Hydrophilic surface-enhanced Raman spectroscopy (SERS) substrates were prepared by a combination of TiO₂-coatings of aluminium plates through a direct titanium tetraisopropoxide (TTIP) coating and drop coated by synthesised gold nanoparticles (AuNPs). Differences between the wettability of the untreated substrates, the slowly dried Ti(OH)₄ substrates and calcinated as well as plasma treated TiO₂ substrates were analysed by water contact angle (WCA) measurements. The hydrophilic behaviour of the developed substrates helped to improve the distribution of the AuNPs, which reflects in overall higher lateral SERS enhancement. Surface enhancement of the substrates was tested with target molecule rhodamine 6G (R6G) and a fibre-coupled 638 nm Raman spectrometer. Additionally, the morphology of the substrates was characterised using scanning electron microscopy (SEM) and Raman microscopy. The studies showed a reduced influence of the coffee ring effect on the particle distribution, resulting in a more broadly distributed edge region, which increased the spatial reproducibility of the measured SERS signal in the surface-enhanced Raman mapping measurements on mm scale.

Electrical signal transmission in power electronic devices takes place through high-purity aluminum bonding wires. Cyclic mechanical and thermal stresses during operation lead to fatigue loads, resulting in premature failure of the wires, which cannot be reliably predicted. The following work presents two fatigue lifetime models calibrated and validated based on experimental fatigue results of an aluminum bonding wire and subsequently transferred and applied to other wire types. The lifetime modeling of Wöhler curves for different load ratios shows good but limited applicability for the linear model. The model can only be applied above 10,000 cycles and within the investigated load range of R = 0.1 to R = 0.7. The nonlinear model shows very good agreement between model prediction and experimental results over the entire investigated cycle range. Furthermore, the predicted Smith diagram is not only consistent in the investigated load range but also in the extrapolated load range from R = −1.0 to R = 0.8. A transfer of both model approaches to other wire types by using their tensile strengths can be implemented as well, although the nonlinear model is more suitable since it covers the entire load and cycle range.

Bonding wires made of aluminum are the most used materials for the transmission of electrical signals in power electronic devices. During operation, different cyclic mechanical and thermal stresses can lead to fatigue loads and a failure of the bonding wires. A prediction or prevention of the wire failure is not yet possible by design for all cases. The following work presents meaningful fatigue tests in small wire dimensions and investigates the influence of the R-ratio on the lifetime of two different aluminum wires with a diameter of 300 µm each. The experiments show very reproducible fatigue results with ductile failure behavior. The endurable stress amplitude decreases linearly with an increasing stress ratio, which can be displayed by a Smith diagram, even though the applied maximum stresses exceed the initial yield stresses determined by tensile tests. A scaling of the fatigue results by the tensile strength indicates that the fatigue level is significantly influenced by the strength of the material. Due to the very consistent findings, the development of a generalized fatigue model for predicting the lifetime of bonding wires with an arbitrary loading situation seems to be possible and will be further investigated.

(1) Aluminum bonding wires are mostly used for electrical contact and transmission of electrical signals in power electronic modules. Combined cyclical mechanical and thermal loads acting on the wires can lead to premature failure of the whole module. For this purpose, based on extensive fatigue tests on a 300 µm Al-Pure wire, the authors developed, calibrated and applied a fatigue life model for a cycle range of $R=0.1$ to $R=0.7$ to other comparable aluminum wires in two previous publications. (2) Since the model is supposed to be used in an FEM post-processor for predicting the lifetime of wire bridges, the existing model was expanded in the following work. (3) Temperature dependence is included in the fatigue model, and it is made more robust in the whole possible R-range to be able to cope with the highly variable load cases in real components. In addition, a creep rupture model was developed and combined with the fatigue model by linear damage accumulation. (4) The applicability of the lifetime consumption model is demonstrated for several combined load cases. It is shown that it is necessary to consider both fatigue and creep in a combined model for a reliable lifetime prediction. Otherwise, the lifetime could be underestimated by several orders of magnitude, depending on the load case.