Recent Applications of Moiré Interferometry

Moiré interferometry has been a valuable experimental technique for the understanding of the mechanical behavior of materials and structures. Over the last decade less emphasis has been placed on the development of the technique and more towards applications. This paper is a review article on recent applications using moiré interferometry in the fields of microelectronics devices, material characterization, micromechanics, residual stress, composite materials, fracture mechanics, and biomechanics. The general principles of moiré interferometry and advancement of techniques will not be discussed in this text, but references will be provided.     

Experimental study of a metal-matrix composite

A metal-matrix specimen was investigated using moiré interferometry with 2400 ℓ/mm (60,960 ℓ/in.). The specimen was a 6-ply [0/±45] _s boron-aluminum tensile coupon with a central slot. The unequal deformations in fibers and matrix were evident. Special attention was given to a plastic slip zone in the matrix. Normal and shear strains were calculated in the slip zone; the shear-strain concentration factor rose dramatically with the onset of plastic slip and continued to rise gradually with load to 95 percent of the failure load. The precipitous change from maximum tensile strain in one fiber to zero tensile strain in the neighboring fiber was accommodated by the very high shear strain in the matrix in the slip zone. Experimental considerations are discussed: shear strains are independent of rigid-body rotations; simplified strain calculations are justified; averaging across the narrow slip region and the influence of finite thickness of the specimen grating contribute to underestimation of peak strains. Paper was presented at the 1986 SEM Spring Conference on Experimental Mechanics held in New Orleans, LA on June 8–13.     

Electromigration induced strain field simulations for nanoelectronics lead-free solder joints

Electromigration is a major road block on the way to realization of nanoelectronics. Determination of plastic deformation under high current density is critical for prediction of electromigration failure. A new displacement–diffusion coupled model is proposed and implemented using finite element method. The model takes into account viscoplastic behavior of solder alloys, as a result, vacancy concentration evolution and electromigration process are accurately simulated. Finite element simulations were performed for lead-free solder joints under high current density and compared with experimental moiré interferometry measurements. The comparison validates the model.     

MEASUREMENT OF NON-UNIFORM RESIDUAL STRESSES BY COMBINED MOIRE INTERFEROMETRY AND HOLE-DRILLING METHOD： THEORY, EXPERIMENTAL METHOD AND APPLICATIONS

Hole-drilling method is one of the most convenient methods for engineering residual stress measurement. Combined with moiré interferometry to obtain the relaxed whole-field displacement data, hole-drilling technique can be used to solve non-uniform residual stress problems, both in-depth and in-plane. In this paper, the theory of moiré interferometry and incremental hole-drilling (MIIHD) for non-uniform residual stress measurement is introduced. Three dimensional finite element model is constructed by ABAQUS to obtain the coefficients for the residual stress calculation. An experimental system including real-time measurement, automatic data processing and residual stresses calculation is established. Two applications for non-uniform in-depth residual stress of surface nanocrystalline material and non-uniform in-plane residual stress of friction stir welding are presented. Experimental results show that MIIHD is effective for both non-uniform in-depth and in-plane residual stress measurements. The project supported by the FRAMATOME ANP     

An Experimental Technique for the Dynamic Characterization of Soft Complex Materials

We describe an experimental technique to study the dynamic behavior of complex soft materials, based on high-speed microscopic imaging and direct measurements of dynamic forces and deformations. The setup includes high sensitivity dynamic displacement measurements based on geometric moiré interferometry and high-speed imaging for in-situ, full-field visualization of the complex micro-scale dynamic deformations. The method allows extracting dynamic stress-strain profiles both from the moiré interferometry and from the high-speed microscopic imaging. We discuss the advantages of using these two complementing components concurrently. We use this technique to study the dynamic response of vertically aligned carbon nanotube foams subjected to impact loadings at variable deformation rates. The same technique can be used to study other micro-structured materials and complex hierarchical structures.     

Using Carrier Fringes to Study the High Temperature Deformation Behavior of a BGA Package Under Extended Dwell Times

There is a compelling need to experimentally understand solder joint deformation behavior at high temperatures over an extended period of time. Accordingly, the deformation behavior of solder joints in a Ceramic Ball Grid Array (CBGA) package mounted on an organic FR4 board under extended dwell time at a high temperature has been studied using laser moiré interferometry. The warpage and the in-plane horizontal deformation of the ceramic substrate and the organic board as a function of time were determined. The variation of the normal strains and shear strains in the solder joints with time were also investigated. It was found that increased sensitivity was necessary to accurately determine the strains in the small sized solder joints. A new method utilizing carrier fringes to increase the sensitivity of the moiré interferometry system is proposed and has been used to determine the strains in the small sized solder joints. Increased sensitivity can be obtained merely by changing the incident angle of the laser light on the surface of the specimen, thereby making it unnecessary to use expensive phase shifting apparatus with the traditional laser moiré system.     

In-plane shear testing of graphite-woven fabric composites

The losipescu shear test method was used to determine the in-plane shear response of AS4 and Celion carbon fiber/epoxy fabric composite materials. Several weave architectures were studied: AS4 uniweave, AS4 and Celion plain weaves, Celion 5-harness and 8-harness satin weaves. Specimens were tested using traditional strain gage techniques and full-field moiré interferometry. A full-node localized hybrid analysis is introduced to perform efficient reduction of moiré data, producing whole-field strain distributions in the specimen test section. It was found that the fabric yarn size greatly influenced the uniformity of the shear field in the specimen test section. However, consistent shear moduli still can be obtained using the modified losipescu specimen and Wyoming fixture except for fabrics with large fiber yarns.     

双列直插器件(DIP)焊接过程中的应力评价

为探讨陶瓷封装双列直插器件在焊接后出现开裂的问题,应用云纹干涉法和Twyman/Green干涉法实时测试了该类型器件在焊接过程中的面内和离面变形情况,并将测试数据与有限元法相结合,评估了焊接过程中器件内部因印制板变形而产生的应力大小。由此对原先"焊接导致开裂"的说法做出了评价。同时,通过器件的变形测试,探讨了优化焊接工艺的方法。研究结果表明,焊接顺序对器件内部热应力和器件变形影响不大,而适当提高器件高度可有效减小焊接时的热应力。     

A Study of Crack–inclusion Interactions and Matrix–inclusion Debonding Using Moiré Interferometry and Finite Element Method

Failure behavior of composite materials in general and particulate composites in particular is intimately linked to interactions between a matrix crack and a second phase inclusion. In this work, surface deformations are optically mapped in the vicinity of a crack–inclusion pair using moiré interferometry. Edge cracked epoxy beams, each with a symmetrically positioned cylindrical glass inclusion ahead of the tip, are used to simulate a compliant matrix crack interacting with a stiff inclusion. Processes involving microelectronic fabrication techniques are developed for creating linear gratings in the crack–inclusion vicinity. The debond evolution between the inclusion–matrix pair is successfully mapped by recording crack opening displacements under quasi-static loading conditions. The surface deformations are analyzed to study evolution of strain fields due to crack–inclusion interactions. A numerical model based on experimental observations is also developed to simulate debonding of the inclusion from the matrix. An element stiffness deactivation method in conjunction with critical radial stress criterion is successfully demonstrated using finite element method. The proposed methodology is shown to capture the experimentally observed debonding process well.

A localized hybrid method of stress analysis: A combination of moiré interferometry and FEM

A method of combining moiré interferometry and the finite-element method to effect localized stress analysis is presented. The displacement data from local regions of interest in the optical experiment are used as boundary conditions for the finite-element stress analysis. The stability of the method is examined with data from simple numerical models one of which corresponded to the stress analysis of a pin-loaded plate with friction. These studies show that the method requires the sensivity of moiré interferometry for successful implementation, i.e., displacement data accuracy within 0.1 μm or 4 μin. This localized hybrid method of stress analysis provides a powerful and efficient method for the reduction of experimental data.     

Observing real-time thermal deformations in electronic packaging

Experimental Techniques - A robust scheme of moiré interferometry for real-time observation of thermal deformations was developed. It was implemented with a convection-type heating/cooling...     

Characterization of short duration stress pulses generated by impacting laminated carbon-fiber/epoxy composites with magnetic flyer plates

Short duration stress pulses are of particular interest in determining the interfacial crack tip instability criteria for the dynamic fracture behavior of laminated carbon-fiber/epoxy composites. However, the heterogeneous architectures of laminated composites can alter the characteristics of a stress pulse as it propagates toward a crack tip. This makes it difficult to use standard dynamic testing techniques for characterizing these materials, since these techniques assume the characteristics of the stress pulse do not change as a result of propagation and can therefore be unambiguously determined from impact conditions. This paper presents a novel experimental technique that has been developed for characterizing short duration stress pulse propagation in laminated composite materials. In this technique, a dynamic moiré interferometer is used to capture fringe patterns corresponding to displacement fields associated with short duration stress pulses that were generated by impacting 0° and 90°/0°/90° carbon-fiber/epoxy composites with a magnetic flyer plate. Appropriate dynamic testing conditions for capturing high fidelity fringe patterns were determined using the recently developed dynamic moiré fringe contrast factor. The effects of the composite architecture on the propagation of short duration stress pulses observed with the dynamic moiré interferometer were confirmed by transient dynamic finite element analysis. From comparisons of experimental and numerical data, it was determined that the impact conditions for the magnetic flyer plate and laminated composite will not necessarily be planar, which has a significant effect on the intensity and duration of the propagating stress pulse.     

Residual strain measurement in composites using the cure-referencing method

This paper describes the details of a novel procedure called the cure-referencing method (CRM) to measure the strains associated with residual stresses on the surface of composite panels. The CRM involves the replication of diffraction gratings onto the surface of composite specimens during the autoclave during cycle. Residual strains associated with the curing process are measured using moiré interferometry at room temperature after the specimens have been taken out of the autoclave. The procedures for both the grating replication and the moiré interferometry experiment are described in detail. A method of high-temperature moiré interferometry was developed to resolve the residual strains due to thermal expansion from those due to chemical matrix shrinkage and stress relaxation. These procedures are demonstrated on unidirectional and multidirectional laminates and on woven textile composites.     

Study on Deformation of Polycrystalline Aluminum Alloy Using Moiré Interferometry

Polycrystalline aluminum alloy is manufactured by annealing, compared to the width of the specimen, the size of the grains can not be omitted, which makes the specimen anisotropic. Under uniaxial tension, the deformation field is inhomogeneous. In this study, moiré interferometry is successfully applied to measure the deformation of the polycrystalline specimen. The experimental results presented the stress versus strain responses of the marked grains in different orientations and different shapes. By using fringe centering method, the strain distributions under certain load in the centers and on the boundaries of the grains are analyzed.     

Effects of material and stacking sequence on behavior of composite plates with holes

Strain distributions to failure, tensile and compressive strain-concentration factors, and strength-reduction factors were determined for glass-, boron-, and graphite-epoxy plates with holes loaded in tension. Strain gages, photoelastic coatings and moiré techniques were used. Ten variations of layup and stacking sequence were studied. The boron-epoxy composite was found to be the stiffest and strongest of the three. The graphite laminate with the highest stress concentration and the most linear strain response exhibited the highest strength-reduction factor. In all cases, the maximum strain at failure on the hole boundary was higher than the ultimate tensile-coupon strain. In general, it was found that, the higher the stress-concentration factor, the higher the strength-reduction factor. Thus, the [0/90/0/90]_s layup with a stress-concentration factor of 4.82 had a strength-reduction factor of 3.18. At the other extreme, the most flexible layup [±45/±45]_s with the lowest stress-concentration factor of 2.06 had the lowest strength-reduction factor of 1.10. Stacking sequences associated with the tensile interlaminar normal stress or high interlaminar shear stress near the boundary, resulted in laminates 10 to 20 percent weaker than corresponding alternate stacking sequences. Furthermore, it was found that stacking-sequence variations can alter the mode of failure from catastrophic to noncatastrophic.     

Mechanical Characterization of Biological Membranes with Moiré Techniques and Multi-Point Simulated Annealing

This paper describes an hybrid procedure for mechanical characterization of biological membranes. The in-plane displacement field of a glutaraldehyde treated bovine pericardium patch obtained with an equi-biaxial tension test is measured with intrinsic moiré and then compared with finite element predictions. Preliminary analysis of moiré patterns observed in the experiments justifies the assumption of the constitutive model based on transversely isotropic hyperelasticity. In order to determine the 16 hyperelastic constants included in the constitutive model and the fiber orientation, the difference Ω between displacement values measured with moiré and their counterpart determined numerically is minimized by means of multi-level and multi-point simulated annealing. Results clearly demonstrate the efficiency of the identification procedure presented in this research: in fact, residual difference between experimental data and numerical values of in-plane displacements is less than 2%. In order to validate the entire identification process, another experimental test is conducted by inflating the same specimen. Out-of-plane displacements, now measured with projection moiré, are compared with predictions of a new finite element model reproducing the experimental test. The 16 hyper-elastic constants previously determined are given in input to the inflation test FE model. Remarkably, experimental and numerical results are again in excellent agreement: maximum percent error on w-displacement is less than 3%.     

Recent research activities in experimental mechanics in China

A brief review is presented of the recent activities in the field of experimental mechanics in the People's Republic of China. The current research work covers the following subjects: (1) photoelastic phenomena, such as the classical three-dimensional photoelasticity, the scattered-light technique, birefringent coatings, birefringent materials; (2) holography, holographic interferometry, speckle interferometry and their applications; (3) moiré method; (4) strain-gage techniques and strain indicators.     

Dynamic moiré measurement of strains induced in a titanium tube plate during the rolling of a series of tubes

The strains developed in a tube plate by the process of roller expansion of tubes were measured by moiré interferometry. The maximum strains during the process were recorded by photographing the fringe patterns during rolling at a rate of five frames per second. The tubes were rolled according to a prearranged pattern, and the deformations over the whole tube-plate element were recorded between the rolling of successive tubes; by this means, the effect of each tube rolling on the overall strain pattern was assessed.     

A moiré microscope for finite deformation micro-mechanical studies

A new version of a moiré microscope is presented that embodies the theory of optical moiré interferometry. To interrogate the deformed specimen grating, the device uses a transmission diffraction grating that allows for a simple and quick change of the virtual reference grating vector without disturbing the optical alignment of the other components in the optical train. To analyze deformation from the acquired moiré interference fringe patterns, the displacement light-itensity moiré optical law introduced by Sciammarella is revisited. The analysis of deformation is consistent with the continuum principles of finite deformation and can readily be used to obtain micro-mechanical quantities of interest such as the local strains, stretches and rotations.     

Automated fringe pattern analysis for moiré interferometry

The theory of an automated fringe-pattern analysis using temporal phase stepping method for moiré interferometry is presented. The automated method provides a fast and accurate strain measurement for moiré interferometry. Measurements on a tapered composite specimen with a dropped ply are shown to highlight the capability of this technique to obtain the strain distribution, particularly around the region with a dropped ply.