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Book Chapter
Book: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780131
EISBN: 978-1-62708-268-6
... Abstract Leaks can occur as the result of several failure causes. This chapter reviews the causes, features, and impact of various types of leaks, namely gasket leaks, O-ring leaks, bond-joint leaks, weld leaks, polyvinyl chloride leaks, valve leaks, and structural leaks. bond-joint leaks...
Book Chapter
Book: Principles of Brazing
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.pb.t51230207
EISBN: 978-1-62708-351-5
... Brazing Technique for Aluminum and Other Metals , Weld. J. Res. Suppl. , Vol 73 ( No. 6 ), p 119s – 128s • Tuah-Poku I. , Dollar M. , and Massalski T.B. , 1988 . A Study of the Transient Liquid Phase Bonding Process Applied to a Ag/Cu/Ag Sandwich Joint , Metall. Trans...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290001
EISBN: 978-1-62708-306-5
...-bonded structure. However, since high-strength adhesives are typically weak in peel, the lap joint should be loaded in shear. To effectively transfer loads through the adhesive, the substrates (or adherends) are overlapped so that the adhesive is loaded in shear. Typical adhesive-bonded joint designs...
Abstract
Joining comprises a large number of processes used to assemble individual parts into a larger, more complex component or assembly. The selection of an appropriate design to join parts is based on several considerations related to both the product and the joining process. Many product design departments now improve the ease with which products are assembled by using design for assembly (DFA) techniques, which seek to ensure ease of assembly by developing designs that are easy to assemble. This chapter discusses the general guidelines for DFA and concurrent engineering rules before examining the various joining processes, namely fusion welding, solid-state welding, brazing, soldering, mechanical fastening, and adhesive bonding. In addition, it provides information on several design considerations related to the joining process and selection of the appropriate process for joining.
Book Chapter
Book: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780109
EISBN: 978-1-62708-268-6
... actions should include appropriate cure-time specifications and monitoring. If all dimensions are in conformance and the bond joint fails, the bond design may be inadequate. The failure analysis team should consider checking with the epoxy manufacturer to identify recommended bond dimensions...
Abstract
This chapter focuses on common failure characteristics exhibited by mechanical and electrical components. The topic is considered from two perspectives: one possibility is that the system failed because parts were nonconforming to drawing requirements and another possibility is that the system failed even though all parts in the system met their drawing requirements. The common failures discussed in this chapter include those associated with metallic components, composite materials, plastic components, ceramic components, and electrical and electronic components.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 April 2013
DOI: 10.31399/asm.tb.imub.t53720411
EISBN: 978-1-62708-305-8
... metals and the types of flaws exhibited by brazed joints. brazed joints brazing filler metals eddy current inspection liquid penetrant inspection magnetic particle inspection nondestructive inspection radiographic inspection ultrasonic inspection visual inspection welding weldments...
Abstract
Weldments made by the various welding processes may contain discontinuities that are characteristic of that process. This chapter discusses the different welding processes as well as the discontinuities typical of each process. It provides a detailed discussion on the methods of nondestructive inspection of weldments including visual inspection, liquid penetrant inspection, magnetic particle inspection, radiographic inspection, ultrasonic inspection, leak testing, and eddy current and electric current perturbation inspection. The chapter also describes the properties of brazing filler metals and the types of flaws exhibited by brazed joints.
Book: Principles of Soldering
Series: ASM Technical Books
Publisher: ASM International
Published: 01 April 2004
DOI: 10.31399/asm.tb.ps.t62440145
EISBN: 978-1-62708-352-2
... 278 – 290 • Dogra K.S. , 1985 . A Bismuth Tin Alloy for Hermetic Seals , Brazing Soldering , Vol 9 (No. 3 ), p 28 – 30 • Dunford D.V. and Partridge P.G. , 1990 . Strength and Fracture Behavior of Diffusion-Bonded Joints in Al-Li (8090) Alloy. Part 1: Shear...
Abstract
This chapter considers the materials and processing aspects of soldering and the manner in which these interrelate in the development of joining processes. It discusses the processes involved in eliminating or suppressing metallurgical and mechanical constraints as well as constraints imposed by the components.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290279
EISBN: 978-1-62708-306-5
... of these methods are covered. The factors influencing joint integrity and the main considerations in welding dissimilar metal combinations are also discussed. adhesive bonding brazing ceramics dissimilar metal welding mechanical fastening plastics welding A NUMBER OF materials and material...
Abstract
This chapter reviews materials issues encountered in joining, including challenges involved in welding of dissimilar metal combinations; joining of plastics by mechanical fastening, solvent and adhesive bonding, and welding; joining of thermoset and thermoplastic composite materials by mechanical fastening, adhesive bonding, and, for thermoplastic composites, welding; the making of glass-to-metal seals; and joining of oxide and nonoxide ceramics to themselves and to metals by solid-state processes and by brazing. The classification, types, applications, and the mechanism of each of these methods are covered. The factors influencing joint integrity and the main considerations in welding dissimilar metal combinations are also discussed.
Book Chapter
Book: Principles of Soldering
Series: ASM Technical Books
Publisher: ASM International
Published: 01 April 2004
DOI: 10.31399/asm.tb.ps.t62440001
EISBN: 978-1-62708-352-2
... slide, sputter metallized with 0.1 μm (4 μin.) of chromium overlaid with 0.1 μm (4 μin.) of gold. Spread ratio is defined in Appendix A1.2 . Fig. 1.5 The strength of pressure-welded joints as a function of the deformation induced during the bonding process. Below the threshold deformation...
Abstract
Soldering and brazing represent one of several types of methods for joining solid materials. These methods may be classified as mechanical fastening, adhesive bonding, soldering and brazing, welding, and solid-state joining. This chapter summarizes the principal characteristics of these joining methods. It presents a comparison between solders and brazes. Further details on pressure welding and diffusion bonding are also provided. Key parameters of soldering are discussed, including surface energy and surface tension, wetting and contact angle, fluid flow, filler spreading characteristics, surface roughness of components, dissolution of parent materials and intermetallic growth, significance of the joint gap, and the strength of metals. The chapter also examines the principal aspects related to the design and application of soldering processes.
Book Chapter
Book: Principles of Brazing
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.pb.t51230001
EISBN: 978-1-62708-351-5
... Fig. 1.9 Superplastic forming and diffusion bonding of titanium. (a) Schematic of the steps involved. (b) Typical three-sheet titanium alloy component formed superplastically and diffusion bonded. (c) Cross section through a diffusion-bonded joint in titanium alloy, made at 980 °C (1795 °F) for 2 h...
Abstract
Brazing and soldering jointly represent one of several methods for joining solid materials. This chapter summarizes the principal characteristics of the various joining methods. It then discusses key parameters of brazing including surface energy and tension, wetting and contact angle, fluid flow, filler spreading characteristics, surface roughness of components, dissolution of parent materials, new phase formations, significance of the joint gap, and the strength of metals. The chapter also describes issues in processing aspects that must be considered when designing a joint, and the health, safety, and environmental aspects of brazing.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2011
DOI: 10.31399/asm.tb.jub.t53290243
EISBN: 978-1-62708-306-5
... information on the theory of adhesion. The chapter then describes the considerations for designing adhesively bonded joints and for testing or characterizing adhesive materials. The following section covers the characteristics of the most important synthetic adhesive systems and five groups of adhesives...
Abstract
Adhesive bonding is a widely used industrial joining process in which a polymeric material is used to join two separate pieces (the adherends or substrates). This chapter begins with a discussion on the advantages and disadvantages of adhesive bonding, followed by a section providing information on the theory of adhesion. The chapter then describes the considerations for designing adhesively bonded joints and for testing or characterizing adhesive materials. The following section covers the characteristics of the most important synthetic adhesive systems and five groups of adhesives, namely structural, hot melt, pressure sensitive, water based, and ultraviolet and electron beam cured. The chapter ends with a discussion on some general guidelines for adhesive bonding and the basic steps in the adhesive bonding process.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870255
EISBN: 978-1-62708-314-0
... joints and assemblies are normally nondestructively inspected after all bonding operations are completed. Radiographic and ultrasonic inspection methods are typically used to look for defects in both the bondlines and the honeycomb core portions of the assemblies. In addition, it is common practice...
Abstract
This chapter discusses the advantages and disadvantages of sandwich and integral cocured structures, and the methods by which they are made. It begins by explaining where and how sandwich construction is used and why it is so efficient. It then describes the design and fabrication of honeycomb panels and foam cores along with their respective applications and unique attributes. The chapter also discusses the cocuring process and its use in fabricating unitized structures.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.pb.9781627083515
EISBN: 978-1-62708-351-5
Series: ASM Technical Books
Publisher: ASM International
Published: 01 April 2004
DOI: 10.31399/asm.tb.ps.9781627083522
EISBN: 978-1-62708-352-2
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870235
EISBN: 978-1-62708-314-0
... to other cured composites, honeycomb core, foam core, or metallic pieces. A number of possible adhesive bonding joint configurations are shown in Fig. 8.1 . The ability to make large bonded structures can eliminate a significant amount of the assembly costs. In addition to fabricating large bonded...
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2002
DOI: 10.31399/asm.tb.stg2.t61280149
EISBN: 978-1-62708-267-9
... bond/joint between/among the respective components. However, it introduces a cast structure of variable size and properties that depends on the metals being welded and the precise welding technique used. Solid-state welding creates the same result as fusion welding, without producing the formerly...
Abstract
Superalloys, except those with high aluminum and titanium contents, are welded with little difficulty. They can also be successfully brazed. This chapter describes the welding and brazing processes most often used and the factors that must be considered when making application decisions. It discusses the basic concepts of fusion welding and the differences between solid-solution-hardened and precipitation-hardened wrought superalloys. It addresses joint integrity, design, weld-related cracking, and the effect of grain size, precipitates, and contaminants. It covers common fusion welding techniques, defect prevention, fixturing, heat treatments, and general practices, including the use of filler metals. It also discusses several solid-state welding methods, superplastic forming, and transient liquid phase bonding, a type of diffusion welding process. The chapter includes extensive information on brazing processes, atmospheres, filler metals, and surface preparation procedures. It also includes examples of nickel-base welded components for aerospace use.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870101
EISBN: 978-1-62708-314-0
.... Electroformed nickel tools can be repaired by soldering or brazing; however, this is generally more difficult than the weld repair of a steel or Invar tool. The lead in some repair solders can react with the nickel, causing joint cracking and leaks. If a superior surface hardness is required, the tool surface...
Abstract
This chapter discusses the tooling used for autoclave curing, one of the most common composite fabrication processes. The discussion covers curing practices, material selection factors, and design challenges associated with thermal expansion, tool shrinkage, part complexity, and heating and cooling rates. The chapter also includes best practices and recommendations for toolmaking and assembly.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2015
DOI: 10.31399/asm.tb.piht2.t55050293
EISBN: 978-1-62708-311-9
... have flexure, particularly at soldered joints that have abrupt changes in direction of the cooling water. This can ultimately cause the coil to fatigue and break. Also, some coils can have localized current concentrations, which can cause the coils to overheat and fail. Coils usually fail at a stress...
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2019
DOI: 10.31399/asm.tb.mfadr7.t91110563
EISBN: 978-1-62708-247-1
... in the marketplace recently. These technologies—wafer bonding, stacked dies, TSV (through-silicon vias), wafer-level packaging, multi-chip modules, etc.— have all helped drive down the costs of MEMS, solve major reliability problems, improve performance, and create new challenges for FA. Wafer bonding (0-level...
Abstract
This chapter discusses the various failure analysis techniques for microelectromechanical systems (MEMS), focusing on conventional semiconductor manufacturing processes and materials. The discussion begins with a section describing the advances in integration and packaging technologies that have helped drive the further proliferation of MEMS devices in the marketplace. It then shows some examples of the top MEMS applications and quickly discusses the fundamentals of their workings. The next section describes common failure mechanisms along with techniques and challenges in identifying them. The chapter also provides information on the testing of MEMS devices. It covers the two common challenges in sample preparation for MEMS: decapping, or opening up the package, without disturbing the MEMS elements; and removing MEMS elements for analysis. Finally, the chapter discusses the aspects of failure analysis techniques that are of particular interest to MEMS.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870333
EISBN: 978-1-62708-314-0
.... , Adhesive-Bonded Joints , ASM Handbook , Vol 17 , Nondestructive Evaluation and Quality Control , ASM International , 1989 , p 612 – 640 • Krautkramer J. and Krautkramer H. , Ultrasonic Testing of Materials , 4th ed. , Springer-Verlag , 1990 10.1007/978-3-662-10680-8_2...
Abstract
This chapter discusses the use of nondestructive inspection methods, including visual, ultrasonic, radiographic, and thermographic techniques, and the types of flaws and damages they can reveal in composite parts and assemblies. It describes the basic principles behind each method along with best practices and procedures.
Book Chapter
Book: Corrosion of Weldments
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2006
DOI: 10.31399/asm.tb.cw.t51820077
EISBN: 978-1-62708-339-3
..., and the vessels were rewelded and put back into service. Some rework involved the use of covered electrodes of dissimilar composition. Leak problems were eliminated using proper welding and cleaning procedures. Recommendations First, to ensure proper joint cleaning, solvent washing and wiping with a clean...
Abstract
Ferritic stainless steels are essentially iron-chromium alloys with body-centered cubic crystal structures. Chromium content is usually in the range of 11 to 30%. The primary advantage of the ferritic stainless steels, and in particular the high-chromium, high-molybdenum grades, is their excellent stress-corrosion cracking resistance and good resistance to pitting and crevice corrosion in chloride environments. This chapter provides information on the classifications, properties, and general welding considerations of ferritic stainless steels. The emphasis is placed on intergranular corrosion, which is the most common cause of failure in ferritic stainless steel weldments. Two case histories involving intergranular corrosion failures of ferritic stainless steel weldments are included. A brief discussion on hydrogen embrittlement is also provided.