The article provides a review of the state-of-art non-destructive testing (NDT) methods used for evaluation of integrated circuit (IC) packaging. The review identifies various types of the defects and the capabilities of most common NDT methods employed for defect detection. The main aim of this paper is to provide a detailed review on the common NDT methods for IC packaging addressing their principles of operation, advantages, limitations and suggestions for improvement. The current methods such as, X-ray, scanning acoustic microscopy (SAM), infrared thermography (IRT), magnetic current imaging (MCI) and surface acoustic waves (SAW) are explicitly reviewed. The uniqueness of the paper lies in comprehensive comparison of the current NDT methods, recommendations for the improvements, and introduction of new candidate NDT technologies, which can be adopted for IC packaging.
Detection and characterisation of structural damage using guided waves is very promising technique in non-destructive testing and structural health monitoring systems. Because of their simplicity and low cost, current techniques normally utilise traditional piezo-electric or optical fibre sensors to capture a directional scattered field from a defect or damaged area. However, the practical implementation of these techniques usually requires an extensive preliminary study in order to identify a suitable location and polarisation of the sensors, as well as determine the optimal parameters for wave excitation, which vary depending on the size and type of damage and structure. Recent advances in 3D laser vibrometry provide an opportunity to avoid many of the restrictions and limitations associated with traditional (1D) sensing systems by capturing the transient 3D displacement/velocity fields rather than the displacement/strain along a single axis and limited to a small number of discrete locations. Using 3D laser vibrometry, this paper suggests a non-contact, baseline-free method for imaging structural defects such as corrosion spots, cracks and dents as well as delamination damage. It focuses on the mode conversion effects and investigates the sensitivity of the in-plane and out-of-plane scattered fields in relation to the presence of common defects. The experimental measurements are presented in terms of the root mean square (RMS) values of the velocity field. The outcomes of the present study can help in a number of ways, including selecting an appropriate strategy for defect detection using guided wave techniques.
SUMMARYDefect detection techniques, which utilise guided waves, have received significant attention over the past twenty years. Many of these techniques implement the baseline signal subtraction approach for damage diagnosis. In this approach, the baseline signal previously recorded for a defect-free structure is compared with/or subtracted from the actual signal recorded during routine inspections. A significant deviation between these two signals (or residual signal/time-trace) can be treated as an indication of the presence of critical damage. However, the accuracy of this common approach can be compromised by various uncontrolled factors, which include ambient temperature variations, unavoidable inconsistencies in the PZT installation procedure and degradation of mechanical properties with time. This paper presents a new method for reconstruction of the baseline signal, which can compensate for the above influences and improve the accurateness of damage diagnosis. The method utilises 3D laser vibrometry measurements in conjunction with high-fidelity FE simulations. This paper also describes an application of this method to the reconstruction of the baseline signal and detection of damage in beam and plate structures.
Compensation of changing environmental and operational conditions (EOC) is often necessary when using guided-wave based techniques for structural health monitoring in real-world applications. Many studies have demonstrated that the effect of changing EOC can mask damage to a degree that a critical defect might not be detected. Several effective strategies, specifically for compensating the temperature variations, have been developed in recent years. However, many other factors, such as changing humidity and boundary conditions or degradation of material properties, have not received much attention. This paper describes a practical method for reconstruction of the baseline time-trace corresponding to the current EOC. Thus, there is no need for differentiation or compensation procedures when using this method for damage diagnosis. It is based on 3D surface measurements of the velocity field near the actuator using laser vibrometry, in conjunction with high-fidelity finite element simulations of guided wave propagation in free from defects structure. To demonstrate the feasibility and efficiency of the proposed method we provide several examples of the reconstruction and damage detection.
Adhesive bonded structures have been widely used in aerospace, automobile, and marine industries. Due to the complex nature of the failure mechanisms of bonded structures, cost-effective and reliable damage detection is crucial for these industries. Most of the common damage detection methods are not adequately sensitive to the presence of weakened bonding. This paper presents an experimental and analytical method for the in-situ detection of damage in adhesive-bonded structures. The method is fully non-contact, using air-coupled ultrasonic transducers (ACT) for ultrasonic wave generation and sensing. The uniqueness of the proposed method relies on accurate detection and localization of weakened bonding in complex adhesive bonded structures. The specimens tested in this study are parts of real-world structures with critical and complex damage types, provided by Hyundai Heavy Industries® and IKTS Fraunhofer®. Various transmitter and receiver configurations, including through transmission, pitch-catch scanning, and probe holder angles, were attempted, and the obtained results were analyzed. The method examines the time-of-flight of the ultrasonic waves over a target inspection area, and the spatial variation of the time-of-flight information was examined to visualize and locate damage. The proposed method works without relying on reference data obtained from the pristine condition of the target specimen. Aluminum bonded plates and triplex adhesive layers with debonding and weakened bonding were used to examine the effectiveness of the method.
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