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This paper investigates the degradation mechanism of pressure-sintered silver (s-Ag) film for silicon carbide (SiC) chip assembly with a 2-millimeter-thick copper substrate by means of thermal shock test (TST). Two different types of silver paste, nano-sized silver paste (NP) and nano-micron-sized paste (NMP), were used to sinter the silver film at 300 °C under a pressure of 60 MPa. The mean porosity (p) of the NP and MNP s-Ag films was 2.4% and 8%, respectively. The pore shape of the NP s-Ag was almost spherical, whereas the NMP s-Ag had an irregular shape resembling a peanut shell. After performing the TST at temperatures ranging from −40 to 150 °C, the scanning acoustic tomography (SAT) results suggested that delamination occurs from the edge of the assembly, and the delamination of the NMP s-Ag assembly was faster than that of the NM s-Ag assembly. The NMP s-Ag assembly showed a random delamination, indicating that the delamination speed varies from place to place. The difference in fracture mechanism is discussed based on cross-sectional scanning electron microscope (SEM) observation results after TST and plastic strain distribution results estimated by finite element analysis (FEA) considering pore configuration.

A severe plastic deformation process for the achievement of favorable mechanical properties for metallic powder is mechanical milling. However, to obtain the highest productivity while maintaining reasonable manufacturing costs, the process parameters must be optimized to achieve the best mechanical properties. This study involved the use of response surface methodology to optimize the mechanical milling process parameters of harmonic-structure pure Cu. Certain critical parameters that affect the properties and fracture mechanisms of harmonic-structure pure Cu were investigated and are discussed in detail. The Box–Behnken design was used to design the experiments to determine the correlation between the process parameters and mechanical properties. The results show that the parameters (rotation speed, mechanical milling time, and powder-to-ball ratio) affect the microstructure characteristics and influence the mechanical performance, including the fracture mechanisms of harmonic-structure pure Cu specimens. The best combination values of the ultimate tensile strength (UTS) and elongation were found to be 272 MPa and 46.85%, respectively. This combination of properties can be achieved by applying an optimum set of process parameters: a rotation speed of 200 rpm; mechanical milling time of 17.78 h; and powder-to-ball ratio of 0.065. The superior UTS and elongation of the harmonic-structure pure Cu were found to be related to the delay of void and crack initiation in the core and shell interface regions, which in turn were controlled by the degree of strength variation between these regions.

Dynamic observation of the microstructure evolution of Sn2.5Ag0.7Cu0.1RE/Cu solder joints and the relationship between the interfacial intermetallic compound (IMC) and the mechanical properties of the solder joints were investigated during isothermal aging. The results showed that the original single scallop-type Cu6Sn5 IMC gradually evolved into a planar double-layer IMC consisting of Cu6Sn5 and Cu3Sn IMCs with isothermal aging. In particular, the Cu3Sn IMC grew towards the Cu substrate and the solder seam sides; growth toward the Cu substrate side was dominant during the isothermal aging process. The growth of Cu3Sn IMC depended on the accumulated time at a certain temperature, where the growth rate of Cu3Sn was higher than that of Cu6Sn5. Additionally, the growth of the interfacial IMC was mainly controlled by bulk diffusion mechanism, where the activation energies of Cu6Sn5 and Cu3Sn were 74.7 and 86.6 kJ/mol, respectively. The growth rate of Cu3Sn was slightly faster than that of Cu6Sn5 during isothermal aging. With increasing isothermal aging time, the shear strength of the solder joints decreased and showed a linear relationship with the thickness of Cu3Sn. The fracture mechanism of the solder joints changed from ductile fracture to brittle fracture, and the fracture pathway transferred from the solder seam to the interfacial IMC layer.

Natural structural materials typically feature complex hierarchical anisotropic architectures, resulting in excellent damage tolerance. Such highly anisotropic structures, however, also provide an easy path for crack propagation, often leading to catastrophic fracture as evidenced, for example, by wood splitting. Here, we describe the weakly anisotropic structure of Ginkgo biloba (ginkgo) seed shell, which has excellent crack resistance in different directions. Ginkgo seed shell is composed of tightly packed polygonal sclereids with cell walls in which the cellulose microfibrils are oriented in a helicoidal pattern. We found that the sclereids contain distinct pits, special fine tubes like a “screw fastener,” that interlock the helicoidal cell walls together. As a result, ginkgo seed shell demonstrates crack resistance in all directions, exhibiting specific fracture toughness that can rival other highly anisotropic natural materials, such as wood, bone, insect cuticle, and nacre. In situ characterization reveals ginkgo’s unique toughening mechanism: pitguided crack propagation. This mechanism forces the crack to depart from the weak compound middle lamella and enter into the sclereid, where the helicoidal cell wall significantly inhibits crack growth by the cleavage and breakage of the fibril-based cell walls. Ginkgo’s toughening mechanism could provide guidelines for a new bioinspired strategy for the design of high-performance bulk materials.

Laser powder bed fusion (L-PBF) is an additive manufacturing technology that is gaining increasing interest in aerospace, automotive and biomedical applications due to the possibility of processing lightweight alloys such as AlSi10Mg and Ti6Al4V. Both these alloys have microstructures and mechanical properties that are strictly related to the type of heat treatment applied after the L-PBF process. The present review aimed to summarize the state of the art in terms of the microstructural morphology and consequent mechanical performance of these materials after different heat treatments. While optimization of the post-process heat treatment is key to obtaining excellent mechanical properties, the first requirement is to manufacture high quality and fully dense samples. Therefore, effects induced by the L-PBF process parameters and build platform temperatures were also summarized. In addition, effects induced by stress relief, annealing, solution, artificial and direct aging, hot isostatic pressing, and mixed heat treatments were reviewed for AlSi10Mg and Ti6AlV samples, highlighting variations in microstructure and corrosion resistance and consequent fracture mechanisms.

Chromium-plated diamond/copper composite materials, with Cr layer thicknesses of 150 nm and 200 nm, were synthesized using a vacuum hot-press sintering process. Comparative analysis revealed that the thermal conductivity of the composite material with a Cr layer thickness of 150 nm increased by 266%, while that with a Cr layer thickness of 200 nm increased by 242%, relative to the diamond/copper composite materials without Cr plating. This indicates that the introduction of the Cr layer significantly enhanced the thermal conductivity of the composite material. The thermal properties of the composite material initially increased and subsequently decreased with rising sintering temperature. At a sintering temperature of 1050 °C and a diamond particle size of 210 μm, the thermal conductivity of the chromium-plated diamond/copper composite material reached a maximum value of 593.67 W∙m−1∙K−1. This high thermal conductivity is attributed to the formation of chromium carbide at the interface. Additionally, the surface of the diamond particles in contact with the carbide layer exhibited a continuous serrated morphology due to the interface reaction. This “pinning effect” at the interface strengthened the bonding between the diamond particles and the copper matrix, thereby enhancing the overall thermal conductivity of the composite material.

This study presents a comprehensive review of the history of research and development of different damage-detection methods in the realm of composite structures. Different fields of engineering, such as mechanical, architectural, civil, and aerospace engineering, benefit excellent mechanical properties of composite materials. Due to their heterogeneous nature, composite materials can suffer from several complex nonlinear damage modes, including impact damage, delamination, matrix crack, fiber breakage, and voids. Therefore, early damage detection of composite structures can help avoid catastrophic events and tragic consequences, such as airplane crashes, further demanding the development of robust structural health monitoring (SHM) algorithms. This study first reviews different non-destructive damage testing techniques, then investigates vibration-based damage-detection methods along with their respective pros and cons, and concludes with a thorough discussion of a nonlinear hybrid method termed the Vibro-Acoustic Modulation technique. Advanced signal processing, machine learning, and deep learning have been widely employed for solving damage-detection problems of composite structures. Therefore, all of these methods have been fully studied. Considering the wide use of a new generation of smart composites in different applications, a section is dedicated to these materials. At the end of this paper, some final remarks and suggestions for future work are presented.

The microstructure of rock plays a vital role in the deformation and fracturing process when subjected to external loading. Conglomerate, being a pivotal part of unconventional reservoir, is characterized by a distinct composition structure and high degree of heterogeneity. Thus, a proper understanding of the impact of microstructure on the mechanical properties of conglomerate is crucial. We conduct uniaxial and triaxial compression tests on conglomerate samples, accompanied by monitoring acoustic emission events and ultrasonic wave velocity. Experimental results show that: (1) conglomerate fails in tension under uniaxial compression, but in shear fracture or cataclastic flow with volume expanding under triaxial compression; (2) the deformation transforms from brittle to ductile with increasing confining pressure. Two failure modes may exist in the brittle–ductile transition regime, namely, shear fracture and cataclastic flow; (3) the relationship between the mechanical characteristics and average gravel size is consistent with the “Hall–Petch” empirical relationship. The confining pressure required for brittle–ductile transformation reduces with larger average gravel size. Microscopic observation demonstrates that two gravels contacting with each other may fail in Hertzian fractures. Shear slip and rotation of gravel occurs under triaxial compression. We propose a conceptual model to describe the deformation of conglomerate under different confining conditions and compare the deformation properties of conglomerate with sandstone.HighlightsThe effects of microstructural and micromechanical properties on the deformation of conglomerate deformation are studied.Both the peak strength and the brittle–ductile transition pressure reduce with higher average gravel size.Discrepancy between gravel and matrix deformation dominates the cracks initiation, while the location of gravel affects the propagation.

The theoretical model of cutting force in turning metal materials is not applicable to the machining of hard-brittle materials. This view is also supported by experimental results. However, the equation for cutting force in turning brittle materials remains to be established. Based on the principle of energy conservation, this paper determines the pattern of energy transfer by analyzing the microfracture mechanism of ceramic materials, and finally establishes a theoretical equation for cutting force. The cutting layer of a hard-brittle material is removed via fracturing, and there are two fracturing modes: large-scale stress rupture and small-scale stress rupture. For large-scale stress rupture, the crack is extended to the interior of the workpiece first, and then extended to the surface of the workpiece after reaching the critical depth. Accordingly, a crack system model can be built in the machining process of turning hard-brittle material. Based on the principle of energy conservation, this paper proposes that in the turning process, the work done by the component force of the main cutting force on the shear plane is equal to the energy changes of the crack system. In light of fracture mechanics, this paper introduces different energy models for the crack system, and builds a theoretical model of cutting force in the turning of hard-brittle materials. The results of this turning experiment indicate that the main cutting force decreases with the rise in turning speed, and increases with the rise in feed speed and back cutting depth. The calculated values of the theoretical model of cutting force in turning hard-brittle materials basically have the same trend as experiment values.

The 50% laser additive manufactured (50%LAMed) tensile samples of Inconel 718 superalloy, i.e., the laser-deposited zone and the substrate zone, occupied 50% volume fraction respectively along the tensile direction, have been fabricated by using laser additive manufacturing (LAM) technology. The inter-dendritic Laves phases were reserved because solution heat treatment could not be used in case of the deteriorating mechanical properties of a forging substrate. Meanwhile, most of the γ″ phases were precipitated in the inter-dendritic area, leading to local stress concentration around the Laves phases in the process of a tensile test. With tensile stress increasing, the degree of deformation and fracture of the Laves phases was closely related to the morphologies of themselves. For the long striped Laves phases, in order to deform with the austenite matrix, they slipped and broke up into small parts. For most of the granular Laves phases, they did not break up and held original morphologies in the process of the tensile test. The broken Laves phases were separated from the γ matrix, and micropores formed at the surface between them. The fracture mechanism was the microvoid coalescence ductile fracture, and the Laves phases were the main nucleuses for the formation of micropores. This study indicates that the mechanical properties of 50%LAMed Inconel 718 can be improved by controlling the morphologies of the Laves phases.