GMacrelli - SummitStuttgart - March2016 - VFinal Isoclima

THIN CHEMICALLY STRENGTHENED GLASS BY ION EXCHANGE:
Perspectives and problems in automotive applications
Guglielmo Macrelli
Isoclima SpA – R&D Dept.
2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

MARCH 2016 - GUGLIELMO MACRELLI - ISOCLIMA R&D
RECENT WEB ANNOUNCEMENTS:
thin chemically strengthened glass in automotive applications

Glass Chemical Strengthening by IX process
in the framework of this presentation
Glass Chemical Strengthening is intended for:
Ion Exchange (IX) processes performed on

Inorganic Silicate Oxide Glasses
at temperature below glass transition temperature
Ion-exchanged glass belongs to the class of “forbidden glass” [*] i.e.,

a glass with a structure that is not attainable by cooling
from a melt using any possible cooling path.
[*] J.Mauro, R.J.Loucks; J.Non-Cryst.Solids, 355 (2009) 676

Silicate Glass network structure

Soda-lime Silicate Glass Chemical Structure

Bi-dimensional Silicate Glass Chemical Structure

Bi-dimensional Soda-lime Silicate Glass Chemical Structure

Bi-dimensional Sodium-Aluminum-Silicate Glass Chemical Structure

Glass Breakage Issues

Glass Surface Flaw - Schematic
Y ⋅σ ⋅ a = KI
Strength is described through Fracture Mechanics concepts
Tensile stress at glass surface σ (MPa) is “amplified” at the flaw/crack tip

by the geometry of the flaw/crack (a,Y).
This is described by the Stress Intensity Factor (SIF) – KI

Strength effect due to a residual stress field
Surface Flaw
a – Flaw depth
Residual Stress Field

Sc – Surface Compression
Cd – Case Depth

Residual stress field effect
Glass strengthening can be obtained by the introduction of

a residual stress field σR(x) either by thermal or chemical processes
2 ⋅Y ⋅ a
a
σ R ( x)
KR = ⋅∫ dx
π 0 a2 − x2

Residual stress field effect
Effect on SIF – ΚΙ
KR + Y ⋅σ ⋅ a = KI
Equation at breakage
K R + Y ⋅ σ B ⋅ a = K IC

Strengthening effect
K Ic − K R
σB =
Y⋅ a
KR<0 (compression residual stress) increases breakage stress → Strengthening effect
KR>0 (tensile residual stress) reduces breakage stress

ION EXCHANGE

Ion exchange : initial conditions

Ion exchange processing

ION SOURCE GLASS MATRIX
Surface Thermodynamic
Equilibrium Process
t >> τ Kinetic Transport in
glass matrix

Stress build-up : a simple scheme

Stress build-up : mathematical model
Unrestrained free strain e y ( x, t ) = B ⋅ c ( x, t )

L
1
Effective strain ε y ( x, t ) = ∫ B ⋅ c( x, t ) dx
2 ⋅ L −L
[ ]
L
1
ε y ( x, t ) x = B ⋅ c ( x, t ) − ∫ B ⋅ c( x, t )dx Restrained strain
2 ⋅ L −L
Stress due to restrained strain for symmetric concentration
B⋅E  
L
1
σ ( x, t ) = − ⋅ c ( x , t ) − ⋅ ∫ c( x, t ) ⋅ dx 
(1 − ν )  2 ⋅ L −L 
Stress due to restrained strain for asymmetric concentration
B⋅E  3⋅ x 
L L
1
σ ( x, t ) = − ⋅ c ( x, t ) − ⋅ ∫ c( x, t ) ⋅ dx − 3 ∫
⋅ x ⋅ c ( x, t )dx 
(1 −ν )  2 ⋅ L −L 2 ⋅ L −L 
Stress build-up : 3D scheme

Characteristics of chemically strengthened glass by IX

Polarizing microscope + compensator
Direct observation of the residual stress field

From: R.Gy, Mat.Science & Eng.B149 (2008) 159-165

Advantages:
Weight reduction about 30% /m2

Hybrid Cross section :
2.1mm Clear Float /0.76mm Aco. PVB/ 0.7 mm Thin IXCSG -7.8 kg/m2
VS traditional cross section:
2.1mm Clear Float / 0.76mm PVB/ 2.1 mm Clear Float - 11.3 kg/m2
Acceleration
Handling
Braking

Drawbacks and problems:
Stiffness reduction → mechanics and aerodynamics issues

Breakage and post-breakage behaviour → fragmentation,
residual visibility
Costs → material costs (glass) , processing costs

New Materials Science Tools:
Molecular Dynamics; Topological Constraints Theory
From: M.Wang;M. Bauchy – Ion Exchange

Strengthening of glasses: Atomic Topology Matters
B ⋅E  1
L

σ (x,t) = − ⋅ c ( x, t) − ⋅ ∫ c ( x , t ) ⋅ dx 
(1 − ν )  2 ⋅ L −L 

From: John C. Mauro

IX Processing: Traditional batch Ion Exchange process
Pictures courtesy of : JSJ – Jena / Germany

New process perspectives: costs reduction, higher throughput
From: Stefan Karlsson et al.

Glass Ion
Source
Spray
Coated
SPRAY COATING
From:Christian Russell
Marek Patschger


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THIN CHEMICALLY STRENGTHENED GLASS BY ION EXCHANGE:

Perspectives and problems in automotive applications

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Ion Exchange (IX) processes performed on

Ion-exchanged glass belongs to the class of “forbidden glass” [*] i.e.,

[*] J.Mauro, R.J.Loucks; J.Non-Cryst.Solids, 355 (2009) 676

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Tensile stress at glass surface σ (MPa) is “amplified” at the flaw/crack tip

This is described by the Stress Intensity Factor (SIF) – KI

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Residual Stress Field

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Glass strengthening can be obtained by the introduction of

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

KR>0 (tensile residual stress) reduces breakage stress

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Unrestrained free strain e y ( x, t ) = B ⋅ c ( x, t )

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Direct observation of the residual stress field

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Weight reduction about 30% /m2

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Stiffness reduction → mechanics and aerodynamics issues

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

From: M.Wang;M. Bauchy – Ion Exchange

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

Pictures courtesy of : JSJ – Jena / Germany

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

From: Stefan Karlsson et al.

2ND ANNUAL AUTOMOTIVE GLAZING SUMMIT - STUTTGART,

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