Industrial case study on the effect of particle size on warpage of alumina substrate

Vasu Thavan, Lingeshpari (2016) Industrial case study on the effect of particle size on warpage of alumina substrate. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This project was conducted at a ceramic company producing alumina substrate to suggest an ideal and consistent range of particle size that gives the lowest warpage percentage ultimately leading to a lower yield lost percentage. Hence, the objectives of this project are to analyze a consistent range of particle size that yields the least warpage and to evaluate the relationship between particle size and shrinkage to the microstructure and bonding in alumina substrate using Scanning Electron Microscope for warp and unwarp samples. Based on the results obtained, the optimum particle size of 2.0 μm to 2.3 μm with a shrinkage rate of 1.1900 to 1.1910 gives a lower warpage percentage of 2.55%. With this range of particle size, warpage percentage is substantially reduced from 3% to 2.55% in line with the first objective. Grouping of particles or better addressed as agglomerates of particles was revealed by the Scanning Electron Microscope at the warp sample. It also revealed cracks at the binder segment due to nonuniformity in shrinkage. As for the X-Ray Diffraction analysis done, peaks for warp and unwarp sample appeared at the same position and phases present for both warp and unwarp are the same. Raman spectra revealed that peaks for both warp and unwarp samples are found at the same band. There is no broadening of peak or spike in the intensities of the warp sample compared to the unwarp and vice versa. Last but not least, X-Ray Fluorescence analysis revealed that the alumina percentage in warp sample, 92% is lower than the percentage of alumina in unwarp sample, 97%. This is due to the inhomegeneity of particle size distribution that deters uniform bonding among the particles present.

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