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applied polarization voltage (100 Vdc) and Method 402, Test condition A44 IPC-SM-840A also includes a test for electromigration resistance The test is conducted at 85 C/90% RH at a 10 Vdc bias with a limiting current of 1 mA for 7 days A significant change in current constitutes a failure The samples are also microscopically inspected for evidence of electrolytic metal migration A common test for dendritic growth due to flux residues is 85/85/1000 h at 20 Vdc bias These tests are empirically based; however, several investigators have attempted to develop acceleration factors for these and similar tests45,46 5763 Printed Circuit Assembly Reliability Tests 57631 Thermal Most thermal cycling of PCAs is intended to accelerate solder joint thermal fatigue failures.

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In spite of the existence of an IPC standard, there is no standard accelerated test today that is suitable for all component and substrate combinations and all service environments There are several acceleration models in the literature, each of which seems to fit the data well in at least some situations All are based on a combination of empirical observations and fundamental arguments under simplifying assumptions This topic remains a subject of active research since in some cases the predictions are significantly different There is also a move to replace thermal cycling tests with mechanical cycling tests, which could be conducted in a shorter period of time; however, these tests are even further from standardization.

da d = 3 a ln = 3 ln a = ln a 3 where we are ignoring constants of integration to get a qualitative answer. The result is that for a matter-dominated universe a 3 we set = gives

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Finally, for some components which dissipate a significant amount of power (usually 1 W or more), cycling the ambient temperature (which heats from the outside) may give quite different results from power cycling (in which heating occurs from the inside); for example, the failure location may shift from corner joints (which see the largest displacements) toward solder joints located near the chip (because they are hotter) Consequently, while thermal cycling will be adequate for most ASICs, memory chips, etc, power cycling should be considered for microprocessors, particularly those that dissipate more than a few watts Thermal shock testing is commonly used to test components, but it is not necessarily a substitute for thermal cycling Because the temperature ramp is extremely rapid and the dwell at the extremes is generally short, there is little time for creep; consequently, the number of cycles to failure is increased.

Furthermore, the rapid temperature change can induce differential thermal stresses that may be larger than those experienced during thermal cycling These stresses can induce early failures, particularly if the failure is not in the solder There are some principles for designing thermal cycling tests to accelerate solder fatigue that seem to be generally agreed on The following guidelines apply to gradual temperature cycling due to ambient heating inside a unit (eg, due to power dissipation) If the unit will be subjected to extreme temperatures or thermal shock in service, these generalizations may not apply A sample cycling protocol is shown in Fig 5725..

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