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HALT/Reliability Testing
Evaluating The Uncertainty Gap
By Joel MandelJan 2007
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Uncertainty Gap Problem
How far is our theoretical design from real capabilities?
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HALT Margin Discovery
Stress
UpperDestruct
Limit
LowerDestruct
Limit
UpperOperating
Limit
LowerOperating
LimitProductSpecs
Margin Margin
OperatingOperating
Destruct Margin Destruct Margin
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The Million Dollar question
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is a science-based approach to reliability that uses modeling and Simulation to design-in reliability. This approach models the root causes of failure such as fatigue, fracture, wear, and corrosion ..
Physics Of Failures
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Physics Of Failures
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Thermodynamics
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Design Objective
• Any system will fail so the objective is delay the failures or to weed out the first failures./or the weak parts of the
system
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Correct Answer
We must test to cause failures not to test to
demonstrate successful achievement
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Physics of Failures Models
• Exponential Model Ae-Bx film resistors ceramic capacitors life temperature dependence
• Power model AV-b Voltage
• Arrhenius (A)1/T e-c/T
temperture dependent processes including diffusion and corrosion
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Every stress source and failure mechanism has a different characteristic
exponential relationship
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High Accelerated Life Testing
Halt
Temp-High Low
Temp Rapid Cycling
Vibration
Combines testing
Power
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Vibration Testing Logic
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Four Corner VoltageTemperature Halt Test
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