porosity content, roughness, etc., has been investigated. The performance of TBCs in terms of thermal cycling fatigue (TCF) lifetime and erosion behaviour were also comprehensively investigated. In view of the high surface roughness of as-built AM surfaces compared to forged substrates, two different types of NiCoCrAlY bond coats were examined: one involved high-velocity air fuel (HVAF) spraying of a finer powder, and the other involved APS deposition of a coarser feedstock. Despite the process and feedstock differences, the above two routes yielded comparable bond coat surface roughness on both types of substrates. Variation in porosity level in the APS topcoat was observed when deposited using different YSZ feedstock powders employing axial or radial injection. However, the resultant TBCs on AM-derived substrates were observed to possess similar microstructures and functional properties as TBCs deposited on reference (forged) substrates for any given YSZ deposition process and feedstock.

Stress Engineering for Mitigating Thermal Cycling Fatigue in Perovskite Photovoltaics

Stress Engineering for Mitigating Thermal Cycling Fatigue in Perovskite Photovoltaics

Prediction of mechanical properties and fatigue life of nanosilver slurry in chip interconnection

This article investigates the failure mode and mechanism of copper pillar solder joints in temperature cycling experiments, focusing on a Cu/nano Ag/Cu solder joint structure. The hot pressing bonding condition at 300 °C with insulation for 10 s is chosen for the experiments. Based on the life test results, the thermal cycling fatigue life of the nanosilver solder joint is determined to be 2050 cycles. To gain further insights, finite element software ANSYS is employed to simulate nanosilver solder joints in flip chips, revealing the stress–strain distribution within the solder joints. The simulation utilizes the Anand viscoplastic constitutive model for the solder joint, providing a reasonable representation of the stress–strain behavior under thermal cycling load. Notably, the simulation highlights that the maximum stress and strain occur in the contact area between the solder joint and the copper column. To enhance accuracy, the calculation equation is refined using relevant experience, resulting in a prediction of the thermal fatigue life of nanosilver solder joints. This prediction aligns closely with the experimental results. The research outcomes not only contribute valuable insights into the behavior of nanosilver solder but also serve as a reference for its application in electronic packaging.

Influence of thermal fatigue cycles on concrete cold joints

Mass concrete structures in northern climates experience extreme oscillations in temperature each year. These fluctuating conditions incur large thermal stresses, which are of particular concern at cold joint locations. To better understand the behaviour of cold joints subjected to these thermal fatigue cycles, an experimental program was conducted at the University of Manitoba, focusing on the performance of concrete cylinders with concrete-to-concrete interfaces. Specimens were prepared with joints oriented either horizontally to evaluate direct tensile performance or at a 35°, 40°, or 45° angle for slant shear. These cylinders were then installed in specially designed vertical translation-restricting frames and placed in an environmental chamber, where they were subjected to temperatures cycling between −25 °C and 40 °C. Static testing after 50, 150, and 250 cycles was performed to ascertain remaining bond strength. An increase in performance of approximately 20 % was observed in direct tension after 50 cycles, followed by a subsequent decrease. In general, the thermal fatigue cycles did not appear to detrimentally impact bond strength after 250 cycles in both direct tension and slant shear. Additionally, interface friction demonstrated no meaningful trend between specimens that had experienced zero to 250 cycles, remaining relatively consistent with their corresponding roughness level defined in the Canadian Design of Concrete Structures code, and bond cohesion appeared to follow a similar trend to mean direct tensile bond strength results.

Thermal fatigue life prediction of Ag-2.5Sn solder joint in flip chip

The heat dissipation needs of high-power devices cannot now be met by traditional packing solders due to the fast development of microelectronics interconnect technology. In addition to having outstanding thermal and electrical conductivity, nano-silver-tin paste better satisfies the needs of electronic devices. Studying the thermal reliability of solder joints is extremely important, this article investigates the fatigue life of the nano-silver-tin solder joints in temperature cycling experiments. Based on the life test results, the thermal cycling fatigue life of the nano-silver-tin solder joint is determined to be 2880 cycles. Finite element software was used to replicate the chip’s bonding process and assess the solder joint stress and strain distribution. The stress and strain of nano-silver-tin solder connections under thermal cycling load are accurately modeled using the Anand viscoplastic model and elastic model. The findings indicate that the contact region between the solder connections and copper columns is where the chip generates the most stress and strain. The fatigue life of the solder joint is estimated by using the Coffin–Manson modified equation, and this prediction aligns closely with the experimental results.

Mechanical and thermal properties of Gyroid-based W[sbnd]Cu composites produced via laser powder bed fusion assisted by infiltration

Plasma-facing components for thermonuclear fusion reactors require the introduction of new materials due to outstanding demands in mechanical, thermal, and thermal cycle fatigue resistivity properties. One promising solution is the WCu composite material or multimaterial that combines the properties of both components. In the present work, WCu samples were obtained by laser powder bed fusion (LPBF) consolidation of a tungsten porous matrix followed by copper infiltration. A design of structures with ordered porosity was achieved by translation of skeletal gyroid unit cell (triply periodic minimal surface). A relative density of 96.7% was achieved for solid pure tungsten samples with optimized LPBF process conditions. As-built W gyroid samples had a 15–20% ultimate compressive strength (UCS) of the solid sample. After the infiltration with copper, the ductility of WCu composites increased drastically, i.e. the samples did not fracture at a strain of 35%. It was found that UCS, yield strength (YS), and thermal diffusivity were sensitive to gyroid unit cell size. The sample with the smallest cell size of 2 mm had superior YS of 626 MPa and thermal diffusivity of 76.4 mm2/s. The obtained results will shed light on the possibilities for further development of WCu manufacturing technology based on the LPBF method combined with subsequent infiltration.

Thermal fatigue performance enhancement of new high-Cr martensitic die steels based on overall microstructure manipulation by trace TiC–TiB2 nanoparticles

Thermal fatigue failure is one of the main factors affecting the service life of hot work die steel. Achieving excellent thermal fatigue resistance for hot working die steels can benefit the industry economically. In this work, (TiC + TiB2)/Al master alloys were used to add TiC–TiB2 nanoparticles into high-Cr die steels, which achieves microstructure manipulation and obtains excellent thermal fatigue resistance and strength-plastic combination. The results showed that after being manipulated by 0.02 wt% TiC–TiB2 nanoparticles, the surface oxidation zone of the high-Cr die steel after different thermal fatigue cycles is reduced than high-Cr die steel without manipulation. TiC–TiB2 nanoparticles effectively refined the heat-treated microstructure of high-Cr die steel, promoting the Cr element and alloy carbides being more uniformly distributed in the matrix, which prevents the occurrence of oxidative pitting and conducive to the formation of a dense and uniform Cr2O3 oxide layer, and further preventing the initiation of thermal fatigue cracks. Moreover, these finer and more uniformly distributed precipitates in TiC–TiB2 nanoparticles manipulated high-Cr die steels will promote stress dispersion and hinder thermal fatigue crack propagation. This work provides a promising avenue for the design of low-cost, high-performance, and long-life die steels for industrial applications.

Understanding the effect of bondcoat surface treatment on enhanced lifetime of suspension plasma sprayed thermal barrier coatings

Thermal barrier coatings (TBCs) are extensively used in gas turbine engines in power generation and aerospace applications. Improvements in TBC performance and lifetime are continuously pursued by the gas turbine industry. Suspension plasma spraying (SPS) has shown promising results in recent years as it could produce a porous columnar TBC microstructure exhibiting low thermal conductivity and high durability. Further improvements in lifetime and fundamental understanding of failure mechanisms would lead to their wider application.Lifetime of a TBC system is dependent not only on the topcoat microstructure and chemistry, but also on topcoat-bondcoat interface and bondcoat characteristics as they influence the growth rate of thermally grown oxide (TGO) layer as well as the mismatch stresses generated in the topcoat during operation. Moreover, in SPS TBCs, the column density and porosity in the topcoat are also affected by the bondcoat surface roughness which in turn affects TBC lifetime. In previous work, it was shown that bondcoat surface treatment by shot peening followed by light grit blasting can significantly enhance the cyclic lifetime of SPS TBCs.The objective of this work was to gain further insight into the lifetime improvements due to surface treatment of bondcoat. Commercial NiCoCrAlY powder was deposited by high velocity air fuel (HVAF) and high velocity oxy fuel (HVOF) spraying while SPS was used to deposit yttria stabilised zirconia topcoat. Before spraying the topcoat, the bondcoat samples were subjected to vacuum heat treatment, shot peening, and/or grit blasting. Residual stress measurements were performed by X-ray diffraction on samples with different variants of bondcoat treatments and compared with Almen strip tests. The lifetime was examined by thermal cyclic fatigue testing. The relationships between changes in bondcoat surface roughness, residual stress state and microstructure due to surface treatments, and resultant topcoat microstructure and lifetime were studied and discussed.

Performance evolution of low heat cement under thermal cycling fatigue: A comparative study with moderate heat cement and ordinary Portland cement

As a promising and environmentally friendly cementitious material for mass concrete applications, the long-term performance evolution of low-heat cement (LHC) and moderate-heat cement (MHC) under the alternating environmental temperature remains unclear. To address this gap, a comprehensive comparative study based on laboratory acceleration test was conducted by evaluating the physicochemical properties and cracking behavior of LHC and MHC in comparison to ordinary Portland cement (OPC) following 1200 thermal cycles (TC) at temperatures ranging from 5 to 45 °C. Cracking behavior is revealed by a quantitative identification analysis. The results indicate a negative linear relationship between porosity, crack density, and compressive strength, highlighting their competing mechanisms in determining the degree of damage under TC. TC sharply diminished the gel pores (<10 nm) and promoted the formation of capillary pores (50–1000 nm), which were the primary forms of pore coarsening observed. Notably, the different proportions of hydrated products such as HD-CSH, LD-CSH, and CH influence the toughness properties of the matrix and contribute to different resistances to cracking and the formation of cracks with varying fracture morphology, although they also impact the stability of the pore structure. Further analysis revealed different degrees of rehydration occurring within the first 200 cycles of both LHC and MHC, which contributed to the mitigation of performance degradation. Moreover, an increase in the water-to-cement (w/c) ratio had a tendency to coarsen the matrix and facilitate the formation of long and narrow cracks.

Numerical investigation of thermal fatigue crack growth behavior in SAC305 BGA solder joints

PurposeThis study aims to investigate the reliability issues of microvoid cracks in solder joint packages exposed to thermal cycling fatigue.Design/methodology/approachThe specimens are subjected to JEDEC preconditioning level 1 (85 °C/85%RH/168 h) with five times reflow at 270°C. This is followed by thermal cycling from 0°C to 100°C, per IPC-7351B standards. The specimens' cross-sections are inspected for crack growth and propagation under backscattered scanning electronic microscopy. The decoupled thermomechanical simulation technique is applied to investigate the thermal fatigue behavior. The impacts of crack length on the stress and fatigue behavior of the package are investigated.FindingsCracks are initiated from the ball grid array corner of the solder joint, propagating through the transverse section of the solder ball. The crack growth increases continuously up to 0.25-mm crack length, then slows down afterward. The J-integral and stress intensity factor (SIF) values at the crack tip decrease with increased crack length. Before 0.15-mm crack length, J-integral and SIF reduce slightly with crack length and are comparatively higher, resulting in a rapid increase in crack mouth opening displacement (CMOD). Beyond 0.25-mm crack length, the values significantly decline, that there is not much possibility of crack growth, resulting in a negligible change in CMOD value. This explains the crack growth arrest obtained after 0.25-mm crack length.Practical implicationsThis work's contribution is expected to reduce the additional manufacturing cost and lead time incurred in investigating reliability issues in solder joints.Originality/valueThe work investigates crack propagation mechanisms of microvoid cracks in solder joints exposed to moisture and thermal fatigue, which is still limited in the literature. The parametric variation of the crack length on stress and fatigue characteristics of solder joints, which has never been conducted, is also studied.

Numerical simulation and mechanism analysis of thermal fatigue crack for low-alloy steel brake disc of high-speed train

ABSTRACT High-speed train brake discs face severe service conditions and subsequently risk of material failure during emergency braking. Thermal fatigue cracking is a major concern leading to catastrophic disc failure and is regarded as a primary service bottleneck in rapid rail transportation. Our proposed work establishes a numerical prediction model to estimate thermal fatigue crack initiation and propagation in low-alloy steel. We used a modified Cockcroft-Latham criterion and material property tests to determine the critical crack initiation value. Through numerical simulations and in-situ experiments, we observed plastic deformation at the median temperature of the thermal fatigue cycle and found that tailored material composition improves brake disc fatigue performance. This research aims to enhance understanding of the cracking mechanism and improve the reliability of brake systems for high-speed trains.

Characteristics and performance of suspension plasma sprayed thermal barrier coatings on additively manufactured superalloy substrates

The complex-shaped hot-section parts of new-generation turbine engines demand unique design solutions. Additive Manufacturing (AM) is an emergent production method that can produce metallic parts with complex geometries and minimal material wastage. In this work, the characteristics and performance behavior of Thermal Barrier Coatings (TBCs) deposited on forged and AM-built HAYNES®282® superalloy substrates were studied and compared. The bond coats were produced by High-Velocity Air-Fuel (HVAF) spraying using NiCoCrAlY powder feedstock and TBC top-coats by Suspension Plasma Spraying (SPS) using water- and ethanol-based suspensions of Yttria-Stabilized Zirconia (YSZ). The microstructural features, adhesion, Thermal Cycling Fatigue (TCF) lifetime, and thermal shock lifetimes of the TBCs were comprehensively investigated. The results showed that the deposition of bond coats reduced the roughness and asperities of the AM-built substrates. Depending on the type of suspension used and the spray parameters employed, the TBCs exhibited vertically cracked and columnar microstructures. However, no significant differences in TCF and thermal shock lifetimes of TBCs on AM and forged substrates were observed. It is demonstrated that TBC systems can be produced on AM-built metallic substrates, and the resulting TBCs can have similar microstructures and properties as TBCs deposited on conventional substrates.

Transformation of carbides and mechanisms for cracking in Co-based alloy surfacing layer during thermal fatigue

A fantastic metallurgical bond of Stellite 6# Co-based alloy/FB2 steel joint was achieved using gas tungsten arc welding, and thermal cyclic tests were employed to investigate the initiation and propagation of cracks, and the microstructure evolution in the weldments. Multiple cracks with the length over 10 μm were found after 300 cycles of thermal fatigue (TF), and the detail microstructure of Stellite 6# layer before and after TF was investigated. Results showed that the thermal cycling led to the accumulation of thermal cyclic stress, coarsening of eutectic carbides, generation of laves phase and transformation of Co phase, which influenced the initiation and propagation of cracks. More specifically, the initiation of the cracks was attributed to newly generated W-rich laves phase in addition the with the accumulation of thermal cyclic stress, while Cr atoms, together with O and W atoms, were distributed near the cracks, and acted as the crack propagation path. Finally, the martensitic transformation of γ-Co to ε-Co, driven by the plastic deformation at the crack tip, could also in turn help to crack propagation.

Effect of the microstructure of suspension plasma-sprayed thermal barrier coatings on their thermal cycling damage

The suspension plasma spray (SPS) technique has recently attracted attention due to the variety of microstructures achievable using submicron spray particles mixed with a solvent to form a suspension. Thermal barrier coatings (TBCs) with a columnar microstructure can be obtained using SPS. Because of its unique columnar microstructure achieving high strain tolerance, a top coat sprayed using this technique can efficiently suppress thermal cycling damage in SPS–TBCs. However, there are few reports on the effect of microstructure on the damage behavior of SPS–TBCs with a columnar structure. In this study, the effect of the top coat microstructure on the thermal cycling fatigue of SPS–TBCs was investigated. The size of the complex oxide formed on the top coat–bond coat interface and the length of the cracks at the interface (formed as a result of thermal cycling) increase with the column diameter in the top coat of SPS–TBCs. The thermal spray conditions affect the thermal cycling fatigue life of SPS–TBCs. The SPS–TBC with fine columnar structure exhibits superior thermal cycling fatigue life.

Thermal cycle fatigue properties of the composite TBCs sprayed by suspension plasma spray technique

Thermal cycle fatigue properties of the composite TBCs sprayed by suspension plasma spray technique

Fatigue life evaluation of gold wire bonding solder joints in MEMS pressure sensors

The failure of the gold wire bonding solder joint of a MEMS pressure sensor caused by the thermal cycling test was investigated with thermal cycling experiments and fatigue simulations. The results show that the maximum stress and strain occurred at the root of the solder joint on the substrate. With the accumulation of strain caused by thermal cycles, the bonding area of solder joint became smaller and the shear force of solder joints reduced to 22.3% after 1600 thermal cycles. The solder joints on the substrate failed after 1940 thermal cycles in plastic fatigue simulations and 3.16 × 108 thermal cycles in creep fatigue simulations. Plastic fatigue is the major factor for thermal failure of gold wire bonding.

A new unified creep‐plasticity constitutive model coupled with damage for viscoplastic materials subjected to fatigue loading

AbstractA new unified creep‐plasticity (UCP) constitutive model coupled with damage is proposed for Sn–3.0Ag–0.5Cu (SAC305), one of the most successfully commercialized Pb‐free solders. By calibrating the proposed damage model based on entropy generation, the fatigue issues are elucidated for SAC305 solder at different temperatures and strain rates. After implementing a user‐defined material subroutine, finite element simulations with the proposed UCP‐damage model are capable of predicting the strength deterioration as the macroscopic response in terms of load‐deformation curves. More importantly, the UCP‐damage model reveals the damage accumulation and evolution of viscoplastic materials sensitive to fatigue deformation at different temperatures and strain rates. By comparing the predictions with and without damage, the equivalent plastic strains are obviously different when evaluating the thermal cycling fatigue life of electronic packaging structures, which confirms the significance of the UCP model reasonably coupled with the intrinsic description of damage by the concept of entropy generation.