A general strategy of in-situ warpage characterization for solder attached packages with digital image correlation method

Recently, 3-D Digital Image Correlation (DIC) is widely applied to the reliability analysis of electronic packages, which particularly characterizes the in-situ deformation of ball grid array (BGA) packages. During the image correlation procedure, many parameters influence the accuracy and data integrity of measurement result. Facet (subset) size is the principal parameter and has been studied with much effort. However, the solder balls, which are built on the substrate surface, make the scenario different with the conventional 3-D DIC experiment for the planar samples. The undulant surface generates more obstacles for the successful image correlation. In order to summarize an effective solution of 3-D DIC measurement method for solder balls attached packages, camera angle, facet size and facet step are studied with different BGA packages and different stereoscopic camera systems to achieve the best correlation quality. Also, a novel surface treatment method is introduced to guarantee the surface speckles are generated uniformly on the fluctuant surface.     

Determining the tensile response of materials at high temperature using DIC and the Virtual Fields Method

An experimental approach based on Digital Image Correlation (DIC) is successfully applied to predict the uniaxial stress-strain response of 304 stainless steel specimens subjected to nominally uniform temperatures ranging from room temperature to 900 °C. A portable induction heating device equipped with custom made water-cooled copper coils is used to heat the specimen. The induction heater is used in conjunction with a conventional tensile frame to enable high temperature tension experiments. A stereovision camera system equipped with appropriate band pass filters is employed to facilitate the study of full-field deformation response of the material at elevated temperatures. Using the temperature and load histories along with the full-field strain data, a Virtual Fields Method (VFM) based approach is implemented to identify constitutive parameters governing the plastic deformation of the material at high temperature conditions. Results from these experiments confirm that the proposed method can be used to measure the full field deformation of materials subjected to thermo-mechanical loading.     

A fast digital image correlation method for deformation measurement

Fast and high-accuracy deformation analysis using digital image correlation (DIC) has been increasingly important and highly demanded in recent years. In literature, the DIC method using the Newton-Rapshon (NR) algorithm has been considered as a gold standard for accurate sub-pixel displacement tracking, as it is insensitive to the relative deformation and rotation of the target subset and thus provides highest sub-pixel registration accuracy and widest applicability. A significant drawback of conventional NR-algorithm-based DIC method, however, is its extremely huge computational expense. In this paper, a fast DIC method is proposed deformation measurement by effectively eliminating the repeating redundant calculations involved in the conventional NR-algorithm-based DIC method. Specifically, a reliability-guided displacement scanning strategy is employed to avoid time-consuming integer-pixel displacement searching for each calculation point, and a pre-computed global interpolation coefficient look-up table is utilized to entirely eliminate repetitive interpolation calculation at sub-pixel locations. With these two approaches, the proposed fast DIC method substantially increases the calculation efficiency of the traditional NR-algorithm-based DIC method. The performance of proposed fast DIC method is carefully tested on real experimental images using various calculation parameters. Results reveal that the computational speed of the present fast DIC is about 120-200 times faster than that of the traditional method, without any loss of its measurement accuracy     

基于主成分分析的光谱重建训练样本选择方法研究

训练样本构成是影响光谱重建精度的一个重要因素,针对学习型光谱重建算法中训练样本选择问题,提出了一种基于主成分分析的训练样本选择方法。为了保证训练样本与重建样本的相似度,首先根据欧式距离最小原则从待选样本集中选择与重建样本相机响应值相似的样本,并去掉其中的重复样本;然后进行主成分分析;设定阈值筛选各主成分系数较大的样本作为训练样本,最后得到与主成分个数相同的训练样本子集。为验证该方法的有效性,通过在镜头前加载宽带滤色片搭建多通道图像获取系统采集多通道图像信息,将得到的各样本子集用作训练样本,利用伪逆法重建光谱信息,最后将重建的光谱精度与常用的训练样本及训练样本选择方法得到的重建光谱精度进行比较。实验结果表明：提出的方法显著提高了光谱重建的色度精度和光谱精度,优于常用的样本选择方法,能较大程度满足高精度颜色复制要求。     

Determination of displacement distributions in bolted steel tension elements using digital image techniques

Digital imaging methods have found a great interest in various engineering fields to study stress-deformation characteristics of materials. Recent enhancements in visual instrumentation with the availability of cost-effective hardware and software products make the digital imaging techniques a viable tool to replace direct strain or displacement measurement methods in engineering applications. In this study, deformation characteristics of bolted steel connections are investigated by calculating in-plane displacement distributions using digital image correlation method (DIC). Validation of the method is presented by comparing the strains measured in standard tension specimens using electrical resistance strain gages and the DIC method. Finite element analysis of the connection specimen is also performed to compare the in-plane displacement distributions calculated from both methods. Results from the validation process indicate that the strains obtained from the DIC method compare well with the results of strain gages. The findings also indicate that the displacement distributions calculated from the finite element method may differ from those of the DIC method in terms of distribution pattern, and the location and magnitude of the extreme values of displacements. It is suggested that the proposed method can be used to determine the in-plane displacement distributions for the bolted connections, hence to evaluate their deformation characteristics under loading.     

Accuracy enhancement of digital image correlation with B-spline interpolation

The interpolation algorithm plays an essential role in the digital image correlation (DIC) technique for shape, deformation, and motion measurements with subpixel accuracies. At the present, little effort has been made to improve the interpolation methods used in DIC. In this Letter, a family of recursive interpolation schemes based on B-spline representation and its inverse gradient weighting version is employed to enhance the accuracy of DIC analysis. Theories are introduced, and simulation results are presented to illustrate the effectiveness of the method as compared with the common bicubic interpolation.     

Strain field estimation based on digital image correlation and radial basis function

Two methods based on digital image correlation (DIC) and radial basis function (RBF) were proposed to obtain the accurate strain field in this paper. One is a combined method. RBF was applied to remove the noisy discrete displacement data first. After that, the strain was computed by a local least-squares algorithm. The other is a partial derivative of RBF (PD-RBF) based strain estimation method which integrated denoising with differential process. The effectiveness and accuracy of the proposed methods were verified through two numerical simulation experiments. A practical application on the normal strain measurement of an aluminum alloy beam under symmetric four-point bending via an outer loading frame was also presented. The measurement results are in good accordance with the data obtained by strain gauges. Furthermore, a shape parameter selection method based on rate of convergence was suggested. The new method simplifies the choice of the good shape parameter.     

Digital image correlation using iterative least squares and pointwise least squares for displacement field and strain field measurements

Digital image correlation (DIC) method using iterative least squares algorithm (ILS) for displacement field measurement and pointwise least squares algorithm (PLS) for strain field measurement is proposed in this paper. A more general and practical intensity change model is employed with consideration of the linear intensity change of the deformed image, followed by an iterative least squares algorithm for calculating displacement field with sub-pixel accuracy. The concept of correlation function is not used in the ILS method, even though we prove that the algorithm is actually equivalent to the optimization of the sum of squared difference correlation function using improved Newton–Raphson method. Besides, different from the conventional strain estimation approaches based on smoothing the displacement fields first and followed by differentiation of the smoothed displacement fields, a simple yet effective PLS algorithm is proposed for extracting strain fields from the computed displacement fields. The effectiveness and accuracy of the proposed techniques is verified through numerical simulation experiments. A practical application of the algorithms to residual plastic deformation field measurement of GH4169 alloy subjected to tensile fatigue is also presented.     

Single-step scanner-based digital image correlation (SB-DIC) method for large deformation mapping in rubber

The incremental digital image correlation (DIC) method has been applied in the past to determine strain in large deformation materials like rubber. This method is, however, prone to cumulative errors since the total displacement is determined by combining the displacements in numerous stages of the deformation. In this work, a method of mapping large strains in rubber using DIC in a single-step without the need for a series of deformation images is proposed. The reference subsets were deformed using deformation factors obtained from the fitted mean stress-axial stretch ratio curve obtained experimentally and the theoretical Poisson function. The deformed reference subsets were then correlated with the deformed image after loading. The recently developed scanner-based digital image correlation (SB-DIC) method was applied on dumbbell rubber specimens to obtain the in-plane displacement fields up to 350% axial strain. Comparison of the mean axial strains determined from the single-step SB-DIC method with those from the incremental SB-DIC method showed an average difference of 4.7%. Two rectangular rubber specimens containing circular and square holes were deformed and analysed using the proposed method. The resultant strain maps from the single-step SB-DIC method were compared with the results of finite element modeling (FEM). The comparison shows that the proposed single-step SB-DIC method can be used to map the strain distribution accurately in large deformation materials like rubber at much shorter time compared to the incremental DIC method.     

Investigation of Portevin-Le Chatelier effect in 5456 Al-based alloy using digital image correlation

A variety of experimental methods have been proposed for Portevin-Le Chatelier (PLC) effect. They mainly focused on the in-plane deformation. In order to achieve the high-accuracy measurement, three-dimensional digital image correlation (3D-DIC) was employed in this work to investigate the PLC effect in 5456 Al-based alloy. The temporal and spatial evolutions of deformation in the full field of specimen surface were observed. The large deformation of localized necking was determined experimentally. The distributions of out-of-plane displacement over the loading procedure were also obtained. Furthermore, a comparison of measurement accuracy between two-dimensional digital image correlation (2D-DIC) and 3D-DIC was also performed. Due to the theoretical restriction, the measurement accuracy of 2D-DIC decreases with the increase of deformation. A maximum discrepancy of about 20% with 3D-DIC was observed in this work. Therefore, 3D-DIC is actually more essential for the high-accuracy investigation of PLC effect.     

数字图像相关中基于位移场局部最小二乘拟合的全场应变测量

为了从含噪声的位移场中计算得到可靠的应变场,提出一种基于位移场局部最小二乘拟合的全场应变求解方法。介绍了数字图像相关方法的原理,阐述了基于位移场局部最小二乘拟合的全场应变求解方法,并讨论了计算区域边界、孔洞及裂纹附近区域等情况下的应变计算。对均匀变形和中心带圆孔的薄铝板拉伸实验的计算结果表明,该方法能有效地从原始位移场数据中提取全场应变信息。在均匀变形情况下应选择大的应变计算窗口,计算结果更逼近真值;在非均匀变形情况下,如果位移场中包含较强的噪声,则应选择较大的应变计算窗口,而位移场精度很高时可选择更小的应变计算窗口。     

Digital image correlation for large deformation applied in Ti alloy compression and tension test

In this paper, digital speckle correlation is used in the measurement of Ti alloy compression and tension test. The key technologies applied in the measurement are discussed in detail, including camera calibration with telephoto lens and digital image correlation in large deformation. Single camera self-calibration algorithm based on photogrammetry is proposed. In the algorithm, the interior parameters of camera are estimated without calibrated object, using the bundle adjustment technique, so the 3-D coordinates of calibration target points are not needed in advance to get a reliable camera calibration result. An updating reference image scheme could be employed to deal with large deformation situation. A large deformation measurement scheme, updating reference image scheme, is proposed in this paper. The un-deformed image is used as reference in correlation at first. Only for extremely large deformation field, in which iteration of correlation is not convergent, the reference image is updated to the image of previous deformed stage. Using this method, not only extremely large deformation can be measured successfully but also the accumulated error could be controlled. The 75 mm lens is calibrated in the measurement and compared the result with extensometer and un-calibrated image. Experimental results show that up to 150% tensile deformation and 50% compression deformation can be measured successfully.     

Radial metrology application to whole-body measurement on hyperelastic tubular samples

This paper focuses on a one-camera/one-shot procedure able to get the whole deformation map of hyperelastic tubular samples. A challenging application of this approach is the investigation of the highly anisotropic and inhomogeneous arterial tissue mechanical response during inflation/extension tests. To address this issue, full field optical methods based on digital correlation (DIC), fringe projection (FP) and stereo-photogrammetry (SP) have been already proposed in literature to overcome limitations of the most widely adopted 2-D video dimension analyzer (VDA) systems.In this paper, the feasibility of a very straightforward full-field procedure that uses radial metrology concepts has been studied. The rationale behind the proposed method relies on the relation existing between image deformation of a world point reflected by a 45° concave conical mirror and the relative position of this point with respect to the specular surface. Under certain assumptions reasonably true for the application of interest, by using simple relationships, it is possible to retrieve the position of markers applied onto the sample surface with great precision. This procedure has several advantages such as the retrieval of the whole 360° surface map in one shot, the ease of application, the use of one single camera, the real-time measurement capability. Conversely, the proposed approach is suitable only for geometries with smooth transversal sections, needs sample preparation and its spatial resolution is limited by the sparsity of the surface control points.The paper describes first the theoretical basis of the procedure; then results of experimental tests on calibration samples and latex tubular specimens are presented and discussed. Further set-up improvements will allow the present procedure to be implemented for in-vitro inflation/extension tests on vascular segments.     

Digital Photography in Measuring the Inclination of the Object Surface with Formation of a Speckle Structure

Optical schemes for measuring surface inclination due to shift or deformation are considered. Speckle-interferometry methods are used. The distinguished features of these schemes are connected with using a digital photocamera and a forming speckle structure in nonmonochromatic light. Several technical solutions are proposed making it possibile to measure inclination with an accuracy up to tenths of degree using standard cheap equipment. To form the speckle structure, the pattern of a random binary structure with unit size of several millimeters is used in the base fixed plane. The digital camera was placed in the analyzed plane and turned together with the plane. It registered a reduced image of the pattern. The registration was done for two positions of the surface, the pattern being illuminated by the camera flash lamp. Measuring the width and orientation of the interference fringes formed for the two speckle structures allows one to determine the inclination and orientation of the rotation axis.     

A novel optimization method of camera parameters used for vision measurement

Camera calibration plays an important role in the field of machine vision applications. During the process of camera calibration, nonlinear optimization technique is crucial to obtain the best performance of camera parameters. Currently, the existing optimization method aims at minimizing the distance error between the detected image point and the calculated back-projected image point, based on 2D image pixels coordinate. However, the vision measurement process is conducted in 3D space while the optimization method generally adopted is carried out in 2D image plane. Moreover, the error criterion with respect to optimization and measurement is different. In other words, the equal pixel distance error in 2D image plane leads to diverse 3D metric distance error at different position before the camera. All the reasons mentioned above will cause accuracy decrease for 3D vision measurement. To solve the problem, a novel optimization method of camera parameters used for vision measurement is proposed. The presented method is devoted to minimizing the metric distance error between the calculated point and the real point in 3D measurement coordinate system. Comparatively, the initial camera parameters acquired through linear calibration are optimized through two different methods: one is the conventional method and the other is the novel method presented by this paper. Also, the calibration accuracy and measurement accuracy of the parameters obtained by the two methods are thoroughly analyzed and the choice of a suitable accuracy evaluation method is discussed. Simulative and real experiments to estimate the performance of the proposed method on test data are reported, and the results show that the proposed 3D optimization method is quite efficient to improve measurement accuracy compared with traditional method. It can meet the practical requirement of high precision in 3D vision metrology engineering.     

High-efficiency and high-accuracy digital image correlation for three-dimensional measurement

The computational efficiency and measurement accuracy of the digital image correlation (DIC) have become more and more important in recent years. For the three-dimensional DIC (3D-DIC), these issues are much more serious. First, there are two cameras employed which increases the computational amount several times. Second, because of the differences in view angles, the must-do stereo correspondence between the left and right images is equivalently a non-uniform deformation, and cannot be weakened by increasing the sampling frequency of digital cameras. This work mainly focuses on the efficiency and accuracy of 3D-DIC. The inverse compositional Gauss–Newton algorithm (IC-GN²) with the second-order shape function is firstly proposed. Because it contains the second-order displacement gradient terms, the measurement accuracy for the non-uniform deformation thus can be improved significantly, which is typically one order higher than the first-order shape function combined with the IC-GN algorithm (IC-GN¹), and 2 times faster than the second-order shape function combined with the forward additive Gauss–Newton algorithm (FA-GN²). Then, based on the features of the IC-GN¹ and IC-GN² algorithms, a high-efficiency and high-accuracy measurement strategy for 3D-DIC is proposed in the end.     

飞行试验中军用1553B总线的实时采集技术

针对飞行试验中飞机结构件的动态变形测量问题,提出了一种基于图像的测量方法,对其中涉及的关键技术进行了研究。采用10参数模型非线性成像模型补偿摄像机系统误差,引入摄像机动态校准算法,使摄像机标校重投影误差小于0.03pixel;采用编码标志作为测量标志,提高了图像自动识别和匹配效率;采用双像机交会测量计算测量标志位移变形量可达到0.15mm/1m。实验证明,该方法满足飞行试验中飞机结构件动态变形要求。     

Single-lens 3D digital image correlation system based on a bilateral telecentric lens and a bi-prism: Systematic error analysis and correction

Recently, we proposed a single-lens 3D digital image correlation (3D DIC) method and established a measurement system on the basis of a bilateral telecentric lens (BTL) and a bi-prism. This system can retrieve the 3D morphology of a target and measure its deformation using a single BTL with relatively high accuracy. Nevertheless, the system still suffers from systematic errors caused by manufacturing deficiency of the bi-prism and distortion of the BTL. In this study, in-depth evaluations of these errors and their effects on the measurement results are performed experimentally. The bi-prism deficiency and the BTL distortion are characterized by two in-plane rotation angles and several distortion coefficients, respectively. These values are obtained from a calibration process using a chessboard placed into the field of view of the system; this process is conducted after the measurement of tested specimen. A modified mathematical model is proposed, which takes these systematic errors into account and corrects them during 3D reconstruction. Experiments on retrieving the 3D positions of the chessboard grid corners and the morphology of a ceramic plate specimen are performed. The results of the experiments reveal that ignoring the bi-prism deficiency will induce attitude error to the retrieved morphology, and the BTL distortion can lead to its pseudo out-of-plane deformation. Correcting these problems can further improve the measurement accuracy of the bi-prism-based single-lens 3D DIC system.     

Dynamic deformation image de-blurring and image processing for digital imaging correlation measurement

This paper proposes a method for de-blurring of images captured in the dynamic deformation of materials. De-blurring is achieved based on the dynamic-based approach, which is used to estimate the Point Spread Function (PSF) during the camera exposure window. The deconvolution process involving iterative matrix calculations of pixels, is then performed on the GPU to decrease the time cost. Compared to the Gauss method and the Lucy–Richardson method, it has the best result of the image restoration. The proposed method has been evaluated by using the Hopkinson bar loading system. In comparison to the blurry image, the proposed method has successfully restored the image. It is also demonstrated from image processing applications that the de-blurring method can improve the accuracy and the stability of the digital imaging correlation measurement.     

A comparison of DIC and grid measurements for processing spalling tests with the VFM and an 80-kpixel ultra-high speed camera

During the last decades, the spalling technique has been more and more used to characterize the tensile strength of geomaterials at high-strain-rates. In 2012, a new processing technique was proposed by Pierron and Forquin [1] to measure the stress level and apparent Young’s modulus in a concrete sample by means of an ultra-high speed camera, a grid bonded onto the sample and the Virtual Fields Method. However the possible benefit to use the DIC (Digital Image Correlation) technique instead of the grid method has not been investigated. In the present work, spalling experiments were performed on two aluminum alloy samples with HPV1 (Shimadzu) ultra-high speed camera providing 1?Mfps maximum recording frequency and about 80?kpixel spatial resolution. A grid with 1?mm pitch was bonded onto the first sample whereas a speckle pattern was covering the second sample for DIC measurements. Both methods were evaluated in terms of displacement and acceleration measurements by comparing the experimental data to laser interferometer measurements. In addition, the stress and strain levels in a given cross-section were compared to the experimental data provided by a strain gage glued on each sample. The measurements allow discussing the benefit of each (grid and DIC) technique to obtain the stress-strain relationship in the case of using an 80-kpixel ultra-high speed camera.