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Methodology for assessing reliability of power electroncis
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Automating lifetime simulation of power PCBs
1.
Automating Lifetime Simulation
of Power PCBs ECPE Workshop November 22, 2012 © 2004 -–2200011070 Greg Caswell and Craig Hillman DfR Solutions, LLC
2.
Agenda o Introduction
o Power PCB Applications o Common Issues o Lifetime Expectations o Failure Mechanisms o Virtual Qualification Approach o Sherlock Solution © 2004 - 200107
3.
Power Modules Are
Used in Several Market Segments © 2004 - 200107 Switching Power Supply Thermoelectric Modules Voltage Power Modules Solar Power Modules Automotive Power Modules 200W Power Amp IGBT
4.
What Do They
All have in Common? o High Temperature Environments o Possible Vibration and Shock Environments o Temperature and Power Cycling Environments o Very High Current Flows and Thermal Transfer Requirements o A variety of materials forming the product o Substrate tiles bonded to copper baseplate © 2004 - 200107
5.
Example Life Expectancies
o IGBT – Rail application – 30 years (Each module 100FIT) o Power Module – Automotive Application – 20 years o 10W/cm2 o DBC Substrate bonded to heatsink o Vibration, shock, humidity, salt spray o Cost o Solar Power Inverters-25 years © 2004 - 200107
6.
Semicron Thermal Module
© 2004 - 200107
7.
Failure Mechanisms o
Thermo-mechanical fatigue induced failures o CTE mismatch o Temperature swings o Bond Wire Fatigue o Shear Stresses between bond pad and wire o Repeated flexure of the wire o Lift off (fast temperature cycling effect) o Heel Cracking o Die Attach Fatigue o Solder Fatigue o Voids o Device Burn Out o Automotive- degradation of power o Solder Fatigue o Bond wire failure (lift off due to fast temperature cycling) o Structural Integrity – ceramic substrate to heat sink in thermal cycling o IGBTs – solder joint fatigue, wirebond liftoff, substrate fracture, conductor delamination © 2004 - 200107
8.
Bond Wire Fatigue
Due to Thermal Effects Bredtmann, et al, “Options for Electric Power Steering Modules a Reliability Challenge.” Automotive Power Electronics, September 2007 © 2004 - 200107
9.
Example of Substrate
Delamination o After 100 cycles of -55 to 200C – DBC Delamination o By 1000 cycles there were cracks in AlN substrate and extensive solder joint failures Scofield, Richmond and Leslie, ”Performance and Reliability Characteristics of 1200V,100A 200C Half Bridge SiC MOSFET-JBS Diode Power Modules,” IMAPS -International Conference on High Temperature Electronics May 2010 © 2004 - 200107
10.
Failure Modes- Solder
and Silicon Cracking Cracks between DBC Substrate and also between silicon die and bond wire Mitsubishi, “Power Module Reliability” © 2004 - 200107
11.
Failure Modes -
Wire Bond Cracking and Lift Off o Examples of wire bond fatigue cracking and also wire bond lift off Dynex – AN5945 – IGBT Module Reliability © 2004 - 200107
12.
Typical Mission Profile
o The stress conditions in the chart are for a railroad braking application © 2004 - 200107
13.
IGBT Qualification Tests-Environmental
o Typically, extensive qualification testing is performed to ascertain the reliability of the power module as shown © 2004 - 200107
14.
Copper Wire and
Temperature Cycling o Power module industry believes copper wire is more robust than aluminum o Changes being implemented for electric drivetrain o Part of improvement is believed to be due to reduced temperature variation from improved thermal conductivity o Part of improvement could be due to recrystallization o Can result in self-healing o Part of improvement could be more robust fatigue behavior © 2004 - 200107 D. Siepe, CIPS 2010 N. Tanabe, Journal de Physique IV, 1995
15.
Aluminum vs. Copper
– Temperature Cycling o Copper clearly superior 100 10 106 107 108 109 © 2004 - 200107 N. Tanabe, Journal de Physique IV, 1995 J. Bielen, EuroSime, 2006
16.
Thermal Aging of
Cu Wire Bonds vs. Gold J. Onuki, M. Koizumi, I. Araki. IEEE Trans. On Comp. Hybrids & Manfg. Tech. 12 (1987) 550 © 2004 - 200107 a. b. Cu
17.
Points o Cu
is comparable in cost to aluminum but less proven – © 2004 - 200107 used on low cost products (not those where the cost of the IC is much greater than the package). o Cu bonding is slower (5 wires/sec) so that adds process cost if high I/O o Pd coating helps but adds cost
18.
Major concerns identified
by DfR o Palladium (Pd) coating creates galvanic couple with copper o Studies have demonstrated thinning or loss of Pd coating during bonding o Uncertain if JEDEC test with acceleration factor based on Peck’s equation (based on aluminum/gold galvanic couple) is still valid o Push out of aluminum pad o Could result in subsurface cracking (metal migration?) o Uncertain if existing JEDEC temp cycling test is sufficient to drive crack growth © 2004 - 200107
19.
Die Attach Fatigue
o Failure mechanisms o CTE mismatch resulting in plastic strain o Thermo-mechanical fatigue as a result of temperature cycling o Coarsening © 2004 - 200107
20.
Typical Thermal Stress
Failures in a Die-Substrate Assembly © 2004 - 200107 Die-Substrate Assembly Chip, E1,1 Crack at the chip’s surface in its mid-portion is due to the normal stresses in the chip Adhesive, E0, 0 Substrate, E2,2 Crack at the chip’s corner is due to the interfacial stresses Crack/delamination at the adherend/adhesive interface (adhesive failure of the bonding material) Is due to the interfacial stresses Crack in the body of the adhesive (cohesive failure) is due to the interfacial stresses
21.
Typical Failure Modes
in Die-Substrate and Similar Assemblies Typical failure modes in die-substrate assemblies are: 1) adherend (die or substrate) failure: a silicon die can fracture in its midportion or at its corner located at the interface; 2) cohesive failure of the bonding material (i.e., failure of the die-attach material); and 3) adhesive failure of the bonding material (i.e., failure at the adherend/adhesive interface). An adhesive failure is not expected to occur in a properly fabricated joint. If such a failure takes place, it usually occurs at a very low load level, at the product development stage, and should be regarded as a manufacturing or a quality control failure, rather than a material’s or a structural one. © 2004 - 200107
22.
Die Attach Solder
Reliability Marie Curie ECON2 2008 © 2004 - 200107
23.
Sherlock o User
Friendly o Quick o Flexible o Intuitive o Reliable o One of a Kind o State of the Art © 2004 - 200107
24.
Why Sherlock o
Mil-HBK-217 actuarial in nature o Physics based algorithms to time consuming o Need to shorten NPI cycles and reduce costs o Increased computing power o Better way to communicate © 2004 - 200107
25.
© 2004 -
200107 PoF: The Complexity Roadblock E 1 1 1 − = 2 V a 1 1 2 t 2 exp K T T V t B n exp(~ 0.063% ) ~ 0.51 exp RH kT eV Tf − × µ h h L L 2 ( ) × − c s − ×D × = × + + + + A G G a A G E A E A T L F c c b s s 9 1 1 2 2 2 1 n a a
26.
© 2004 -
200107
27.
Traditional Iterative NPI
Cycle © 2004 - 200107
28.
NPI Cycle Using
PoF Modeling © 2004 - 200107
29.
Why DfA? Total
Costs are Determined During Design 95% of the OS Cost Drivers are Based on Decisions Made during Design. Source: Architectural Design for Reliability, R. Cranwell and R. Hunter, Sandia Labs, 1997 © 2004 - 200107 29
30.
© 2004 -
200107 Concurrent Engineering
31.
Introduction o The
foundation of a reliable product is a robust design o Provides margin o Mitigates risk from defects o Satisfies the customer © 2004 - 200107
32.
© 2004 -
200107 Intuitive o Easy-to-locate commands o Industry terminology (parts list, stackup, pick place, etc.)
33.
© 2004 -
200107 Reliability Goals o Compatible with wide variety of reliability metrics
34.
© 2004 -
200107 Ambient Environment o Handles very complex environments
35.
© 2004 -
200107 Input Design Files o Takes standard output files (Gerber / ODB) 35
36.
© 2004 -
200107 Inputs: Parts List o Color coding of data origin o Minimizes data entry through intelligent parsing and embedded package and material databases
37.
Part Database Manager
o Enables user to rapidly build their own internal parts database o Enables user to use both manufacturer and internal part numbers © 2004 - 200107
38.
© 2004 -
200107 Inputs: Stackup o Automatically generates stackup and copper percent (%) o Embedded database with almost 400 laminate materials with 48 different properties
39.
© 2004 -
200107 Results: Automated Mesh Generation o Identifies optimum mesh density based on board size o Expert user no longer required; model time reduced by 90%
40.
ICT Module (optional)
o Uses embedded FEA engine to compute board © 2004 - 200107 deflection and strain cause by ICT fixture
41.
DFMEA Module (optional
o Uses ODB++ data including net list to create board © 2004 - 200107 level DFMEA o Includes customizable spreadsheets for export
42.
© 2004 -
200107 Results: Five Different Outputs
43.
o Comprehensive report
© 2004 - 200107 generated in PDF format o Key summary points o Detailed inputs and findings o User control over contents o 50-100 page professionally formatted document Automated Report Generation
44.
o Sherlock performs
a comprehensive assessment of © 2004 - 200107 potential wearout mechanisms from a variety of environments o Elevated Temperature o Thermal Cycling o Random Vibration o Sinusoidal (Harmonic) Vibration o Mechanical Shock o Only software on the market to provide a complete life-cycle prediction o Allows the user to incorporate traditional empirical prediction as necessary Unmatched
45.
Summary - What
is Physics of Failure (PoF)? o Common Definition: © 2004 - 200107 o The process of using modeling and simulation based on the fundamentals of physical science (physics, chemistry, material science, mechanics, etc.) to predict reliability and prevent failures o Mechanisms that can be modeled include fatigue, creep, diffusion, etc. o The foundation of a reliable product is a robust design o Provides margin o Mitigates risk from defects o Satisfies the customer
46.
© 2004 -–2200011070
Thank You! Greg Caswell Sr. Member of the Technical Staff DfR Solutions gcaswell@dfrsolutions.com
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