Finite element analysis of the powder metallurgy process for manufacturing LED ceramic sub-mounts

• Published in: Computational materials science Vol. 100; pp. 15 - 20
• Main Authors: Jeong, Myeong-Sik, Lee, Sang-Kon, Lee, Jae-Wook, Kim, Da Hye, Hwang, Sun Kwang, Choi, Yong-Jin, Park, Hoon-Jae, Rhee, Kyong-Yop
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01.04.2015
• Subjects: Angle of reflection; Ceramic powders; Ceramic sub-mount; Computer simulation; Finite element analysis; LED; Light-emitting diodes; Mathematical analysis; Mathematical models; PM model; Powder metallurgy; Powder metallurgy process; Sintering (powder metallurgy); LED; PM model; Finite element analysis; Ceramic sub-mount; Powder metallurgy process
• ISSN: 0927-0256; 1879-0801
• DOI: 10.1016/j.commatsci.2014.11.035

[Display omitted] •The shape deformation of the powder product was predicted using numerical simulations.•A unified model is proposed for describing the continuous powder metallurgy process.•Finite element analysis was performed using this model for predicting the reflective surface angle of LED ceramic sub-mounts.•The results were compared to experimental results for verification. In the powder metallurgy process, if the compact body has a non-uniform density distribution, it would be very difficult to achieve the desired dimensional accuracy because of the non-uniform shrinkage that occurs during the sintering process. In the case of the ceramic sub-mounts of a light-emitting diode (LED), produced from a porous ceramic powder tape, the fabrication involves punch-forming, warm isostatic pressing, and sintering. To ensure the proper functioning of the reflective surface of the LED package, the surface should be produced with the designed angle. In this study, the shape deformation of the final product was predicted using a numerical simulation. A simulation model that can describe the deformation of a porous body based on the plasticity theory. The model considers both the compaction and sintering that occurs during the continuous fabrication process, and was used in a finite element analysis for designing the fabrication process. The angle of the reflective surface of the sub-mount was calculated for various punch angles, and the reliability of the simulation model was verified by comparing its predictions with experimental results.