Breaking Glass

(and other abuses)

John D. Helfinstine
Sr. Research Associate - Mechanics
Corning Inc.
Ph.D., Cornell 72 T&AM

March 1, 200 1
 Why Glass Strength?

Everybody knows glass is strong, but

sometimes breaks

(Rachel Helfinstine, April 18, 1995)

March 1, 200 2
March 1, 200 3
 topics
willing to discuss any topic that catches
your attention
my intention is to provide information
mostly about bulk glass measurement that
might compliment the work being done at
Cornell

March 1, 200 4
 topics
testing categories - ignore non-mechanical
breaking
not breaking
scale of testing
MEMS
36 TV panels
100 m long OWG
discussion not necessarily a linear process

March 1, 200 5
 ASTM Standardization

March 1, 200 6 News, Dec. 1997, pg. 43

 Tinius Olsen

60,000 lb
(267 kN)

March 1, 200 7
 NanoIndenter II
resolution:
50 nN
0.2 nm

March 1, 200 8
Materials - Objects -
All things Great and
small

March 1, 200 9
 Long Term - Short Term
Dynatup
drop weight
impact machine
1930s-Static Deflection

March 1, 200 10
 Test Methods
Typical Methods Include:

3 point bending 4 point bending

March 1, 200 11
 Errors Associated With Flexure Testing of Brittle
Materials, F.I. Baratta, W.T. Matthews, and G.D.
Quinn, MTL TR 87-35, 1987

E (tension) = E (compression); Isotropic

Max Deflection < t/2
Bending, no torsion or twisting
Eccentric loading
Dimension measurements
Friction
Contact Stresses
Contact point tangency shift
March 1, 200 12
 MOR Specimen Preparation
10
Bar Breadth:Depth Ratio
1.0
8 2.0
Depth
% Error in Calculated MOR

4.0
Breadth
6

0
0.00 0.05 0.10 0.15 0.20
Corner Radius:Bar Depth
Baratta, Matthews, & Quinn, "Errors Associated with Flexure Testing of Brittle Materials, MTL TR 87-35
March 1, 200 13
 Standard Tests
ASTM
BS, JIS, DIN
International Electrotechnical Commission
(IEC)
Institute for Interconnecting and Packaging
Electronic Circuits (IPC)
TIA/EIA
etc.
March 1, 200 14
pulling & bending & other abuse
MOR (Modulus Of Rupture)
Compressive mode of loading
Do generate controlled abuse -
abrasion with sand, SiC
surface processes

March 1, 200 15
 Fiber Bending:
Large & Small Radii
Semicircle - large
radius - simple beam
d R
max = Ed/2R
More deformation -
small radius
nodal elastica
undulating elastica
a
max ~ 1.2Ed/D

D
March 1, 200 16
 Biaxial Test Methods
Typical Methods Include:

Ring On Ring Ball On Three Balls

*Contact portion of rings are
rounded
March 1, 200 17
Effect of Large Deflections on ROR
700M

Small Deflection Theory

600M
Stress via Strain Gage (Pa)

1.1 mm Thick 1737G

500M
0.7 mm Thick 1737G
400M
0.5 mm Thick 1737G
300M

200M

100M

0
0 100M 200M 300M 400M 500M 600M 700M

Small Deflection Stress (Pa)

March 1, 200 18
 Scale or Size Effects
physical dimensions of specimen
absolute - relative
homogeniaty - isotropy
Resultant Behavior
fit simple assumptions? beam or plate?
large deflections?
time scale (fatigue)

March 1, 200 19
 Compositional or surface finishing studies
MOR
Compression
RCFT
Bond strengths

March 1, 200 20
 Cantilever - T-Specimen

Bond Strength -
typically tensile

Loading Machine

March 1, 200 21
 A Field of T-Specimens

March 1, 200 22
 T-Specimen for Frit Bond Test

March 1, 200 23
 Single Lap Shear Specimens

March 1, 200 24
 Cross-Bar Fixtures
(When you cant get a grip)

March 1, 200 25
 Statistics
Mean & Standard Deviations are not
enough
Strength is Not Normally a Normal
Distribution
Weibull Distribution is Normally Better

March 1, 200 26
 Weibull Distribution?
Type III extreme value distribution
Waloddi Weibull - 1939
A Statistical Theory of the Strength of
Materials, Ingeniors Vetenskaps
Akademien, Handlingar Nr 151
Weak-Link Distribution

March 1, 200 27
 Uses of Weibull
Yield strength of a Bofors steel
Size distribution of fly ash
Fiber strength of Indian cotton
Length of Cyrtoideae
Fatigue life of a St-37 steel
Statures for adult males, born in the British Isles
Breadth of beans of Phaseolus Vulgaris
Walodddi Weibull, A Statistical Distribution Function of Wide
Applicability, JAM, ASME, 9/51, 1951, pp 293-297

March 1, 200 28
 W EIBULL DISTRIBUTION
Unaged Abraded ROR
99.5
98
95 Unaged Abraded ROR
90
Code 1737
80
NA 35
60
Failure Probability

40

20

10

1
25 30 35 40 45 50
STRENGTH (M Pa)
March 1, 200 29
 Fractography, or the Inspection
of Broken Things
Fracture Analysis Purpose
Find the Origin of Failure
Describe Failure Cause and Sequence
Fracture Analysis Techniques
Examination of Cracks Patterns on the
Structure
Examination of Markings on Fracture Surfaces

March 1, 200 30
 Mirror
mirror shapes relates
2R
to stress distribution
symmetric = uniform
stress
not symmetric =
bending stress 2R
mirror size related to
stress at failure
large = low stress
small = high stress

March 1, 200 31
 Mist Hackle, Mirror
Mist Hackle
Fine hackle marks
Mirror region
Mirror Mist Hackle
Exist around origin
r
Slow crack grows portion
Radius of mirror is in
inverse proportion to
failure stress
A

r
March 1, 200 32
 Origin
Defect concentrated applied stress.
Need to know the mechanism of origin generation.
Necessary things are: Origin
Location of origin
What is around origin
Process information

March 1, 200 33
 Chatter Mark
Damage caused by surface-surface rubbing
(Friction).
Often, invisible

10m
Actual Chatter marks on
LCD glass surface
(etched)

March 1, 200 34
 T.R. Wilshaw, The Hertzian fracture test, J.Phys.D, 1971

March 1, 200
35
Contact (Hertzian) Flaw Generation
 March 1, 200 36
R.F. Cook and G.M. Pharr, Direct Observation and Analysis of Indentation Cracking in Glasses and Ceramics, J.Am.Ceram.Soc, 1990
March 1, 200 37
 Scoring Signature Cracks

ScoreTrack
Score Track
Surface
Surface Checks
Checks

Lateral
Lateral
Checks
Checks

Median
MedianCrack
Crack

March 1, 200 38
 History Lesson
Delayed failure in glass observed by
L. Grenet in France (1899) - fatigue
Not much else until 1940s, 50s, etc.
Still a technically HOT topic
Fatigue - Life Prediction

March 1, 200 39
 What Is Fatigue?
Not metals definition of fatigue
Stress Enhanced Corrosion
Slow/Subcritical Crack Growth
Requires-
flaw
water or other polar molecule
stress, but not necessarily cyclic

March 1, 200 40
 Fatigue -
Subcritical Crack Growth

III

II
ln(Crack Tip Velocity)
I

ln(Stress Intensity)
March 1, 200 41
 Examples of Fatigue Behavior
Dynamic Static

+
+

Stress
+
Stress

+ +

Time Time

March 1, 200 42
 Glass Fatigue Coefficient
Glass Power Law Coefficient,
n
Soda-lime silicate ~ 15
Borosilicate ~ 20
TiO2 doped silicate ~ 33
Fused Silica ~ 45
Standard OWG ~ 22

March 1, 200 43
 Fracture Mechanics
-the classics-
1913; Inglis, Stresses in a Plate Due to the
Presence of Cracks and Sharp Corners

1920; Griffith, The Phenomena of Rupture and

Flow in Solids

1956; Irwin, Onset of Fast Crack Propagation in

High Strength Steel and Aluminum Alloys

March 1, 200 44
 Griffith - 1920
Table V. - Strength of Glass Fibres
1000
400

200

100
Stress (kpsi)

60

40
0 1 2 3 4 5

Diameter (0.001 inch)

March 1, 200 45
 Typical Glass Fracture Toughness
ASTM STP 745

Glass MPa-m1/2 kpsi-in1/2

61 % Lead 0.62 0.57
TiO2 doped silicate 0.70 0.63
Fused silica 0.74 0.67
Soda-lime silicate 0.75 0.68
Borosilicate 0.76 0.69
Aluminosilicate 0.85 0.77
Borosilicate crown 0.86 0.78

March 1, 200 46
 Other test techniques
hardness and indenting
Knoop & Vickers
NanoIndenter
Ball
NDE
Photoelasticity
Ultrasonics

March 1, 200 47
 No element of human endeavor
progresses faster than we can
measure it

Don Keck

March 1, 200 48
 Now for a change

March 1, 200 49
 Subaru Mirror - 8.3 m Diameter
The Problem - Lift & Flip
Solution Required -
Stress & Deformation Analysis
Testing real (as-manufactured) strengths
Low probability Weibull distribution
extrapolation
Time to flip - Fatigue Strength Reduction
Moral: Big Items Can Bend & Have Flaws

March 1, 200 50
 A Used Fused Silica Window
Removed for optical reasons
Surface haze reduced visibility
Question of current strength
Original window pressure proofed to
8.6 kpsi (59.3 Mpa)
What is the current strength?
In the hazed area
In the Clear area

March 1, 200 51
 Used Fused Silica Window

March 1, 200 52
 Typical Origin - Surface View

Impact
Pit

March 1, 200 53
 Impact Check/Pit Origin

March 1, 200 54
 Ge02-Si02 Glasses
Interesting properties
High refractive index
Low strain point
Low elastic modulus
Excellent dielectric properties
No known published data on fatigue
behavior of the bulk glass

March 1, 200 55
 GeO2-SiO2 Normalized Properties
1.1

Strain point
Annealing point
Elastic modulus
Normalized Value

1.0

0.9

0.8
0 10 20 30 40
Wt. Percent GeO2
March 1, 200 56
 Strength vs. Stress Rate Plot
20k
0 wt. % GeO2

Best fit n = 31.2

15k 95% CI (24.3 - 43.3)
Strength (psi)

10k
9k
8k
7k

6k

5k
10 -1 10 0 10 1 10 2 10 3 10 4

Stress Rate (psi/s)

March 1, 200 57
 GeO2 - SiO2 Glasses: Fatigue
Coefficient n
120
Best fit n
100 95% upper conf.
Fatigue Coefficient, n

95% lower conf.

80

60

40

20

0 10 20 30 40
Weight Percent GeO2

March 1, 200 58