CSP Consortia Activies: Program Objectives and Status
The paper will provide an overview and independent articles provided by team members.
Chip Scale Packages (CSPs) microvia boards isother↗
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Results for “thermal aging”
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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Chip Scale Package and Assembly Joint Reliability
The popularity of emerging miniaturized Chip Scale Packages (CSPs) is rapidly growing because of their benefits and smaller size.
CSP Solder joint Reliability Thermal aging chip Sc↗
Flexible Thermal Protection System Development for Hypersonic Inflatable Aerodynamic Decelerators
The Hypersonic Inflatable Aerodynamic Decelerators (HIAD) project has invested in development of multiple thermal protection system (TPS) candidates to be used in inflatable, high downmass, technology flight projects. Flexible TPS is one element of the HIAD project which is tasked with the research and development of the technology ranging from direct ground tests, modelling and simulation, characterization of TPS systems, manufacturing and handling, and standards and policy definition. The intent of flexible TPS is to enable large deployable aeroshell technologies, which increase the drag performance while significantly reducing the ballistic coefficient of high-mass entry vehicles. A HIAD requires a flexible TPS capable of surviving aerothermal loads, and durable enough to survive the rigors of construction, handling, high density packing, long duration exposure to extrinsic, in-situ environments, and deployment. This paper provides a comprehensive overview of key work being performed within the Flexible TPS element of the HIAD project. Included in this paper is an overview of, and results from, each Flexible TPS research and development activity, which includes ground testing, physics-based thermal modelling, age testing, margins policy, catalysis, materials characterization, and recent developments with new TPS materials.
DelCorso, Joseph A.↗
Separating the Influence of Environment from Stress Relaxation Effects on Dwell Fatigue Crack Growth in a Nickel-Base Disk Alloy
Both environmental embrittlement and crack tip visco-plastic stress relaxation play a significant role in determining the dwell fatigue crack growth (DFCG) resistance of nickel-based disk superalloys. In the current study performed on the Low Solvus High Refractory (LSHR) disk alloy, the influence of these two mechanisms were separated so that the effects of each could be quantified and modeled. Seven different microstructural variations of LSHR were produced by controlling the cooling rate and the subsequent aging and thermal exposure heat treatments. Through cyclic fatigue crack growth testing performed both in air and vacuum, it was established that four out of the seven LSHR heat treatments evaluated, possessed similar intrinsic environmental resistance to cyclic crack growth. For these four heat treatments, it was further shown that the large differences in dwell crack growth behavior which still persisted, were related to their measured stress relaxation behavior. The apparent differences in their dwell crack growth resistance were attributed to the inability of the standard linear elastic fracture mechanics (LEFM) stress intensity parameter to account for visco-plastic behavior. Crack tip stress relaxation controls the magnitude of the remaining local tensile stresses which are directly related to the measured dwell crack growth rates. It was hypothesized that the environmentally weakened grain boundary crack tip regions fail during the dwells when their strength is exceeded by the remaining local crack tip tensile stresses. It was shown that the classical creep crack growth mechanisms such as grain boundary sliding did not contribute to crack growth, but the local visco-plastic behavior still plays a very significant role by determining the crack tip tensile stress field which controls the dwell crack growth behavior. To account for the influence of the visco-plastic behavior on the crack tip stress field, an empirical modification to the LEFM stress intensity parameter, Kmax, was developed by incorporating into the formulation the remaining stress level concept as measured by simple stress relaxation tests. The newly proposed parameter, Ksrf, did an excellent job in correlating the dwell crack growth rates for the four heat treatments which were shown to have similar intrinsic environmental cyclic fatigue crack growth resistance.
Dwell crack growth↗
Separating the Influence of Environment from Stress Relaxation Effects on Dwell Fatigue Crack Growth
Seven different microstructural variations of LSHR were produced by controlling the cooling rate and the subsequent aging and thermal exposure heat treatments. Through cyclic fatigue crack growth testing performed both in air and vacuum, it was established that four out of the seven LSHR heat treatments evaluated, possessed similar intrinsic environmental resistance to cyclic crack growth. For these four heat treatments, it was further shown that the large differences in dwell crack growth behavior which still persisted, were related to their measured stress relaxation behavior. The apparent differences in their dwell crack growth resistance were attributed to the inability of the standard linear elastic fracture mechanics (LEFM) stress intensity parameter to account for visco-plastic behavior. Crack tip stress relaxation controls the magnitude of the remaining local tensile stresses which are directly related to the measured dwell crack growth rates. It was hypothesized that the environmentally weakened grain boundary crack tip regions fail during the dwells when their strength is exceeded by the remaining local crack tip tensile stresses. It was shown that the classical creep crack growth mechanisms such as grain boundary sliding did not contribute to crack growth, but the local visco-plastic behavior still plays a very significant role by determining the crack tip tensile stress field which controls the dwell crack growth behavior. To account for the influence of the visco-plastic behavior on the crack tip stress field, an empirical modification to the LEFM stress intensity parameter, Kmax, was developed by incorporating into the formulation the remaining stress level concept as measured by simple stress relaxation tests. The newly proposed parameter, Ksrf, did an excellent job in correlating the dwell crack growth rates for the four heat treatments which were shown to have similar intrinsic environmental cyclic fatigue crack growth resistance.
environmental damage↗
Chip Scale Package Implementation Challenges
The JPL-led MicrotypBGA Consortium of enterprises representing government agencies and private companies have joined together to pool in-kind resources for developing the quality and reliability of chip scale packages (CSPs) for a variety of projects.
chipscale↗
Initial Motor Winding Insulation Lifetime Experimental Results for Electric Aircraft Applications
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Reliability↗
Evaluation of Ultrasonic and Thermal Nondestructive Evaluation for the Characterization of Aging Degradation in Braided Composite Materials
This paper examines the ability of traditional nondestructive evaluation (NDE) techniques to measure the degradation of braided polymer composite materials subjected to thermal-humidity cycling to simulate aging. A series of braided composite coupons were examined using immersion ultrasonic and pulsed thermography techniques in the as received condition. These same specimens were then examined following extended thermal-humidity cycling. Results of this examination did not show a significant change in the resulting (NDE) signals.
Martin, Richard E.↗
Microstructure and Aging of Powder-Metallurgy Al Alloys
Report describes experimental study of thermal responses and aging behaviors of three new aluminum alloys. Alloys produced from rapidly solidified powders and contain 3.20 to 5.15 percent copper, 0.24 to 1.73 percent magnesium, 0.08 to 0.92 percent iron, and smaller amounts of manganese, nickel, titanium, silicon, and zinc. Peak hardness achieved at lower aging temperatures than with standard ingot-metallurgy alloys. Alloys of interest for automobile, aircraft, and aerospace applications.
Blackburn, L. B.↗
Predicting Maximum Temperatures of a Li-ion Battery on a Simulated Flight Profile using a Model-based Prognostics
One of the challenges in using Li-ion packs in aeronautics is their safety, and thermal runaway (TR) is a major concern. The current engineering solutions to prevent a Li-ion pack from a catastrophic TR require additional mass and volume to isolate cells. The excess mass could be reduced by improving detection and, thus, preventing a TR event. One of the possible early warning indicators of a TR is crossing a threshold temperature. We have developed an approach, based on the Unscented Kalman Filter (UKF), to predict the likelihood of reaching the threshold temperature for simulated flight profiles. The current battery prognostics algorithms for aerospace predict state-of-charge (SOC) and end-of-life (EOL) [1]. We extended this two-level algorithm to predict the maximum temperature during discharge. The amount of heat generated in a cell depends on factors such as cell chemistry, cell packaging, total cycles, operating temperature, and abuse history [2]. Our semi-empirical thermal model depends on three phenomenological parameters which account for those factors. In addition, a two-parameter reduced-order model is developed to predict the temperature rise for short bursts of “random-walk” (RW) discharge current sequence, which simulates a flight's current-loading profile. The performance of these models on different datasets and types of current loading will be presented. To predict the maximal temperatures for future cycles we must estimate the evolution of thermal parameters as the batteries age. It is found that the parameters of the 3-parametric thermal model cannot be estimated only from the RW data. To address the issue, we will present two alternative approaches: i) expanding the datasets to include discharge profiles beyond RWs; ii) model reduction to a two-parametric model. The two approaches will be illustrated by an application to the cycling data from a commercial LG 18650 cell. References: 1. M. Daigle, C.S. Kulkarni, End-of-discharge and End-of-life Prediction in Lithium-ion Batteries with Electrochemistry-based Aging Models, in: AIAA Infotech @ Aerospace, American Institute of Aeronautics and Astronautics, San Diego, California, USA, 2016. 2. M. Börner, et. al, Correlation of aging and thermal stability of commercial 18650-type lithium ion batteries, Journal of Power Sources. 342 (2017) 382–392.
Thermal runaway↗
Physics Based Electrolytic Capacitor Degradation Models for Prognostic Studies under Thermal Overstress
Electrolytic capacitors are used in several applications ranging from power supplies on safety critical avionics equipment to power drivers for electro-mechanical actuators. This makes them good candidates for prognostics and health management research. Prognostics provides a way to assess remaining useful life of components or systems based on their current state of health and their anticipated future use and operational conditions. Past experiences show that capacitors tend to degrade and fail faster under high electrical and thermal stress conditions that they are often subjected to during operations. In this work, we study the effects of accelerated aging due to thermal stress on different sets of capacitors under different conditions. Our focus is on deriving first principles degradation models for thermal stress conditions. Data collected from simultaneous experiments are used to validate the desired models. Our overall goal is to derive accurate models of capacitor degradation, and use them to predict performance changes in DC-DC converters.
Kulkarni, Chetan S.↗
International Research Project on the Effects of Chemical Ageing of Polymers on Performance Properties: Chemical and Thermal Analysis
Work during the past six months has included significant research in several areas aimed at further clarification of the aging and chemical failure mechanism of thermoplastics (PVDF or Tefzel) pipes. Among the areas investigated were the crystallinity changes associated with both the Coflon and Tefzel after various simulated environmental exposures using X-ray diffraction analysis. We have found that significant changes in polymer crystallinity levels occur as a function of the exposures. These crystallinity changes may have important consequences on the fracture, fatigue, tensile, and chemical resistance of the materials. We have also noted small changes in the molecular weight distribution. Again these changes may result in variations in the mechanical and chemical properties in the material. We conducted numerous analytical studies with methods including X-ray Diffraction, Gel Permeation Chromatography, Fourier Transform Infrared Spectroscopy, Ultra- Violet Scanning Analysis, GC/Mass Spectrometry, Differential Scanning Calorimetry and Thermomechanical Analysis. In the ultra-violet analysis we noted the presence of an absorption band indicative of triene formation. We investigated a number of aged samples of both Tefzel and Coflon that were forwarded from MERL. We also cast films at SWT and subjected these films to a refluxing methanol 1% ethylene diamine solution. An updated literature search was conducted using Dialog and DROLLS to identify any new papers that may have been published in the open literature since the start of this project. The updated literature search and abstracts are contained in the Appendix section of this report.
Bulluck, J. W.↗
Experimental Techniques for Evaluating the Effects of Aging on Impact and High Strain Rate Properties of Triaxial Braided Composite Materials
An experimental program is underway to measure the impact and high strain rate properties of triaxial braided composite materials and to quantify any degradation in properties as a result of thermal and hygroscopic aging typically encountered during service. Impact tests are being conducted on flat panels using a projectile designed to induce high rate deformation similar to that experienced in a jet engine fan case during a fan blade-out event. The tests are being conducted on as-fabricated panels and panels subjected to various numbers of aging cycles. High strain rate properties are being measured using a unique Hopkinson bar apparatus that has a larger diameter than conventional Hopkinson bars. This larger diameter is needed to measure representative material properties because of the large unit cell size of the materials examined in this work. In this paper the experimental techniques used for impact and high strain rate testing are described and some preliminary results are presented for both as-fabricated and aged composites.
Pereira, J. Michael↗
Microstructure/mechanical property relationships for various thermal treatments of Al-Cu-Mg-X PM aluminum alloys
The thermal response and aging behavior of three 2XXX-series powder metallurgy aluminum alloys have been investigated, using Rockwell B hardness measurements, optical and electron microscopy, and energy-dispersive chemical analysis, in order to correlate microstructure with measured mechanical properties. Results of the thermal response study indicated that an increased solution heat treatment temperature was effective in resolutionizing large primary constituents in the alloy bearing more copper but had no apparent effect on the microconstituents of the other two. Aging studies conducted at room temperature and at 120, 150, and 180 C for times ranging up to 60 days indicated that classic aging response curves, as determined by hardness measurements, occurred at lower aging temperatures than were previously studied for these alloys, as well as at lower aging temperatures than are commonly used for ingot metallurgy alloys of similar compositions. Microstructural examination and fracture surface analysis of peak-aged tension specimens indicated that the highest tensile strengths are associated with extremely fine and homogeneous distributions of theta-prime or S-prime phases combined with low levels of both large constituent particles and dispersoids. Examination of the results suggest that refined solution heat treatments and lower aging temperatures may be necessary to achieve optimum mechanical properties for these 2XXX series alloys.
Blackburn, L. B.↗
High temperature composites for advanced missile and space transportation systems
A study has been conducted to characterize a state-of-the-art graphite/polyimide composite system by determining mechanical and thermophysical properties of selected laminates over a temperature range of -250 F to 600 F. The material studied was Celion 3000/PMR-15. Material property data obtained from testing included tension, compression and shear strengths, and coefficient of thermal expansion. Environmental conditions examined were: as cured/post-cured, isothermal aged at 600 F, thermal cycled from -250 F to 600 F, and moisture conditioned. This study has provided an initial data base on a graphite/polyimide composite system capable of operating in 500/600 F applications.
Mccleskey, S. F.↗
Kinematic, flexural, and thermal modelling in the Central Andes: Unravelling age and signal of deformation, exhumation, and uplift
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Victoria M. Buford Parks↗
Space Shuttle Corrosion Protection Performance
The reusable Manned Space Shuttle has been flying into Space and returning to earth for more than 25 years. The launch pad environment can be corrosive to metallic substrates and the Space Shuttles are exposed to this environment when preparing for launch. The Orbiter has been in service well past its design life of 10 years or 100 missions. As part of the aging vehicle assessment one question under evaluation is how the thermal protection system and aging protective coatings are performing to insure structural integrity. The assessment of this cost resources and time. The information is invaluable when minimizing risk to the safety of Astronauts and Vehicle. This paper will outline a strategic sampling plan and some operational improvements made by the Orbiter Structures team and Corrosion Control Review Board.
Curtis, Cris E.↗
TAB interconnects for space concentrator solar cell arrays
The Boeing Company has evaluated the use of Tape Automated Bonding (TAB) and Surface Mount Technology (SMT) for a highly reliable, low cost interconnect for concentrator solar cell arrays. TAB and SMT are currently used in the electronics industry for chip interconnects and printed circuit board assembly. TAB tape consists of sixty-four 3-mil/1-oz tin-plated copper leads on 8-mil centers. The leads are thermocompression gang bonded to GaAs concentrator solar cell with silver contacts. This bond, known as an Inner Lead Bond (ILB), allows for pretesting and sorting capability via nondestruct wire bond pull and flash testing. Destructive wire pull tests resulted in preferred mid-span failures. Improvements in fill factor were attributed to decreased contact resistance on TAB bonded cells. Preliminary thermal cycling and aging tests were shown excellent bond strength and metallurgical results. Auger scans of bond sites reveals an Ag-Cu-Tin composition. Improper bonds are identified through flash testing as a performance degradation. On going testing of cells are underway at Lewis Research Center. SMT techniques are utilized to excise and form TAB leads post ILB. The formed leads' shape isolates thermal mismatches between the cells and the flex circuit they are mounted on. TABed cells are picked and placed with a gantry x-y-z positioning system with pattern recognition. Adhesives are selected to avoid thermal expansion mismatch and promote thermal transfer to the flex circuit. TAB outer lead bonds are parallel gap welded (PGW) to the flex circuit to finish the concentrator solar cell subassembly.
Avery, J.↗