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distribution estimation (accelerated reliability estimation) Burn-in, more generally known as environmental stress screening (ESS), is an important subject in its own right that has been extensively written about; only its goals are described here Acceptance or qualification testing and accelerated reliability testing are discussed together in sections covering testing of PCBs and PCAs under various environmental stresses Burn-in, also known as environmental stress screening (ESS), is used to eliminate early failures when infant mortality due to latent defects is a problem by exposing all parts to worstcase, but realistic, conditions The conditions should not be too severe because burn-in decreases the useful life of the parts On the other hand, in addition to increasing the reliability of the parts that are shipped, burn-in provides rapid feedback on process defects that can cause field failures.

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The most common use of burn-in in electronics is for integrated circuits, particularly memory chips, designed into leading-edge integrated circuit manufacturing processes Accelerated reliability tests are designed to cause failures that would occur by wear-out sometime during the service life of the part and provide the data for estimating the life distribution of the part Estimating the life distribution requires that the test be continued until a large percentage of the parts fail Qualification tests may be conducted under similar or even more severe conditions, but they are essentially pass/fail tests that are terminated after a specified period of time Because there are few if any failures in a successful qualification, little new reliability information can be gained from this type of test These tests should not be used routinely on all parts because they will greatly shorten the life of the parts.

Unfortunately, there is no standard suite of reliability tests in the industry, nor is there likely to be in the near future There are several reasons for this First, there are numerous service environments The IPC has identified seven major application segments for electronic assemblies Second, within these categories, the environment experienced by the assembly may differ from the external service environment, depending on product-specific design parameters, such as power dissipation and cooling efficiency, which influence the temperature and humidity in the vicinity of the assembly Third, the desired product life and acceptable failure rates vary widely among applications and manufacturers Finally, but of equal importance, as technology evolves, the tests must evolve, too.

Use of reliability tests that once made sense but now are either unduly conservative or do not bring out potential failure modes of new designs has a high price in overdesigned assemblies that are larger or more costly than necessary and field failures that could have been predicted and prevented This section describes some commonly used tests and methodologies for designing tests for new technologies or new applications As stated at the outset, reliability can be defined only after the service environment has been identified, and the acceptable failure rate over a specified service life is specified If this environment proves unacceptable, the design can be modified by improving cooling, package hermeticity, cleaning, etc If it is unclear whether the PCA will achieve the designed reliability goals, accelerated reliability tests should be designed to estimate the life distribution 576.

1 Design of Accelerated Reliability Tests There are seven steps in accelerated reliability test design 1 Identify the service environment and the acceptable failure rate over a specified service life 2 Identify actual environment of the PCA (modified service environment) The service environment should be translated into the ambient environment actually experienced by the PCA For example, the temperature experienced by the PCA is influenced by both power dissipation and cooling The mechanical environment is influenced by shock-absorbing material, resonances, and so on 3 Identify probable failure modes (eg, solder joint fatigue, conductive anodic filament growth) Accelerated reliability tests are based on the premise that the frequency and/or severity of the environmental exposure can be increased to accelerate the incidence of the failure that.