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The electrical resistance of metal-polymer conductive inks increases as they undergo cyclic loading, posing a major challenge to their reliability as interconnect materials for flexible electronic devices. To characterize an ink’s fatigue performance, extensive electro-mechanical testing is usually performed. Phenomenological models that can accurately predict the resistance increase with cyclic loading can save time and be useful in flexible conductor design against fatigue failure. One such model was recently developed for only one composite ink type. The model is based on experiments monitoring resistance under monotonic stretch data and multiple experiments measuring the rate of increase of the resistance under different strain amplitudes and mean strains. The current work examines whether such resistance rate model could be generalized to apply for more types of composite inks. Two composite inks with different binder material, metal flake sizes and shapes, and substrate material were experimentally tested under monotonic and cyclic loading. It was found that the two new inks are also more sensitive to strain amplitude than mean strain. The resistance rate model accurately predicts early/catastrophic failure (<1000 cycles) in all inks and conservatively estimates high fatigue life for low strain amplitudes. A protocol detailing the procedures for applying the resistance model to new inks is outlined.

 

Instabilities that develop at the contact interface of solid rollers or airless tires while in motion can lead to increased energy losses and reduced service life. This manuscript describes an instrument that can give better insight into the origin of such instabilities by monitoring both local and global roller mechanics. This is done by simultaneously obtaining force and displacement data from sensors as well as optical measurements and local deformation fields across two different planes, extracted from images taken by a high-speed camera. Multiple loading configurations are possible, ranging from static normal loading of the roller to free rolling and rolling with a propulsive or a braking torque. Instrument functions, elements, and design are presented in detail and its capabilities are demonstrated by obtaining measurements such as width of the contact interface under normal loading, strain fields of the roller sidewall and contact interface under normal loading, and the roller’s resistance to motion for free and forced rolling. 

Abstract Flexible electronics often employ composite inks consisting of conductive flakes embedded in a polymer matrix to transmit electrical signal. Recently, localized necking was identified as a cause of a substantial increase in normalized resistance with applied strain thereby adversely impacting electrical performance. The current study explores two possible contributing factors for the formation of such localization—ink surface roughness and local variations in silver flake volume fraction. Uniaxial tension experiments of a DuPont 5025 type ink are used to inform a constitutive model implemented using finite element method on different substrates. Surface roughness was modeled by sinusoidal variation in ink height, whose amplitude and wavelength are informed by experimental laser profilometry scan data. Local flake fraction variations obtained from experimental measurements before applying any strain, were modeled as local variations in the elastic modulus according to an inverse rule of mixtures between the silver flake and acrylic binder material properties. The study identified that the ink height roughness is the most impactful contributor to the subsequent strain localization. The substrate elastic properties impact the number and magnitude of localization bands, with the stiffer substrate delocalizing strain and averting catastrophic crack formation seen with a more compliant substrate. The model incorporating surface roughness closely matches experimental measurements of local strain across different substrates. The study can inform designers of the adverse impact of ink surface roughness on localization and subsequent detrimental increase of the resistance. 

Porous metals represent a class of materials where the interplay of ligament length, width, node structure, and local geometry/curvature offers a rich parameter space for the study of critical length scales on mechanical behavior. Colloidal crystal templating of three-dimensionally ordered macroporous (3DOM, i.e., inverse opal) tungsten provides a unique structure to investigate the mechanical behavior at small length scales across the brittle–ductile transition. Micropillar compression tests show failure at 50 MPa contact pressure at 30 °C, implying a ligament yield strength of approximately 6.1 GPa for a structure with 5% relative density. In situ SEM frustum indentation tests with in-plane strain maps perpendicular to loading indicate local compressive strains of approximately 2% at failure at 30 °C. Increased sustained contact pressure is observed at 225 °C, although large (20%) nonlocal strains appear at 125 °C. The elevated-temperature mechanical performance is limited by cracks that initiate on planes of greatest shear under the indenter.