• Journal of the Korean Society for Nondestructive Testing
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• v.18 no.2
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• pp.92-102
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• 1998

Prediction of failure behavior in filament-wound composite motor cases is one of the important issues for their reliable application. Acoustic emission during hydroproof testing of the cases is used to solve this problem. Based on the acoustic emission behavior, failure sites can be located successfully. The identification of failure modes is also possible using the distribution of acoustic emission amplitude. Due to the limitation in the number of samples, it is not possible to predict the final burst pressure of motor cases and the effect of impact damage on the final burst pressure.

• Journal of Applied Reliability
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• v.17 no.4
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• pp.280-288
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• 2017

Purpose: PBA buried in underwater requires high reliability because of its mission critical characteristic and harsh operational environment during its life cycle. Therefore, various reliability improvement activities are necessary. The defect on PBA manufacturing process have been studied, as a result, many activities and standards have been presented. However, there are less studies regarding failure pattern on physical features based on design. In this paper, we studied a possible failure patten based on physical features that is related with manufacturing process of PBA. And reliability improvement design based on PoF (Physical of Failure) were intruduced in this paper. Methods: A reliability prediction simulation were performed on the components A and B of the H system using Sherlock Software which is a PoF commercial tool from DFR solution. Solder fatigue and PTH fatigue analysis based on thermal cycling profiles and random vibration was analyzed on three earthquake response spectrum. Result: It was validated that life time and reliability improvement design through solder fatigue and PTH fatigue analysis in case of component. For compoenet B, random vibration fatigue was additionally analyzed and validated reliability for earthquakes profile. Conclusion: In design stage prior to manufacturing, PoF can be analyzed, and it is possible to make a reliability improvement/validated design using design data. This study can be applied in every design step and contribute to make more stable development product.

• Applied Science and Convergence Technology
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• v.24 no.2
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• pp.27-32
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• 2015

We analyzed the destruction patterns of a turbo-molecular pump (TMP) resulting from its sudden exposure of a foreline to the atmospheric pressure due to a destruction of the foreline connecting clamp of an ICP dry etcher for 300 mm wafers during high-vacuum operation ($5{\times}10^{-6}$ Torr). Unlike in the case of view port's breakage, the TMP's rotor module was crashed inside the chamber. The primary damage resulted from the collision of the blades and stators, and the secondary damage resulted from the breaking of the rotor - driving shaft assembly. The fixing screws of the rotor and axial shaft were bent and broken when the TMP controller output the maximum current even after the crash event. Electrical power consumption analysis of the TMP power controller confirmed it. The stress distributions were analyzed by a finite element method using CFD-ACE+ multi physics software. Rotating inertia of each parts and kinetic energies were calculated as well. 68% of the rotational kinetic energy is deposited by the rotor - shaft module.

• Journal of Welding and Joining
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• v.32 no.3
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• pp.74-80
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• 2014

Due to environmental regulations (RoHS, WEEE and ELV) of the European Union, electronics and automotive electronics have to eliminate toxic substance from their devices and system. Especially, reliability issue of lead-free solder joint is increasing in car electronics due to ELV (End-of-Life Vehicle) banning from 2016. We have prepared engine control unit (ECU) modules soldered with Sn-40Pb and Sn-3.0Ag-0.5Cu (SAC305) solders, respectively. Degradation characteristics of solder joint strength were compared with various conditions of automobile environment such as cabin and engine room. Thermal cycle test (TC, $-40^{\circ}C$ ~ ($85^{\circ}C$ and $125^{\circ}C$), 1500 cycles) were conducted with automotive company standard. To compare shear strength degradation rate with eutectic and Pb-free solder alloy, we measured shear strength of chip components and its size from cabin and engine ECU modules. Based on the TC test results, finally, we have known the difference of degradation level with solder alloys and use environmental conditions. Solder joints degradation rate of engine room ECU is superior to cabin ECU due to large CTE (coefficient of thermal expansion) mismatch in field condition. Degradation rate of engine room ECU is 50~60% larger than cabin room electronics.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1730-1733
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• 2007

As semiconductor and MEMS devices become smaller, testing process during their production should follow such a high density trend. A circuit inspection tool "probe card" makes contact with electrode pads of the device under test (DUT). Nowadays, electrode pads are irregularly arranged and have height difference. In order to absorb variations in the heights of electrode pads and to generate contact loads, contact probes must have some levels of mechanical spring properties. Contact probes must also yield a force to break the surface native oxide layer or contamination layer on the electrodes to make electric contact. In this research, new vertical micro contact probe with bellows shape is developed to overcome shortage of prior work. Especially, novel bellows shape is used to reduce stress concentration in this design and stopper is used to change the stiffness of micro contact probe. Variable stiffness can be one solution to overcome the height difference of electrode pads.

• Journal of Sensor Science and Technology
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• v.28 no.6
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• pp.371-376
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• 2019

We have developed an acoustic resonance inspection system to inspect the welding defects in the mechanical parts fabricated using friction stir welding method. The inspection system was consisted of a DAQ board, a microphone sensor, an impact hammer, and controlled by a PC software. The system was developed to collect and analyze the sound signal generated by hitting the sample with an impact hammer to determine whether it is defective. In this study, 100% welded good samples were compared with 95%, 90%, and 85% welded samples, respectively. The variation of the completeness in welding did not affect the visual appearance in the samples. As a result of analyzing the natural frequencies of the good samples, the five natural frequency peaks were identified. In the case of the defective samples, the frequency change was observed. The welding failure detection time was fast enough to be only 0.7 seconds. Employing our welding defect inspection system to the actual industrial field will maximize the efficiency of quality inspection and thus improve the productivity.

• Journal of Sensor Science and Technology
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• v.25 no.2
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• pp.155-159
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• 2016

In this work, we have developed a test system to examine whether the charge indicator of the plug-in hybrid electric vehicle (PHEV) works properly or not. In PHEV, the driver should charge the necessary electricity by plugging in manually and be able to know the charging status through the charge indicator conveniently located for the charging individual. Our system used the CAN bus to transmit the same commands from ECU to the indicator to test the proper operation of the indicator lights. It measured the electric current values during operation and analyzed to determine the quality of the indicators. The inspection items included the proper packaging, the electrical shorts, the LED lighting during charging, the LED lighting for charging failure, and the LED lighting when errors occur. We developed the system for the operators in the factory allowing them to approve the test results at the site. We developed the hardware, the control software, and the software to store the test results and the history of the products in the database. Serial numbers were given to the good quality products and the bar code labels were printed to trace the products afterwards. Through this work, we developed a system to inspect the electric parts in real time upon fabrication. We are planning to further improve our system to inspect the brightness of the indicator by adding the vision inspection in future.

• Composites Research
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• v.32 no.1
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• pp.50-55
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• 2019

In this study, we investigated the effect of fiber alignment in helicoidal structure on the mechanical properties of biomimetic fiber-reinforced composites. Using finite element analysis, circular biomimetic fiber composites were designed and studied. Various amounts of pressure loads were applied to a surface of the composites, and then bending and failure behaviors of the composites were analyzed. The results showed various failure morphologies according to the orientation of the fibers, and it turned out that the fiber alignment in helicoidal structure significantly improved the bending strength of the composite under pressure loading. This was because the fiber alignment in various directions for each layer dispersed effectively the fracture energy from the external load into multiple directions.

• Steel and Composite Structures
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• v.43 no.1
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• pp.19-30
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• 2022

The static strength and fatigue crack resistance of the aircraft skin structures depend on the materials used and joint type. Most of the commercial aircraft's skin panel structures are made from aluminium alloy and carbon fibre reinforced epoxy. In this study, the fatigue resistance of four joint configurations (metal/metal, metal/composite, composite/composite and composite/metal) with riveted, adhesive bonded, and hybrid joining techniques are investigated with experiments and finite element analysis. The fatigue tests were tension-tension because of the typical nature of the loads on aircraft skin panels susceptible of experimenting fatigue. Experiment results suggest that the fatigue life of hybrid joints is superior to adhesive bonded joints, and these in turn much better than conventional riveted joints. Thanks to the fact that, for hybrid joints, the adhesive bond provides better load distribution and ensures load-carrying capacity in the event of premature adhesive failure while rivets induce compressive residual stresses in the joint. Results from FE tool ABAQUS analysis for adhesive bonded and hybrid joints agrees with the experiments. From the analysis, the energy release rate for adhesive bonded joints is higher than that of hybrid joints in both opening (mode I) and shear direction (mode II). Most joints show higher energy release rate in mode II. This indicates that the joints experience fatigue crack in the shear direction, which is responsible for crack opening.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.5
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• pp.523-528
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• 2012

A bendable electronic module is developed for a mobile application by using a low-cost roll-to-roll manufacturing process. In the module, a thin silicon chip is embedded in a polymer-based encapsulating adhesive between flexible copper clad polyimide layers. A set of tests are conducted for the purpose of qualification: thermal shock, high temperature storage, and autoclave tests. During the autoclave test, delamination occurs at many places within the module layers. To investigate the failure mechanism, moisture diffusion analysis is conducted for the interior of the module under the autoclave test condition. For the analysis, the hygroscopic characteristics of the encapsulating materials are experimentally determined. Analysis results indicate the moisture saturation process in the interior of the module under the autoclave test condition.