implementing physics of failure into the design process
TRANSCRIPT
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Implementing Physics of Failure into the Design ProcessSeptember 15, 2016
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Nathan Blattau, Ph.D.
Senior Vice President of DfR Solutions, has been involved in the packaging and reliability of electronic equipment for more than ten years. His specialties include best practices in design for reliability, robustness of Pb-free, failure analysis, accelerated test plan development, finite element analysis, solder joint reliability, fracture, and fatigue mechanics of materials.
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Role of Modeling in Design
o Nobody can afford to repeatedly test and redesign to create reliable, cost
effective products
o Working with models allows an interdisciplinary design team to create a more
reliable design smarter, faster & cheaper!
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Simulation & Modeling
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o Performing thermal, mechanical & electrical simulations & extracting the results into a time-to-failure prediction
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Physics of Failure (PoF)
5
o PoF Definition: Use of science to capture an understanding of failure
mechanisms & evaluate useful life under actual operating conditions
o Using PoF, design, perform, and interpret the results of accelerated life
tests
o Starting at design stage
o Continuing through lifecycle of the product
o Start with standard industry specifications
o Modify or exceed them
o Tailor test strategies specifically for product design & materials, use
environment, and reliability needs
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Physics of Failure Definitions
6
o Failure of a physical device or structure attributed to
o Gradual or rapid degradation of the material(s) in the device
o In response to the stress or combination of stresses the device is exposed
to, such as:
o Thermal, Electrical, Chemical, Moisture, Vibration, Shock, Mechanical Loads . . .
o Failures May Occur:
o Prematurely
o Gradually
o Erratically
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Using Physics of Failure During the Design Stage
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o Design the product for robustness and to meet the
environmental requirements
o Vibration
o Mechanical Shock
o Thermal Cycling
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Designing for Mechanical Loads
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o Unlike other materials, solder is a poor engineering
material
o Extreme dimensional variations
o Presence of voids is normal and expected
o Is constantly being subjected to inelastic deformations
under thermal cycling and shock
o You would never use steel, titanium or aluminum under these
types of conditions, unless you want it to fail
o During vibration we need to prevent inelastic deformations
(plasticity)
o This makes the field of electronics reliability unique
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Vibration Fatigue
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o Due to the high number of cycles we need to avoid
inelastic deformations at all cost
o Inelastic deformations (plasticity and creep) are low
cycle fatigue (< 100,000 cycles)
o During vibration cycles accumulate quickly
o Example, 100 Hz vibration – 100 cycles per second
o Time to accumulate 100,000 cycles, 16.67 minutes
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Designing for Vibration
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o Octave rule: the PCB natural frequencies should be at
least 2X the chassis natural frequencies to prevent
coupling
o Recommended reading Steinberg’s Vibration Analysis
of Electronic Equipment
o If the chassis resonant frequency is close to the PCB then
there can be significant amplification of the PCB
deformations
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Natural Frequency
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o Do it by hand
o Limited shapes
o Simple support
conditions
o Use FEA to handle
complex shapes and
boundary conditions
Vibration Analysis of Electronic Equipment
David S. Steinberg
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Using Sherlock or FEA for Vibration During Design Phase
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o There are many factors that can be adjusted to modify
the natural frequency response of the printed circuit
board
o Component placement
o Boundary conditions (mount points)
o PCB properties (thickness, laminate)
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Boundary ConditionsComponent Mass – HeatsinksPrinted Circuit Board Properties
Typically, the higher natural frequency the more robust the design
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Boundary Conditions
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o Chassis typically have
lower natural frequencies
than circuit boards
o Usually looking for circuit
boards having natural
frequencies greater than
150 Hz
o Natural frequency should
not coincide with peaks
in the expect vibration
input
23 Hz is too low for most
applications, need to
make changes
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Boundary Conditions
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o Current, PCI-E type
o Add an additional
mount at high
deflection area
Add more support
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Modifying Boundaries in Sherlock
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o Almost a 4X
increase with
one additional
mount
o Changing
heatsink from
Copper to
Aluminum
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o Heatsink from
Copper to
Aluminum
o 82 to 93Hz
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Additional Mount Point and Increasing PCB Thickness
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1.544 to 1.65 mm
NF increases to 108.5 Hz
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Conduct Physics of Failure Assessment
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o Once an acceptable NF is achieved
o During vibration the assembly is assumed to deform
elastically so that strain on the PCB is proportional to the
strain in the solder and leads
o This allows PCB strain to be used to make fatigue
predictions
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Vibration Fatigue
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o HCF failures typically occur in the lead or solder joint
Component Motion Board bending
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o Lifetime under vibration
is divided into two regimes
o Low cycle fatigue (LCF)
o High cycle fatigue (HCF)
o LCF is driven by inelastic strain
(Coffin-Manson)
o HCF is driven by elastic strain
(Basquin) b
f
f
e NE
2
c
ffp N2
-0.5 < c < -0.7; 1.4 < -1/c > 2
-0.05 < b < -0.12; 8 > -1/b > 20
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Harmonic
Steinberg D.S. Vibration analysis for electronic
equipment.
John Wiley & Sons, 2000.
Random
MIL-STD-810G Figure 514.6C-1
US Highway truck vibration exposure
1 hour is equivalent to 1000 miles
Typical Vibration Levels
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Enter profile into Sherlock
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Physics of Failure Results – Random Vibration
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Random Vibration Results
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o U1 is failing because
it is in areas of high
bending (red)
o Further design
changes are
necessary to get this
board to survive the
expected field
environment
o Additional mount
points, stiffeners, etc..
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Mechanical Shock
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o Very similar to vibration
o The higher the board stiffness
(Natural Frequency is directly related) the
more robust with regards to mechanical
shock
o Lower component mass, Increase board
thickness
o Due to today’s low profile
surface mount components,
shock failures are primarily
driven by board flexure
o BGAs don’t care about in-plane
shock, unless it causes the board
to bend
o Shock tends to be an overstress
event (though, not for car doors)
o Failure distribution is ‘random’
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In Plane Shock
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Design - Board Thickness Effects
Board thickness 1.575 mm
0.97 mm displacement
Board thickness 1.836 mm
0.68 mm displacement
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Board thickness 2.285 mm
0.41 mm displacement
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Using Sherlock During Design for Thermal Cycling Fatigue
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Examples
o Package selection
o Printed circuit board properties
o Solder pad design
o Plated through hole
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Predictive Models: Physics of Failure (PoF)
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o Modified Engelmaier for Pb-free Solder (SAC305)o Semi-empirical analytical approach
o Energy based fatigue
o Determine the strain range (Dg)
o C is a correction factor that is a function of dwell time and
temperature, LD is diagonal distance, a is coefficient of
thermal expansion (CTE), DT is temperature cycle, h is
solder joint height
Th
LC
s
D DDD ag
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Predictive Models: Physics of Failure (PoF)(cont.)
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o Determine the shear force applied to the solder joint
o F is shear force, L is length, E is elastic modulus, A is the area, h
is thickness, G is shear modulus, and a is edge length of bond
pad
o Subscripts: 1 is component, 2 is board, s is solder joint, c is bond
pad, and b is board
o Takes into consideration foundation stiffness and both
shear and axial loads
D
aGGA
h
GA
h
AE
L
AE
LFLT
bcc
c
ss
s
9
2
221112
aa
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Predictive Models – Physics of Failure (PoF)(cont.)
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o Determine the strain energy dissipated by the
solder joint
o Calculate cycles-to-failure (N50), using energy
based fatigue models
10019.0
D WN f
sA
FW DD g5.0
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Thermal Cycling Design – Component Choices
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o Plastic components typically perform better than ceramic
components
o Smaller components usually perform better than larger
components
o Larger solder joints (pad size, thickness) perform better
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2512 resistor or two 1206 size resistors?
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2512 1206
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Bond Pad Influence2512 Resistor
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o Increase bond
pad length from
1.28 mm to 2.00
mm
o 862 cycles
o 1296 cycles
o 54% increase in
life
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PCB Influence2512 Resistor
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o Decrease PCB CTE
from 16 ppm to
15 ppm
o 1296 cycles
o 1632 cycles
o 26% increase in
life
o 14 ppm - 2117
cycles, 63%
increase over
baseline
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Plated Though Holes
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o Design influences
o PCB thickness
o Plating thickness
o Hole diameter
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IPC TR-579
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Round Robin Reliability Evaluation of Small
Diameter (<20 mil) Plated Through Holes in
PWBs
Activity initiated by IPC and published in 1988
Objectives
Confirm sufficient reliability
Benchmark different test procedures
Evaluate influence of PTH design and
plating (develop a model)
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o Determine applied stress applied (σ)
o Determine strain range (∆ε)
o Apply calibration constantso Strain distribution factor, Kd(2.5 –5.0)
o PTH & Cu quality factor KQ(0 –10)
o Iteratively calculate cycles-to-failure (Nf50)
Plated Through Hole Via Barrel Cracking Fatigue Life Based On IPC TR-579
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PoF Durability/Reliability Risk AssessmentsPCB Plated Through Hole Via Fatigue Analysis
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When a PCB experiences thermal cycling the
expansion/ contraction in the z-direction is much
higher than that in the x-y plane. The glass fibers
constrain the board in the x-y plane but not
through the thickness. As a result, a great deal of
stress can be built up in the copper via barrels
resulting in eventual cracking near the center of
the barrel
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IMEC Plated Through Hole Fatigue Model
41
o Alternative model
o Better accuracy when predicting
fatigue of large plated through holes
o Less reliance on correction coefficients
o TR-579 can be overly conservative in
certain cases
Kd and Kq are IPC-TR-579 correction factors
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Plating Thickness
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20 microns – 1621 cycles 30 microns – 2166 cycles
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Printed Circuit Board Thickness
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1.6 mm – 2166 cycles 2.0 mm – 1623 cycles
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Printed Circuit Board Expansion (z-axis)
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60 ppm – 1293 cycles 45 ppm – 2984 cycles
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Accuracy of PoF-Based Models
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o Once a physics of failure model has been developed and validated, it typically displays accuracy similar to a validated finite element model
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Traditional Reliability Growth in Product Development Empirical “TRIAL & ERROR” Method to Demonstrate Statistical Confidence
Today, This Reactive Approach Is Not Enough!
o Testing doesn’t truly simulate actual usage.
o Can not afford the time or money to test to high reliability.
o Problems found too late for effective corrective action, quick fixes often used.
o Testing more parts & more/longer tests “seen as only way” to increase reliability.
DESIGN - BUILD - TEST - FIX (D-B-T-F)
6) REPEAT 3-5 Until Nothing Else Breaks Or
You Run Out Of Time/Money.
Yes
No4)
Faults Detected
?
5) Fix Whatever Breaks.
2) Build 3) Test1) Design
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Traditional Reliability Growth in Product Development Empirical “TRIAL & ERROR” Method to Demonstrate Statistical Confidence
47
Implementing Physics of Failure gets you through the loop the
first time
47
DESIGN - BUILD - TEST - FIX (D-B-T-F)
Yes
No4)
Faults Detected
?
5) Failure Analysis
2) Build 3) Test1a) Design
1b) PoF
6) Fix and PoF