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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1977

Particle size and velocity measurement by laser anemometry

The use of a forward scattering Laser Anemometer system for the measurement of particle diameters larger than the fringe spacing is investigated. A systematic calibration experiment demonstrates a direct relationship between signal amplitude and particle diameter for transparent particles between 30 microns and 240 microns in diameter. A light scattering analysis confirms these measurements and indicates how the range of particles which can be measured using the peak (mean) signal depends on the optical arrangement and particle properties. On the basis of this work a real time Laser Anemometer signal processor is modified so that the peak of the mean of each signal can be measured. A method of correcting data for the effect of particles which do not go through the center of the measurement volume is derived. Good agreement is found between particle size distributions measured in sprays by using the Laser Anemometer and size distributions measured by collecting the particles on a slide and using an image analysis computer.

Yule, A. J.↗
NASA NTRS1987

Knowledge-based vision for space station object motion detection, recognition, and tracking

Computer vision, especially color image analysis and understanding, has much to offer in the area of the automation of Space Station tasks such as construction, satellite servicing, rendezvous and proximity operations, inspection, experiment monitoring, data management and training. Knowledge-based techniques improve the performance of vision algorithms for unstructured environments because of their ability to deal with imprecise a priori information or inaccurately estimated feature data and still produce useful results. Conventional techniques using statistical and purely model-based approaches lack flexibility in dealing with the variabilities anticipated in the unstructured viewing environment of space. Algorithms developed under NASA sponsorship for Space Station applications to demonstrate the value of a hypothesized architecture for a Video Image Processor (VIP) are presented. Approaches to the enhancement of the performance of these algorithms with knowledge-based techniques and the potential for deployment of highly-parallel multi-processor systems for these algorithms are discussed.

Symosek, P.↗
NASA NTRS1993

High-performance mass storage system for workstations

Reduced Instruction Set Computer (RISC) workstations and Personnel Computers (PC) are very popular tools for office automation, command and control, scientific analysis, database management, and many other applications. However, when using Input/Output (I/O) intensive applications, the RISC workstations and PC's are often overburdened with the tasks of collecting, staging, storing, and distributing data. Also, by using standard high-performance peripherals and storage devices, the I/O function can still be a common bottleneck process. Therefore, the high-performance mass storage system, developed by Loral AeroSys' Independent Research and Development (IR&D) engineers, can offload a RISC workstation of I/O related functions and provide high-performance I/O functions and external interfaces. The high-performance mass storage system has the capabilities to ingest high-speed real-time data, perform signal or image processing, and stage, archive, and distribute the data. This mass storage system uses a hierarchical storage structure, thus reducing the total data storage cost, while maintaining high-I/O performance. The high-performance mass storage system is a network of low-cost parallel processors and storage devices. The nodes in the network have special I/O functions such as: SCSI controller, Ethernet controller, gateway controller, RS232 controller, IEEE488 controller, and digital/analog converter. The nodes are interconnected through high-speed direct memory access links to form a network. The topology of the network is easily reconfigurable to maximize system throughput for various applications. This high-performance mass storage system takes advantage of a 'busless' architecture for maximum expandability. The mass storage system consists of magnetic disks, a WORM optical disk jukebox, and an 8mm helical scan tape to form a hierarchical storage structure. Commonly used files are kept in the magnetic disk for fast retrieval. The optical disks are used as archive media, and the tapes are used as backup media. The storage system is managed by the IEEE mass storage reference model-based UniTree software package. UniTree software will keep track of all files in the system, will automatically migrate the lesser used files to archive media, and will stage the files when needed by the system. The user can access the files without knowledge of their physical location. The high-performance mass storage system developed by Loral AeroSys will significantly boost the system I/O performance and reduce the overall data storage cost. This storage system provides a highly flexible and cost-effective architecture for a variety of applications (e.g., realtime data acquisition with a signal and image processing requirement, long-term data archiving and distribution, and image analysis and enhancement).

Chiang, T.↗
NASA NTRS1984

Geometric error analysis for shuttle imaging spectrometer experiment

The demand of more powerful tools for remote sensing and management of earth resources steadily increased over the last decade. With the recent advancement of area array detectors, high resolution multichannel imaging spectrometers can be realistically constructed. The error analysis study for the Shuttle Imaging Spectrometer Experiment system is documented for the purpose of providing information for design, tradeoff, and performance prediction. Error sources including the Shuttle attitude determination and control system, instrument pointing and misalignment, disturbances, ephemeris, Earth rotation, etc., were investigated. Geometric error mapping functions were developed, characterized, and illustrated extensively with tables and charts. Selected ground patterns and the corresponding image distortions were generated for direct visual inspection of how the various error sources affect the appearance of the ground object images.

Wang, S. J.↗
NASA NTRSDate not supplied

Towards Qualification and Certification of Laser Powder Bed Fusion Ti-6Al-4V with In-Situ Process Monitoring and Automated Defect Detection

Qualification and certification of laser powder bed fusion (LPBF) parts are two challenges that must be answered to ensure suitability for critical applications. In-situ monitoring using high frame rate thermal and conventional optical imaging sensors is applied to the LPBF build process. Currently, the large volume of data from such sensors becomes untenable for manual inspection in production environments. This presentation serves to address this in-situ monitoring deficiency in two ways. First, a framework for managing data streams from LPBF process monitoring sensors is described. Second, two candidate image analysis techniques are presented: one is a set of heuristics that are easily interpretable, and the other is an uninterpretable convolutional neural network. These strategies are compared in terms of performance, computational expense, and speed. These methodologies represent platforms for connecting processing conditions to process modeling efforts aligned with the qualification and certification mission for LPBF Ti-6Al-4V components.

Qualification↗
NASA NTRS2007

Genesis Concentrator Target Particle Contamination Mapping and Material Identification

The majority of surface particles were found to be < 5 microns in diameter with increasing numbers close to the optical resolution limit of 0.3 microns. Acceleration grid EDS results show that the majority of materials appear to be from the SRC shell and SLA materials which include carbon-carbon fibers and Si-rich microspheres in a possible silicone binder. Other major debris material from the SRC included white paint, kapton, collector array fragments, and Al. Image analysis also revealed that SRC materials were also found mixed with the Utah mud and salt deposits. The EDS analysis of the acceleration grid showed that particles < 1 m where generally carbon based particles. Chemical cleaning techniques with Xylene and HF in an ultrasonic bath are currently being investigated for removal of small particles by the Genesis science team as well as ultra-pure water megasonic cleaning by the JSC team [4]. Removal of organic contamination from target materials is also being investigated by the science team with the use of UV-ozone cleaning devices at JSC and Open University [5]. In preparation for solar wind oxygen analyses at UCLA and Open University [1, 2], surface particle contamination on three Genesis concentrator targets was closely examined to evaluate cleaning strategies. Two silicon carbide (Genesis sample # 60001 and 60003) and one chemical vapor deposited (CVD) 13C concentrator target (60002) were imaged and mosaic mapped with optical microscopes. The resulting full target mosaic images and particle feature maps were subsequently compared with non-flight, but flight-like, concentrator targets and sample return capsule (SRC) materials. Contamination found on the flown concentrator acceleration grid was further examined using a scanning electron microscope (SEM). Energy dispersive X-ray spectroscopy (EDS) for particle identification was subsequently compared with the optical images from the flown targets. Figure 1 show that all three targets imaged in this report are fully intact and do not show any signs of material fractures. However, previous ellipsometry results and overview imaging of both flown SiC targets show a solar wind irradiation gradient from the center focal point to the outer edge [3]. In addition, due to the hard landing, each target has experienced varying degrees of impacts, scratches, and particle debris from the spacecraft and Utah impact site.

Calaway, Michael J.↗
NASA NTRS1972

Coastal environment of the Beaufort Sea from field data and ERTS-1 imagery, summer 1972

The author has identified the following significant results. An extensive field program during the spring and summer in the coastal Beaufort Sea test site has been completed using a wide variety of sensing techniques. Reduction of field data and ERTS-1 image analysis have shown the coastal environment to be complexly influenced by unique processes, most of which involve or are related to sea ice. Active sedimentologic processes along the Arctic coast are set in motion by the melting, flooding, and eventual overflow of rivers onto the sea ice. It is now apparent that only minor amounts of sediment are transported offshore at this stage; however, scouring of the bottom is significant beneath the strudels (drain holes) which develop in the fast ice canopy in the region of overflow. Areal salinity and turbidity patterns together with ERTS-1 imagery confirm a consistent influx of colder, clearer, saltier water towards the coast just east of the Colville River. Strong (up to 3 knots) bidirectional but intermittent currents often manifest themselves in imagery and aerial photographs as wakes behind grounded ice. Ice movement vectors generated from repetitive images indicate that ice drift is closely associated with wind direction, especially in shallow bays, and displacements of 4-22 kilometers were noted in 24 hours.

Reimnitz, E.↗
NASA NTRS2008

Analysis of International Space Station Materials on MISSE-3 and MISSE-4

For high-temperature applications (> 2,000 C) such as solid rocket motors, hypersonic aircraft, nuclear electric/thermal propulsion for spacecraft, and more efficient jet engines, creep becomes one of the most important design factors to be considered. Conventional creep-testing methods, where the specimen and test apparatus are in contact with each other, are limited to temperatures ~1,700 deg. C. Development of alloys for higher-temperature applications is limited by the availability of testing methods at temperatures above 2000 C. Development of alloys for applications requiring a long service life at temperatures as low as 1500 C, such as the next generation of jet turbine superalloys, is limited by the difficulty of accelerated testing at temperatures above 1700 0c. For these reasons, a new, non-contact creep-measurement technique is needed for higher temperature applications. A new non-contact method for creep measurements of ultra-high-temperature metals and ceramics has been developed and validated. Using the electrostatic levitation (ESL) facility at NASA Marshall Space Flight Center, a spherical sample is rotated quickly enough to cause creep deformation due to centrifugal acceleration. Very accurate measurement of the deformed shape through digital image analysis allows the stress exponent n to be determined very precisely from a single test, rather than from numerous conventional tests. Validation tests on single-crystal niobium spheres showed excellent agreement with conventional tests at 1985 C; however the non-contact method provides much greater precision while using only about 40 milligrams of material. This method is being applied to materials including metals and ceramics for noneroding throats in solid rockets and next-generation superalloys for turbine engines. Recent advances in the method and the current state of these new measurements will be presented.

Finckenor, Miria M.↗
NASA NTRS2002

Root gravitropism in response to a signal originating outside of the cap

We have developed image analysis software linked to a rotating stage, allowing constraint of any user-selected region of a root at a prescribed angle during root gravitropism. This device allows the cap of a graviresponding root to reach vertical while maintaining a selected region within the elongation zone at a gravistimulated angle. Under these conditions gravitropic curvature of roots of Zea mays L. continues long after the root cap reaches vertical, indicating that a signal from outside of the cap can contribute to the curvature response.

Non-NASA Center↗
NASA NTRS2005

Fluorescent Approaches to High Throughput Crystallography

X-ray crystallography remains the primary method for determining the structure of macromolecules. The first requirement is to have crystals, and obtaining them is often the rate-limiting step. The numbers of crystallization trials that are set up for any one protein for structural genomics, and the rate at which they are being set up, now overwhelm the ability for strictly human analysis of the results. Automated analysis methods are now being implemented with varying degrees of success, but these typically cannot reliably extract intermediate results. By covalently modifying a subpopulation, 51%, of a macromolecule solution with a fluorescent probe, the labeled material will add to a growing crystal as a microheterogeneous growth unit. Labeling procedures can be readily incorporated into the final stages of purification. The covalently attached probe will concentrate in the crystal relative to the solution, and under fluorescent illumination the crystals show up as bright objects against a dark background. As crystalline packing is more dense than amorphous precipitate, the fluorescence intensity can be used as a guide in distinguishing different types of precipitated phases, even in the absence of obvious crystalline features, widening the available potential lead conditions in the absence of clear hits. Non-protein structures, such as salt crystals, will not incorporate the probe and will not show up under fluorescent illumination. Also, brightly fluorescent crystals are readily found against less fluorescent precipitated phases, which under white light illumination may serve to obscure the crystals. Automated image analysis to find crystals should be greatly facilitated, without having to first define crystallization drop boundaries and by having the protein or protein structures all that show up. The trace fluorescently labeled crystals will also emit with sufficient intensity to aid in the automation of crystal alignment using relatively low cost optics, further increasing throughput at synchrotrons. This presentation will focus on the methodology for fluorescent labeling, the crystallization results, and the effects of the trace labeling on the crystal quality.

Pusey, Marc L.↗
NASA NTRS2005

Fluorescent Approaches to High Throughput Crystallography

X-ray crystallography remains the primary method for determining the structure of macromolecules. The first requirement is to have crystals, and obtaining them is often the rate-limiting step. The numbers of crystallization trials that are set up for any one protein for structural genomics, and the rate at which they are being set up, now overwhelm the ability for strictly human analysis of the results. Automated analysis methods are now being implemented with varying degrees of success, but these typically cannot reliably extract intermediate results. By covalently modifying a subpopulation, less than or = 1 %, of a macromolecule solution with a fluorescent probe, the labeled material will add to a growing crystal as a microheterogeneous growth unit. Labeling procedures can be readily incorporated into the final stages of purification. The covalently attached probe will concentrate in the crystal relative to the solution, and under fluorescent illumination the crystals show up as bright objects against a dark background. As crystalline packing is more dense than amorphous precipitate, the fluorescence intensity can be used as a guide in distinguishing different types of precipitated phases, even in the absence of obvious crystalline features, widening the available potential lead conditions in the absence of clear "hits." Non-protein structures, such as salt crystals, will not incorporate the probe and will not show up under fluorescent illumination. Also, brightly fluorescent crystals are readily found against less fluorescent precipitated phases, which under white light illumination may serve to obscure the crystals. Automated image analysis to find crystals should be greatly facilitated, without having to first define crystallization drop boundaries and by having the protein or protein structures all that show up. The trace fluorescently labeled crystals will also emit with sufficient intensity to aid in the automation of crystal alignment using relatively low cost optics, further increasing throughput at synchrotrons. Preliminary experiments show that the presence of the fluorescent probe does not affect the nucleation process or the quality of the X-ray data obtained.

Pusey, Marc L.↗
NASA NTRS2004

Fluorescent Approaches to High Throughput Crystallography

X-ray crystallography remains the primary method for determining the structure of macromolecules. The first requirement is to have crystals, and obtaining them is often the rate-limiting step. The numbers of crystallization trials that are set up for any one protein for structural genomics, and the rate at which they are being set up, now overwhelm the ability for strictly human analysis of the results. Automated analysis methods are now being implemented with varying degrees of success, but these typically can not reliably extract intermediate results. By covalently modifying a subpopulation, less than or = 1%, of a macromolecule solution with a fluorescent probe, the labeled material will add to a growing crystal as a microheterogeneous growth unit. Labeling procedures can be readily incorporated into the final stages of purification. The covalently attached probe will concentrate in the crystal relative to the solution, and under fluorescent illumination the crystals show up as bright objects against a dark background. As crystalline packing is more dense than amorphous precipitate, the fluorescence intensity can be used as a guide in distinguishing different types of precipitated phases, even in the absence of obvious crystalline features, widening the available potential lead conditions in the absence of clear "hits." Non-protein structures, such as salt crystals, will not incorporate the probe and will not show up under fluorescent illumination. Also, brightly fluorescent crystals are readily found against less fluorescent precipitated phases, which under white light illumination may serve to obscure the crystals. Automated image analysis to find crystals should be greatly facilitated, without having to first define crystallization drop boundaries and by having the protein or protein structures all that show up. The trace fluorescently labeled crystals will also emit with sufficient intensity to aid in the automation of crystal alignment using relatively low cost optics, further increasing throughput at synchrotrons. This presentation will focus on the methodology for fluorescent labeling, the crystallization results, and the effects of the trace labeling on the crystal quality.

Pusey, Marc L.↗
NASA NTRS2004

Fluorescent Approaches to High Throughput Crystallography

X-ray crystallography remains the primary method for determining the structure of macromolecules. The first requirement is to have crystals, and obtaining them is often the rate-limiting step. The numbers of crystallization trials that are set up for any one protein for structural genomics, and the rate at which they are being set up, now overwhelm the ability for strictly human analysis of the results. Automated analysis methods are now being implemented with varying degrees of success, but these typically cannot reliably extract intermediate results. By covalently modifying a subpopulation, less than or = 1%, of a macromolecule solution with a fluorescent probe, the labeled material will add to a growing crystal as a microheterogeneous growth unit. Labeling procedures can be readily incorporated into the final stages of a macromolecules purification. The covalently attached probe will concentrate in the crystal relative to the solution, and under fluorescent illumination the crystals will show up as bright objects against a dark background. As crystalline packing is more dense than amorphous precipitate, the fluorescence intensity can be used as a guide in distinguishing different types of precipitated phases, even in the absence of obvious crystalline features, widening the available potential lead conditions in the absence of clear "bits." Non-protein structures, such as salt crystals, will not incorporate the probe and will not show up under fluorescent illumination. Also, brightly fluorescent crystals are readily found against less fluorescent precipitated phases, which under white light illumination may serve to obscure the crystals. Automated image analysis to find crystals should be greatly facilitated, without having to first define crystallization drop boundaries and by having the protein or protein structures all that show up. The trace fluorescently labeled crystals will also emit with sufficient intensity to aid in the automation of crystal alignment using relatively low cost optics, further increasing throughput at synchrotrons. This presentation will focus on the methodology for fluorescent labeling, the crystallization results, and the effects of the trace labeling on the crystal quality.

Minamitani, Elizabeth Forsythe↗
NASA NTRS1989

Mass balance investigation of alpine glaciers through LANDSAT TM data

An analysis of LANDSAT Thematic Mapper (TM) data of the Pasterze Glacier and the Kleines Fleisskees in the Austrian Alps was undertaken and compared with meteorological data of nearby weather stations. Alpine or valley glaciers can be used to study regional and worldwide climate changes. Alpine glaciers respond relatively fast to a warming or cooling trend in temperature through an advance or a retreat of the terminus. In addition, the mass balance of the glacier is being affected. Last year two TM scenes of the Pasterze Glacier of Aug. 1984 and Aug. 1986 were used to study the difference in reflectance. This year, in addition to the scenes from last year, one MSS scene of Aug. 1976 and a TM scene from 1988 were examined for both the Pasterze Glacier and the Kleines Fleisskees. During the overpass of the LANDSAT on 6 Aug. 1988 ground truthing on the Pasterze Glacier was undertaken. The results indicate that there was considerable more reflectance in 1976 and 1984 than in 1986 and 1988. The climatological data of the weather stations Sonnblick and Rudolfshuette were examined and compared with the results found through the LANDSAT data. There were relations between the meteorological and LANDSAT data: the average temperature over the last 100 years showed an increase of .4 C, the snowfall was declining during the same time period but the overall precipitation did not reveal any significant change over the same period. With the use of an interactive image analysis computer, the LANDSAT scenes were studied. The terminus of the Pasterze Glacier retreated 348 m and the terminus of the Kleines Fleisskees 121 m since 1965. This approach using LANDSAT MSS and TM digital data in conjunction with meteorological data can be effectively used to monitor regional and worldwide climate changes.

Bayr, Klaus J.↗
DOE OSTI2024

Measurement of Photovoltaic Module Deformation Dynamics During Hail Impact Using Digital Image Correlation

Stereo high-speed video of photovoltaic modules undergoing laboratory hail tests was processed using digital image correlation to determine module surface deformation during and immediately following impact. The purpose of this work was to demonstrate a methodology for characterizing module impact response differences as a function of construction and incident hail parameters. Video capture and digital image analysis were able to capture out-of-plane module deformation to a resolution of ±0.1 mm at 11 kHz on an in-plane grid of 10 × 10 mm over the area of a 1 × 2 m commercial photovoltaic module. With lighting and optical adjustments, the technique was adaptable to arbitrary module designs, including size, backsheet color, and cell interconnection. Furthermore, impacts were observed to produce an initially localized dimple in the glass surface, with peak deflection proportional to the square root of incident energy. Subsequent deformation propagation and dissipation were also captured, along with behavior for instances when the module glass fractured. Natural frequencies of the module were identifiable by analyzing module oscillations postimpact. Limitations of the measurement technique were that the impacting ice ball obscured the data field immediately surrounding the point of contact, and both ice and glass fracture events occurred within 100 μs, which was not resolvable at the chosen frame rate. Increasing the frame rate and visualizing the back surface of the impact could be applied to avoid these issues. Applications for these data include validating computational models for hail impacts, identifying the natural frequencies of a module, and identifying damage initiation mechanisms.

14 SOLAR ENERGY↗
DOE OSTI2024

High–Performance NiCo 2 O 4 /Graphene Quantum Dots for Asymmetric and Symmetric Supercapacitors with Enhanced Energy Efficiency

For the sustainable growth of future generations, energy storage technologies like supercapacitors and batteries are becoming more and more common. However, reliable and high-performance materials’ design and development is the key for the widespread adoption of batteries and supercapacitors. Quantum dots with fascinating and unusual properties are expected to revolutionize future technologies. However, while the recent discovery of quantum dots honored with a Nobel prize in Chemistry, their benefits for the tenacious problem of energy are not realized yet. In this context, herein, chemical-composition tuning enabled exceptional performance of NiCo 2 O 4 (NCO)/graphene quantum dots (GQDs) is reported, which outperform the existing similar materials, in supercapacitors. A comprehensive study is performed on the synthesis, characterization, and electrochemical performance evaluation of highly functional NCO/GQDs in supercapacitors delivering enhanced energy efficiency. The high-performance, functional NCO/GQDs electrode materials are synthesized by the incorporation of GQDs into NCO. The effect of variable amount of GQDs on the energy performance characteristics of NCO/GQDs in supercapacitors is studied systematically. In-depth structural and chemical bonding analyses using X-ray diffraction (XRD) and Raman spectroscopic studies indicate that all the NCO/GQDs composites crystallize in the spinel cubic phase of NiCo 2 O 4 while graphene integration evident in all the NCO/GQDs. The scanning electron microscopy imaging analysis reveals homogeneously distributed spherical particles with a size distribution of 5–9 nm validating the formation of QDs. The high-resolution transmission electron microscopy analyses reveal that the NCOQDs are anchored on graphene sheets, which provide a high surface area of 42.27 m 2 g –1 and high mesoporosity for the composition of NCO/GQDs-10%. In addition to establishing reliable electrical connection to graphene sheets, the NCOQDs provide reliable 3D-conductive channels for rapid transport throughout the electrode as well as synergistic effects. Chemical-composition tuning, and optimization yields NCO/GQDs-10% to deliver the best specific capacitance of 3940 Fg –1 at 0.5 Ag –1 , where the electrodes retain ≈98% capacitance after 5000 cycles. The NCO/GQD-10%//AC asymmetric supercapacitor device demonstrates outstanding energy density and power density values of 118.04 Wh kg –1 and 798.76 W kg –1 , respectively. The NCO/GQDs-10%//NCO/GQDs-10% symmetric supercapacitor device delivers excellent energy and power density of 24.30 Wh kg –1 and 500 W kg –1 , respectively. These results demonstrate and conclude that NCO/GQDs are exceptional and prospective candidates for developing next-generation high-performance and sustainable energy storage devices.

25 ENERGY STORAGE↗
DOE OSTI2025

Evaluation of desiccation cracking characteristics of inorganic micro-fiber-reinforced engineered barrier material (IMEBM) for geological repository

Abstract Buffer material is crucial for the engineering barrier system to dispose of high-level radioactive waste in a geological repository. A reliable buffer material should be able to maintain good sealing characteristics and minimize desiccation cracking. In this study, the effectiveness of inorganic fiber-reinforced engineering barrier material in reducing desiccation cracks in bentonite was evaluated via desiccation tests, image analysis, and air permeability tests. The effects of fiber type (E-glass fiber and basalt fiber) and fiber content (0.0%, 0.5%, 1.0%, 1.5%, 3.0%, and 5.0% of dry weight of the bentonite) on the development of desiccation cracks in the fiber–bentonite mixtures with the same given initial moisture content were evaluated. The results indicated that the addition of fibers could significantly reduce the crack size and area in bentonite during the drying. Basalt fibers showed a slightly better reinforcement effect than E-glass fibers when the fiber content was lower than 3.0%. The addition of fibers prevented the development of penetrating cracks and significantly reduced the permeability of the bentonite after drying. The permeabilities of basalt fiber- and E-glass fiber-reinforced bentonite composites with 3% reinforcement were 5.81 × 10 –11 m 2 and 7.24 × 10 –11 m 2 , respectively, which were 64 and 51 times smaller than that of pure bentonite. X-ray–CT observation of the internal structure of the samples after drying showed that the addition of fibers significantly changed the crack morphology and potentially increased the tortuosity.

Feng, Yuan↗
DOE OSTI2024

Microstructural Coarsening Kinetics and Mechanical Property Changes in Long-Term Aged Sn–Pb–Sb Solder Joints

Tin-lead-antimony (50Sn–47Pb–3Sb wt.%) soldered assemblies were mechanically tested approximately 30 years after initial production and found to have solder joints of reduced strength. The microstructure of this solder alloy exhibits a ternary eutectic structure with Sn-rich, Pb-rich, and SnSb phases. Accelerated aging was performed to evaluate solder microstructural coarsening and associated strength of laboratory solder joints to correlate these properties to the “naturally aged” solder joints. Isothermal aging was conducted at room temperature, 55, 70, 100, and 135 °C and aging times that ranged from 0.1 to 365 days. The coarsening kinetics of the Pb-rich phase were determined through optical microscopy and image analysis methods established in previous studies on binary Sn–Pb solder. A kinetic equation was developed with time exponent n of 0.43 and activation energy of 24000 J/mol, suggesting grain boundary diffusion or other fast diffusion pathways controlling the microstructural evolution. Compression testing and Vickers microhardness showed significant strength loss within the first 20–30 days after soldering; then, the microstructure and mechanical properties changed more slowly over long periods of time. Further, by combining accelerated aging data and the microstructure-based kinetics, strength predictions were made that match well with the properties of the actual soldered assemblies naturally aged for 30 years. However, aging at the highest temperature of 135 °C produced anomalous behavior suggesting that extraneous aging mechanisms are active. Therefore, data obtained at this temperature or higher should not be used. Overall, the combined microstructural and mechanical property methods used in this study confirmed that the observed reduction in strength of ~ 30-year-old solder joints can be accounted for by the microstructural coarsening that takes place during long-term solid-state aging.

36 MATERIALS SCIENCE↗