Residual Stresses from Incremental Hole Drilling Using Directly Deposited Thin Film Strain Gauges

Background Commonly, polymer foil-based strain gauges are used for the incremental hole drilling method to obtain residual stress depth profiles. These polymer foil-based strain gauges are prone to errors due to application by glue. For example zero depth setting is thus often erroneous due to necessary removal of polymer foil and glue. This is resulting in wrong use of the calibration coefficients and depth resolution and thus leading to wrong calculations of the obtained residual stress depth profiles. Additionally common polymer foil-based sensors are limited in their application regarding e.g. exposure to high temperatures. Objective This paper aims at a first step into the qualification of directly deposited thin film strain gauges for use with the incremental hole drilling method. With the directly deposited sensors, uncertainties regarding the determination of calibration coefficients and zero depth setting due to the absence of glue can be reduced to a minimum. Additionally, new areas of interest such as the investigation of thermally sprayed metallic layers can be addressed by the sensors due to their higher temperature resilience and their component inherent minimal thickness. Methods For the first time, different layouts of directly deposited thin film strain gauges for residual stress measurements were manufactured on a stainless steel specimen. Strain measurements during incremental hole drilling using a bespoke hole drilling device were conducted. Residual stress depth profiles were calculated using the Integral method of the ASTM E837 standard. Afterwards, strain measurements with conventional polymer foil-based strain gauges during incremental hole drilling were conducted and residual stress depth profiles were calculated accordingly. Finally the obtained profiles were compared regarding characteristic values. Results The residual stress depth profiles obtained from directly deposited strain gauges generally match the ones obtained from conventional polymer foil based strain gauges. With the novel strain gauges, zero depth setting is simplified due to the absence of glue and polymer foil. With the direct deposition, a wide variety of rosette designs is possible, enabling a more detailed evaluation of the strain field around the drilled hole. Conclusions The comparative analysis of the obtained residual stress depth profiles shows the general feasibility of directly deposited strain gauges for residual stress measurements. Detailed investigations on uncertainty sources are still necessary.

Application of a sound-conducting polymer foil for calibration of hydrophones by optical interferometry

Modern calibration of hydrophones at megahertz frequencies is based on the method of optical interferometry, in which the vibrational velocity of an acoustic wave is measured using a thin sound-transparent polymer foil (membrane), metallized on one side to improve light reflection and installed in an ultrasonic field, followed by its replacement with a hydrophone to be calibrated. The main problem of implementing this calibration method is to assess the adequacy of tracking vibrations of the metallized side of the foil to vibrational displacements of water particles under the action of a sound wave incident on the opposite side of the foil. On the basis of the simplified theory of acoustic plane waves passing through layers of dissimilar materials, methods for measuring the speed of sound in the applied foil and an algorithm for calculating the frequency dependence of the sound wave transmission coefficient (in terms of vibrational velocity) from water through the foil to water or air, introduced as a correction to the results of hydrophone calibration, were developed. The uncertainty of the introduction of this correction is estimated.

Wireless retina implant with optical energy supply

We present the first results of work towards a foil-based epiretinal prosthesis that can stimulate retinal cells. The prosthesis receives trigger signals and energy in the form of high intensity infrared radiation. Array-like silicon photodiodes with attached thin film electrodes convert the received infrared light into electrical stimulation signals, which are intended to stimulate ganglion cells. The photodiodes are arranged like stones in a mosaic on an only 10 µm thin and thus flexible polymer foil. Like this, the prosthesis can adapt to the curved shape of the eye and will have close contact with the retina.The photodiode array is fabricated on silicon wafers. Etched trenches guarantee the electrical separation between the individual photodiodes and pixels. Spectral sensitivities of backside-illuminated photodiodes were measured for wafers thinned to different thicknesses. The thin polymer foil is realized by spin coating polyimide on the photodiode array followed by imidization. Via holes are etched into the polyimide film for contacting the pads of the photodiodes. First spin coating tests were performed using silicon wafers without photodiodes but with metal pads and with etched trenches to simulate the gap between individual photodiodes.Although the thickness of the spin-coated polyimide layer was very inhomogeneous, we succeeded in realizing vias for connecting contact pads by thin film gold tracks crossing deep trenches. The realized via holes had inclined sidewalls as desired. Electrical measurements showed sufficient electrical contact between two connected pads.