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The new failure mode may be promoted more or less effectively by the test conditions than the mode originally assumed (3) There may be several failure modes In this case, the two failure distributions should be considered separately, so that life predictions will be meaningful The difficulty in determining which of the above scenarios holds is that for genuinely new technologies or service environments, the failure mode in service may not be known In these situations, it is desirable to conduct a parallel test with less aggressive acceleration for comparison 7 Determine life distribution from accelerated life distribution The accelerated life distribution should be determined by fitting the data with the appropriate statistical distribution, such as the Weibull or log-normal distribution The life distribution in service can be determined by transforming the time axis of the life distribution using the acceleration model.

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This predicted life distribution in service can then be used to estimate the number of failures in the specified service life The following discussion of testing for some specific failures will provide examples of this methodology 5762 Printed Circuit Board Reliability Tests 57621 Thermal PTH failures are the predominant source of PCB failures in service and predicting them is the primary goal of PCB testing at elevated temperatures PTH reliability testing should simulate the thermal excursions of a PTH throughout its life Generally, the most severe thermal cycles are experienced during assembly and rework Two basic types of tests are conducted: thermal stress or solder float tests, and thermal cycling tests Both of these tests are intended to be accelerated tests for the PTH, not for the laminate; the thermal stress test, in particular, is expected to severely degrade the laminate.

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The delamination test is similar to a solder float test, but is conducted at a lower temperature specified by the laminate manufacturer; typically, a different fluid is required The most commonly accepted thermal stress test is MIL-P-55110 (also found in IPC-TM650) Following baking at 120 to 150 C (250 to 300 F), the specimens are immersed in an RMA flux and floated in a eutectic (or near-eutectic) Sn-Pb solder bath at 288 C (550 F) for 10 s Other investigators use a bath at 260 C Following the test, the samples are crosssectioned and the PTHs are examined for cracks This is a severe test that ensures that the sample will survive a single wave-soldering or solder pot rework cycle Most thermal cycling tests for PCBs cycle the PCB repeatedly over a wide temperature range; many are actually thermal shock tests using liquid-liquid cycling.

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The results of five accelerated tests with different temperature extremes, ramp rates, and dwell times have been compared by the IPC, which also provides a simplified analytical model to estimate PTH life3 The results of all tests suggest the same approaches for maximizing PTH reliability, but they do not all correlate well quantitatively Two of the most common tests are (1) oven cycling from 65 to +125 C, and (2) thermal shock cycling between oil or fluidized sand baths at +25 to 260 C Figure 5723 shows a suitable test coupon that contains 3000 PTHs interconnected in series, several PTH sizes, and varying annular ring sizes The PTHs can be monitored during the testing Figure 5718b shows the type of data that can be collected in this type of test..

A closed universe expands to some maximum size, then reverses, and then falls back on itself. Think of a closed universe as a sphere. From our discussion in the previous section, this corresponds to k = +1 and is illustrated in Fig. 12-2.

TABLE 7.9 Tensile and Elongation Properties of Grade 3 Copper Foil Property Tensile strength @ 23 C: kpsi MPa Elongation % @ 23 C Tensile strength @ 180 C: kpsi MPa Elongation % @ 180 C

TABLE 7.10 Foil Profile Criteria Max. Foil Profile (Microns) N/A 10.2 5.1 N/A Max. Foil Profile (m Inches) N/A 400 200 N/A

form trapezoidal circuit traces increases since there is more time for lateral etching of the conductor. This has obvious implications for manufacturing fine-line circuits in high-yield and controlling impedance properties. Low-profile and very-low-profile characteristics are included in the IPC-4562 specification and are summarized in Table 7.10. Figures 7.23 and 7.24 give an example of profile differences between a standard and low-profile copper foil. In addition, as circuit operating frequencies increase, roughness of the copper foil can also impact signal attenuation. At higher frequencies, more of the electrical signal is conducted near the surface of the conductor. A rougher profile results in a longer path for the signal to travel, which also results in greater attenuation, or loss. As a result, high-performance materials require foils with low profiles that have adequate adhesion to the high-performance resin systems. Subsequent to the manufacturing of the base copper foil, a variety of surface treatments are typically applied, and these too will vary depending on the usage environments. These treatments fall into four categories.

FIGURE 7.23 Cross section and the matte side of standard Grade 1 foil. (Courtesy of Gould Electronics)

FIGURE 7.24 Cross section and the matte side of low-profile Grade 1 foil. (Courtesy of Gould Electronics)

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