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An Interface-Enriched eXtended Finite Element-Level Set Simulation of Solutal Melting of Additive Powder Particles during Transient Liquid Phase Bonding

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Abstract

A new numerical simulation model is developed by using an interface-enriched eXtended Finite Element-Level Set (XFE-LS) method to study the solute-induced melting of additive powder particles (APPs) during transient liquid phase (TLP) bonding. The robust model captures rapidly occurring concurrent interfacial events at multiple propagating liquid-solid interfaces to simulate the melting behavior. In contrast to the critical assumption in analytical models, numerical calculations show that solute-transport into the APPs during the equilibration of the liquid composition is a significant factor that affects the APPs melting behavior. Also, the study shows that the solute-transport dependence of extent of APPs melting is influenced by the kinetics of solid-state solute diffusion within the particles. The understanding generated by the numerical analysis has resulted in the use of interlayer powder mixture that contains base-alloy APPs to produce single crystal TLP joint that has matching crystallographic orientations with single crystal substrate material, at a substantially reduced processing time, which has been previously considered unfeasible.

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Acknowledgment

The authors gratefully acknowledge financial support by NSERC of Canada.

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Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, University of Manitoba, Winnipeg, MB, R3T 5V6, Canada

    A. Ghoneim (Research Associate), J. Hunedy (Graduate Student) & O. A. Ojo (Associate Professor)

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  1. A. Ghoneim
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  2. J. Hunedy
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  3. O. A. Ojo
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Correspondence to O. A. Ojo.

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Manuscript submitted March 24, 2012.

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Ghoneim, A., Hunedy, J. & Ojo, O.A. An Interface-Enriched eXtended Finite Element-Level Set Simulation of Solutal Melting of Additive Powder Particles during Transient Liquid Phase Bonding. Metall Mater Trans A 44, 1139–1151 (2013). https://doi.org/10.1007/s11661-012-1412-1

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