A thermodynamics based damage mechanics constitutive model for low cycle fatigue analysis of microelectronics solder joints incorporating size effects

Below certain length scales and in the presence of a non-uniform plastic strain field the mechanical behavior of many metals and its alloys is substantially different from that in bulk specimens. In particular, an increase in resistance with decreasing size has been observed in Pb/Sn eutectic solder alloys which are extensively used in microelectronics packaging interconnects. Due to the high homologous temperature, the Pb/Sn solder exhibits creep–fatigue interaction and significant time, temperature, stress and rate dependent material characteristics. The simultaneous consideration of all the above mentioned factors makes constitutive modeling an extremely difficult task. In this paper, a viscoplastic constitutive model unified with a thermodynamics based damage evolution model is embedded into a couple stress framework in order to simulate low cycle fatigue response coupled to size effects. The model is implemented into commercial finite element code ABAQUS. The microbending experiment on thin nickel foils is used to validate the model. Analyses are performed on a thin layer solder joint in bending under cyclic loading conditions.     

锡铅钎料粘塑性行为及其本构描述

随着航天事业的发展，航天电子产品使用环境变得越来越复杂苛刻，对焊点可靠性要求日益提高，因此，研究焊点材料服役环境下的本构关系对于分析焊点性能、准确预测焊点可靠性具有重要意义．本文分析锡铅钎料Sn63Pb37在-45~150 ℃温度范围内和10-5~10-3/s应变率范围内的粘塑性行为，在此基础上，建立了修正的Anand本构模型．通过构建材料参数与温度的函数关系，提升Anand本构模型在不同环境温度尤其是低温环境下对材料应力-应变关系的预测能力，为航天电子产品可靠性设计提供技术支撑．     

跌落冲击载荷下焊锡接点金属间化合物层的动态开裂

跌落冲击载荷作用下,含铅焊锡接点与无铅焊锡接点的破坏模式明显不同,而导致这种差异的原因目前尚不明朗。本文提出了一种可用于模拟焊锡接点在跌落冲击载荷下破坏行为的有限元模型,此模型中,金属间化合物（IMC）与焊料间的界面采用粘性区模型（CZM）来模拟其损伤开裂过程,而IMC层内的破坏程度则通过计算其能量释放率来判断。通过对板级封装跌落冲击过程的数值模拟发现,与无铅焊锡接点（Sn3.5Ag）相比,含铅焊锡接点（Sn37Pb）与IMC间的CZM层更容易发生损伤破坏,而该层的开裂会减小IMC层的应力,即降低了其内部的裂纹驱动力,从而缓解了IMC层裂纹的起始和扩展。     

Integrated numerical–experimental analysis of interfacial fatigue fracture in SnAgCu solder joints

In ball grid array (BGA) packages, solder balls are exposed to cyclic thermo-mechanical strains arising from the thermal mismatch between package components. Thermo-mechanical fatigue crack propagation in solder balls is almost always observed at the chip side of the bump/pad junction. The objective of the experimental part of this study is to characterize the bump/pad interface under fatigue loading. Fatigue specimens are prepared by reflowing Sn3.8Ag0.5Cu lead-free solder alloy on Ni/Au substrates. Obtained results show that fatigue damage evolution strongly depends on the microstructure. Applied strain and solder volume both have an influence on the fatigue damage mechanism. In the numerical part of the study, fatigue experiments are modeled using the finite element technique. A cohesive zone approach is used to predict the fatigue damage evolution in soldered connections. Crack propagation is simulated by an irreversible linear traction–separation cohesive zone law accompanied by a non-linear damage parameter. Cohesive zone elements are placed where failure is experimentally observed. Damage evolution parameters for normal and tangential interaction are scrutinized through dedicated fatigue tests in pure tensile and shear directions. The proposed cohesive zone model is quantitatively capable of describing fatigue failure in soldered joints, which can be further extended to a numerical life-time prediction tool in microelectronic packages.     

温度循环应力剖面对QFP焊点热疲劳寿命的影响

采用统一型粘塑性Anand本构方程描述了QFP(四方扁平封装)焊点的粘塑性力学行为,利用有限元分析软件建立组装在印制电路板上QFP的有限元模型,通过研究焊点内部总应变范围的变化进而研究温度循环应力剖面各个参数对焊点热疲劳寿命的影响,为设计合理的温度循环应力剖面提供了理论依据。     

SnPb钎料合金的粘塑性Anand本构方程

采用统一型粘塑性本构 Anand方程描述了电子封装焊点 Sn Pb钎料合金的非弹性变形行为 ,基于 Sn Pb 合金的弹塑性蠕变本构方程和实验数据 ,确定了6 2 Sn36 Pb2 Ag、6 0 Sn40 Pb、96 .5 Sn3.5 Ag和 97.5 Pb2 .5 Sn四种钎料合金 Anand方程的材料参数 ,验证了粘塑性 Anand本构方程对 Sn Pb合金在恒应变速率和稳态塑性流动条件下应力应变行为的预测能力。结果表明 ,Anand方程能有效描述 Sn Pb钎料的粘塑性本构行为 ,并可应用于电子封装 Sn Pb焊点的可靠性模拟和失效分析     

A thermo-viscoelastic–viscoplastic–viscodamage constitutive model for asphaltic materials

A temperature-dependent viscodamage model is proposed and coupled to the temperature-dependent Schapery’s nonlinear viscoelasticity and the temperature-dependent Perzyna’s viscoplasticity constitutive model presented in Abu Al-Rub et al., 2009, Huang et al., in press in order to model the nonlinear constitutive behavior of asphalt mixes. The thermo-viscodamage model is formulated to be a function of temperature, total effective strain, and the damage driving force which is expressed in terms of the stress invariants of the effective stress in the undamaged configuration. This expression for the damage force allows for the distinction between the influence of compression and extension loading conditions on damage nucleation and growth. A systematic procedure for obtaining the thermo-viscodamage model parameters using creep test data at different stress levels and different temperatures is presented. The recursive-iterative and radial return algorithms are used for the numerical implementation of the nonlinear viscoelasticity and viscoplasticity models, respectively, whereas the viscodamage model is implemented using the effective (undamaged) configuration concept. Numerical algorithms are implemented in the well-known finite element code Abaqus via the user material subroutine UMAT. The model is then calibrated and verified by comparing the model predictions with experimental data that include creep-recovery, creep, and uniaxial constant strain rate tests over a range of temperatures, stress levels, and strain rates. It is shown that the presented constitutive model is capable of predicting the nonlinear behavior of asphaltic mixes under different loading conditions.     

Fatigue damage modeling in solder interconnects using a cohesive zone approach

The objective of this work is to model the fatigue damage process in a solder bump subjected to cyclic loading conditions. Fatigue damage is simulated using the cohesive zone methodology. Damage is assumed to occur at interfaces modeled through cohesive zones in the material, while the bulk material is assumed to be linear elastic. The state of damage at a cohesive zone is incorporated into the cohesive zone constitutive law by a elasticity-based damage variable. The gradual degradation of the solder material and the corresponding damage accumulation throughout the cycling process is accounted for by a damage evolution law which captures the main damage characteristics. The model prediction of the solder bump life-time is shown to be in good agreement with one of the commonly used empirical life-time prediction laws.     

Uniaxial ratcheting and fatigue failure of tempered 42CrMo steel: Damage evolution and damage-coupled visco-plastic constitutive model

Uniaxial ratcheting and fatigue failure of tempered 42CrMo steel were observed by the tests under the uniaxial stress-controlled cyclic loading with non-zero mean stress [G.Z. Kang, Y.J. Liu, Mater. Sci. Eng. A 472 (2008) 258–268]. Based on the obtained experimental results, the evolution features of whole-life ratcheting behavior and low-cycle fatigue (LCF) damage of the material were discussed first. Then, in the framework of unified visco-plasticity and continuum damage mechanics, a damage-coupled visco-plastic cyclic constitutive model was proposed to simulate the whole-life ratcheting and predict the fatigue failure life of the material presented in the uniaxial stress cycling with non-zero mean stress. In the proposed model, the damage was divided into two parts, i.e., elastic damage and plastic damage, which were described by the evolution equations with the same form but different constants, since the maximum applied stresses in most of loading cases were lower than the nominal yielding strength of the material. The ratcheting of the material was still described by employing a nonlinear kinematic hardening rule based on the Abdel-Karim–Ohno combined kinematic hardening model [M. Abdel Karim, N. Ohno, Int. J. Plast. 16 (2000) 225–240] but extended by considering the effect of damage. The maximum strain criterion combined with an elastic damage threshold was employed to determine the failure life of the material caused by two different failure modes, i.e., fatigue failure (caused by low-cycle fatigue due to plastic shakedown) and ductile failure (caused by large ratcheting strain). The simulated whole-life ratcheting behavior and predicted failure life of tempered 42CrMo steel are in a fairly good agreement with the experimental ones.     

Dynamic damage constitutive relation of mesoscopic heterogenous brittle rock under rotation of principal stress axes

A micro-mechanics-based model is developed to investigate microcrack damage mechanism of four stages of brittle rock under rotation of the principal stress axes. They consist of linear elastic, non-linear hardening, rapid stress drop and strain softening. The frictional sliding crack model is applied to analyze microcracks nucleation, propagation and coalescence. The strain energy density factor approach is applied to determine the critical condition of microcrack nucleation, propagation and coalescence. The inelastic strain increments are formulated within the framework of thermodynamics with internal variables. Rotation of principal stress axes affect the dynamic damage constitutive relationship and the failure strength of brittle rock.     

96.5Sn-3.5Ag钎料合金的时相关单轴应变循环变形行为及其本构关系研究

在室温下对96.5Sn-3.5Ag钎料合金进行了不同加载波形下的单轴应变循环实验。研究了在具有不同保持时间、不同应变率、不同应变幅值及其历史对材料的循环变形行为的影响。基于材料时相关变形行为,提出了统一粘塑性本构模型,并对该材料的变形行为进行本构模拟。实验结果表明:该钎料合金单轴变形行为具有应变率、保持时间以及应变幅值依赖性。本构关系的预言结果与实验结果吻合得一致性说明该种模型能够很好地描述材料的单轴应变循环变形行为。     

Prediction of fatigue life improvement in natural rubber using configurational stress

To some extent, continua can no longer be considered as free of defects. Experimental observations on natural rubber revealed the existence of distributed microscopic defects which grow upon cyclic loading. However, these observations are not incorporated in the classical fatigue life predictors for rubber, i.e. the maximum principal stretch, the maximum principal stress and the strain energy. Recently, Verron et al. [Verron, E., Le Cam, J.B., Gornet, L., 2006. A multiaxial criterion for crack nucleation in rubber. Mech. Res. Commun. 33, 493–498] considered the configurational stress tensor to propose a fatigue life predictor for rubber which takes into account the presence of microscopic defects by considering that macroscopic crack nucleation can be seen as the result of the propagation of microscopic defects. For elastic materials, it predicts privileged regions of rubber parts in which macroscopic fatigue crack might appear. Here, we will address our interest to a broader context. Rubber is assumed to exhibit inelastic behavior, characterized by hysteresis, under fatigue loading conditions. The configurational mechanics-based predictor is modified to incorporate inelastic constitutive equations. Afterwards, it is used to predict fatigue life. The emphasis of the present work is laid on the prediction of the well-known fatigue life improvement in natural rubber under tension–tension cyclic loading.     

混凝土的弹塑性损伤双面本构模型

针对混凝土材料拉压应变空间下损伤机制的不同,结合连续损伤力学和塑性理论建立了一个全新的本构模型。该模型中损伤和塑性变形的演变由应变空间的同一个非弹性曲面来控制,但对拉压应变空间中非弹性曲面的演变分别采用了随动强化法则和各向同性演化规律。计算结果表明,该模型能较好地描述混凝土材料在单轴及多轴单调加载和低周反复荷载下的典型非线性特征。     

An application of a damage constitutive model to concrete at high temperature and prediction of spalling

A characteristic feature of concrete under uniaxial compression is the development of cracks parallel to the loading direction. A damage constitutive model proposed by Ortiz [Ortiz, M., 1985. A constitutive theory for the inelastic behaviour of concrete. Mech. Mater. 4, 67–93] can predict the transverse tensile stress responsible for these cracks by considering the interaction between the aggregate and the mortar and the development of damage in the latter. When concrete is exposed to high temperature, as is the case during fire, the failure mode is thermal spalling. In order to improve the prediction of the stresses involved in this failure Ortiz’s model is extended to account for the effects of high temperature. Published experimental results for uniaxial and biaxial compression at high temperatures are used to calibrate the temperature dependence of some of the material properties. The transient creep strain is accounted for by modifying the constrained thermal strain. The stress analysis is coupled with hygro-thermal analysis of heat, mass transfer and pore pressure build-up. The effect of pore pressure on the damage evolution is modeled by applying a body force in the stress analysis module proportional to the pressure gradient. A numerical example of concrete under fire is solved and the computed results are discussed. Spalling is predicted when the damage variable reaches its maximum value of unity. The predicted depth and time of spalling for a range of variation of permeability and initial liquid water content are presented. They are in good agreement with published experimental results.     

Stochastic damage model for concrete based on energy equivalent strain

Starting with the framework of conventional elastoplastic damage mechanics, a class of stochastic damage constitutive model is derived based on the concept of energy equivalent strain. The stochastic damage model derived from the parallel element model is adopted to develop the uniaxial damage evolution function. Based on the expressions of damage energy release rates (DERRs) conjugated to the damage variables thermodynamically, the concept and its tensor formulations of energy equivalent strain is proposed to bridge the gap between the uniaxial and the multiaxial constitutive models. Furthermore, a simplified coupling model is proposed to consider the evolution of plastic strain. And the analytical expressions of the constitutive model in 2-D are established from the abstract tensor expression. Several numerical simulations are presented against the biaxial loading test results of concrete, demonstrating that the proposed models can reflect the salient features for concrete under uniaxial and biaxial loading conditions.     

63Sn-37Pb钎料合金在非比例循环加载下的非弹性流动特性研究

基于63Sn-37Pb钎料舍金在多种非比例应变循环加载下的实验结果,通过考察材料的非弹性应变率与偏应力之间的夹角随累积非弹性应变的变化规律,对63Sn-37Pb钎料合金的非弹性流动特性进行了定量分析。分析结果显示：在相同的非比例加载路径下,当加载等效应变幅值相同时,等效应变率越高,非弹性应变率与偏应力之间夹角平均水平越低,当等效应变率相同时,等效应变幅值越大,相应的夹角平均水平越低;在保持时间范围内,非弹性应变率方向与偏应力方向趋于一致;当非比例路径形状不同时,其非弹性应变率与偏应力之间的夹角随累积非弹性应变的变化趋势明显不同。研究表明,材料的非弹性流动特性强烈依赖于等效应变幅值、等效应变率、保持时间、非比例路径形状。     

A new distortion energy-based equivalent stress for multiaxial fatigue life prediction

A new equivalent stress amplitude expression has been developed for the assessment of fatigue life in components under multiaxial loading. The expression was generated by incorporating non-linear/plastic stress–strain relation into a mechanical energy calculation, and then applying the calculation to the distortion energy theory for a cyclic loading case. Therefore, the new uniaxial equivalent stress expression determines an appropriate stress amplitude value for multiaxial cyclic loading. The purpose of the equivalent stress value is to determine multiaxial fatigue failure using an energy-based fatigue life prediction criterion. The governing understanding behind the criterion states that the physical damage quantity for failure is equal to the accumulated strain energy in a monotonic fracture, which is also equal to the accumulated strain energy during fatigue failure. Using the new equivalent stress amplitude expression and the energy-based life prediction method, a comparison is made between prediction results and multiaxial empirical data. The multiaxial data was acquired by a vibration-based biaxial bending fatigue test and a torsion fatigue test with an assumed axial misalignment. The results of the comparison provide encouragement regarding the capability of the newly developed equivalent stress amplitude expression for fatigue life prediction.     

A rate-dependent damage model for brittle materials based on the dominant crack

A rate-dependent, continuum damage model is developed for brittle materials under dynamic loading. This model improves on the approach (ISOSCM) of [Addessio, F.L., Johnson, J.N., 1990. A constitutive model for the dynamic response of brittle materials. Journal of Applied Physics 67, 3275–3286] in several respects. (1) A new damage surface is found by applying the generalized Griffith instability criterion to the dominant crack (having the most unstable orientation), rather than by averaging the instability condition over all crack orientations as done previously. The new surface removes a discontinuity in the damage surface in ISOSCM when the pressure changes sign. (2) The strain due to crack opening is more consistent with crack mechanics, with only the tensile principal stresses contributing to the crack opening strain. This is achieved by incorporating a projection operator in the equation for the crack opening strain. One consequence of incorporating the projection operator is a prediction of shear dilatancy, which is not accounted for in ISOSCM. (3) The evolution of damage, which is based on the energy-release rate for the dominant crack, has a physical basis, whereas in the previous approach the damage growth rate was assumed to be an exponential function of the distance from the stress state to the damage surface without specific physical justification.An implicit algorithm has been developed so that a larger time step can be used than with the explicit algorithm used in ISOSCM. The numerical results of a silicon carbide (SiC) ceramic under several loading paths (hydrostatic tension/compression, uniaxial strain, uniaxial stress, and shear) and strain rates are presented to illustrate the main features of the model.     

用云纹干涉法研究金属焊点的热变形问题

本文采用现代光测力学的云纹干涉法，对铜－可伐焊接件热应变问题进行了实验研究，确定了焊层的热应变特征，结果表明：由于热膨胀系数不匹配、焊层存在复杂的应力状态，它不仅受到焊板材料对它的剪切作用，而且受到纵向拉伸、挤压作用。这对于认识微电子封装芯片焊层的热疲劳失效机理有重要意义     

Nanoindentation of Pb/Sn solder alloys; experimental and finite element simulation results

A thermodynamics based damage mechanics coupled constitutive model is used to simulate the nanoindentation experiment on eutectic commercial Pb/Sn solder alloys. The study is aimed at explaining the apparent size dependent behavior observed at small indentation depths for this class of highly rate dependent materials. Interest is at small depths of indentation and a small-strains small-displacements theory is used. The study is motivated by the fact, that in the case of rate independent materials such a size dependence of the response is explained in terms of storage of the so-called geometrically necessary dislocations. Presently it is not clear if this is the source of size effects in a rate dependent material. Moreover, the storage of dislocations is difficult in eutectic solder alloys due to thermally activated diffusion processes that promote dislocation mobilization as opposed to storage. Therefore, a classical theory constitutive model should be able to capture such a size dependent feature of the response. The paper describes the constitutive model and its integration scheme. Simulations of the nanoindentation problem are performed at different temperatures and indentation strain rates and numerical results are compared with experiments.