Process Technology and Its Implications for Inspection and Manufacturing of Ceramic Multi-Chip Modules

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9313126 Lewis The broad objective of the research is to improve the quality, reproducibility, and speed of ceramic-based multi-chip module manufacturing. An interdisciplinary effort will simultaneously focus on materials and processing issues, and on automated visual inspection of tape-cast ceramic layers. Currently, a scientific understanding of the effects of materials composition on both suspension rheology and as-cast properties (both macrostructural and microstructural) is lacking. This will be addressed by an experimental program which (1) characterizes the rheological properties as a function of suspension composition and time, and (2) determines the microstructural variations within the layers. Insights gained from this experimental program will be used to derive statistical models for defect occurrence, which will then drive the inspection process. An inspection methodology that combines process knowledge with computer vision and image processing techniques does not yet exist. The end result of the research will be improved dimensional control and reproducibilty and automated visual inspection of tape-cast sheets. In addition, this work will provide a basic understanding of the relationship between the materials system, processing parameters, and microstructural development that is readily applicable to the production of advanced ceramic components. Such understanding may allow the production of more reliable electronic devices and assemblies.