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occurs in service in a known way, i.e., that the data can be used to predict the life distribution in the in-service PCA environment. This assumption makes sense only if the same failure modes occur in the test as in real life. It cannot be overemphasized that the accelerated tests must be designed around the real failure modes. Probable failure modes may be identified from past service experience, the literature, or preliminary testing or analysis. 4. For each failure mode, construct an acceleration model. An acceleration model that allows test data to be interpreted in terms of the expected service environment is crucial to life distribution estimation. It is also extremely helpful in designing good tests, so ideally the acceleration model should be developed before the accelerated reliability tests are carried out. Equation 57.2 for solder joint reliability plus Eq. 57.1 for strain in solder joints to rigid components is an example of an acceleration model. It predicts that increasing strain will decrease the number of cycles to failure in a specific way. Within a certain temperature range, increasing the temperature cycling range is a way of increasing the strain. In general, the acceleration model should be based on the rate-controlling step in the failure process. In some cases, the rate will be determined by an Arrhenius type equation; for example, if diffusion is the rate-controlling process: D = Doexp t2 = where D Do Ea k = = = = Ea kT and x Dt (57.3)
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and T1 and T2 and t1 and t2 are two temperatures and corresponding equivalent diffusion times Note that even when temperature is an important factor, an Arrhenius relationship may not exist; in the preceding thermal cycling example, the failure rate is roughly proportional to ( T)2 Some acceleration models will be explored in the following sections The limits of applicability of an acceleration model are as important as the model itself Increasing or decreasing the temperature too much may promote new failure modes that would not occur in service or invalidate the quantitative acceleration relationship For example, if the temperature is elevated above the Tg of the board, the z-axis CTE increases sharply and the modulus decreases, which may actually lessen the strains imposed on solder joints, but may also promote PTH failures.
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Finite element modeling (FEM) can be invaluable in developing and/or applying acceleration models for thermal and mechanical tests Two-dimensional nonlinear modeling capability will usually be required in order to get meaningful results Models can be constructed to estimate the stresses and strains in the material (eg, the Cu in a PTH barrel or the solder in a surface-mount or through-hole joint) under operating conditions as well as under test conditions These estimates will be far more accurate than the simple models provided in this overview because they can account for the interactions between materials in a complex structure and both elastic and plastic deformation 5 Design tests based on the acceleration models and accepted sampling procedures Using the acceleration model and the service environment and life, select test conditions and test times that simulate the life of the product in a much shorter period of time.
The sample size must be large enough that it is possible to determine whether the reliability goal (acceptable number of failures over the service life) has been met41 Ideally, the life distribution in the accelerated test should be determined, even when the test period must be extended to do so..
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6 Analyze failures to confirm failure mode predictions Since an accelerated test is based on the assumption that a particular failure mode in the accelerated test is the same one that occurs in service, it is important to confirm by failure analysis that this assumption is valid If the failure mode in the accelerated test is different from the one expected, several possibilities should be considered (1) The accelerated test is introducing a new failure mode different from the one that will occur in service Usually this means that the acceleration of one parameter (eg, frequency, temperature, humidity) was too severe (2) The initial determination of the dominant failure mode was incorrect In this case, to understand the significance of the test results, a new acceleration model must be developed for this failure mode.
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