Cover image for Accelerated stress testing handbook : guide for achieving quality products
Title:
Accelerated stress testing handbook : guide for achieving quality products
Publication Information:
New York : IEEE Press, 2001
ISBN:
9780780360259

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30000010047111 TK7870.23 A22 2001 Open Access Book Book
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Summary

Summary

As we move closer to a genuinely global economy, the pressure to develop highly reliable products on ever-tighter schedules will increase. Part of a designer's "toolbox" for achieving product reliability in a compressed time frame should be a set of best practices for utilizing accelerated stress testing (AST).

The Accelerated Stress Testing Handbook delineates a core set of AST practices as part of an overall methodology for enhancing hardware product reliability. The techniques presented will teach readers to identify design deficiencies and problems with component quality or manufacturing processes early in the product's life, and then to take corrective action as quickly as possible. A wide array of case studies gleaned from leading practitioners of AST supplement the theory and methodology, which will provide the reader with a more concrete idea of how AST truly enhances quality in a reduced time frame.

Important topics covered include:

Theoretical basis for AST General AST best practices AST design and manufacturing processes AST equipment and techniques AST process safety qualification In this handbook, AST cases studies demonstrate thermal, vibration, electrical, and liquid stress application; failure mode analysis; and corrective action techniques. Individuals who would be interested in this book include: reliability engineers and researchers, mechanical and electrical engineers, those involved with all facets of electronics and telecommunications product design and manufacturing, and people responsible for implementing quality and process improvement programs.


Author Notes

About the Editors H. Anthony Chan has been with AT&T Labs and the former AT&T Bell Labs for 14 years, specializing in product development and manufacturing, including interconnection technology, manufacture assembly and reliability, network management, and wireless network. He has been responsible for R&D in robust product design and manufacture and for guiding various manufacturing locations in planning and conducting reliability and stress testing programs. Dr. Chan has taught several training courses in reliability and stress testing and is a regular speaker on these topics. Moreover, he is an adjunct faculty member at the Hong Kong Polytechnic University.
Paul J. Englert is a distinguished member of the technical staff in the Product Realization Department of Lucent Technologies' Wireless Networks Group. He is responsible for wide-scale deployment of mechanical computer-aided design (CAD) and work-in-progress data management solutions. Also, Dr. Englert develops Web-based, multimedia training tools for engineering practices and CAD tools and has lectured in China, Singapore, South Korea, and Taiwan on these subjects. Also, his experience spans a broad spectrum of projects in assembly, manufacturing, stress testing, chemical solvent replacement process development, and statistical modeling.


Table of Contents

Frank IannaH. Anthony Chan and Paul J. EnglertH. Anthony Chan and Paul J. EnglertH. Anthony Chan and Paul J. EnglertH. Anthony Chan and Paul J. EnglertH. Anthony Chan and Paul J. EnglertH. Anthony Chan and Paul J. EnglertClifton J. SeusyGreg PfeifferCharles FelkinsWayne TustinKing Lo and Frank LoVascoKumar Upadhyayula and Abhijit DasguptaPaul J. EnglertS. RajaramDennis E. PachukiCharles SchinnerDonald DallandEdmond L. KyserHarry McLeanT. Paul Parker and Gordon L. HarrisonKevin GranlundHenry Malec
Forewordp. xvii
Prefacep. xix
Acknowledgmentsp. xxi
Part I Overviewp. 1
Chapter 1 Introductionp. 3
1.1 Synopsis of Reliability Trends and Aim of Bookp. 3
1.2 Background of Military and Industrial Stress Testing Practicesp. 5
1.3 Overview of the AST Handbookp. 6
Referencesp. 9
Chapter 2 Principles of Stress Testingp. 10
2.1 Rationale for Stress Testingp. 11
2.1.1 Product Robustnessp. 11
2.1.2 AST and Accelerated Testingp. 12
2.1.3 AST and the Bath-Tub Curvep. 14
2.1.4 Bimodal Product Strength Distributionp. 14
2.1.5 Relevance of AST Failuresp. 17
2.1.6 Types of Stress Failuresp. 18
2.2 Stress Testing Technical and Implementation Issuesp. 19
2.2.1 Modes of ASTp. 19
2.2.2 Other Forms of Stress Testingp. 20
2.2.3 Stress Stimuli and Flaws Precipitated by Themp. 21
2.2.4 Stress Stimuli Selectionp. 22
2.2.5 Stress Level Determinationp. 23
2.2.6 Safety Testingp. 23
2.2.7 Fault Simulation and Detection Issuesp. 24
2.2.8 Form of Product to Testp. 25
2.3 Economic Issuesp. 27
2.3.1 Benefitsp. 27
2.3.2 Cost of ASTp. 27
2.3.3 Optimizing the Application of ASTp. 28
Referencesp. 29
Part II Process and Guidelinesp. 31
Chapter 3 Stress Testing Program: Generic Processesp. 33
3.1 Overview of the Stress Testing Strategyp. 33
3.1.1 Select AST Optionsp. 36
3.2 Design Stress Testing (D-AST)p. 36
3.2.1 Plan Program (A)p. 36
3.2.2 Baseline Product (B)p. 36
3.2.3 Take Corrective Action (C)p. 37
3.3 Manufacturing Qualification Stress Testing (MQ-AST)p. 38
3.3.1 Plan Program (A)p. 39
3.3.2 Baseline Product (B)p. 39
3.3.3 Take Corrective Action (C)p. 39
3.3.4 Develop Manufacturing AST Regimen (D)p. 39
3.3.5 Demonstrate Safety of the AST Regimen (E)p. 40
3.3.6 Perform Manufacturing AST (F)p. 40
3.4 Periodic Qualification Stress Testing (PQ-AST)p. 40
3.5 Production Sampling Stress Test (PS-AST)p. 41
3.5.1 Plan Program (A)p. 41
3.5.2 Develop Manufacturing AST Regimen (D)p. 41
3.5.3 Perform Manufacturing AST Regimen (F)p. 42
3.5.4 Take Corrective Action (C)p. 42
3.5.5 Optimize Manufacturing AST Regimen (G)p. 43
3.6 Full Production Stress Testing (FP-AST)p. 43
Chapter 4 Stress Testing Program Subprocessesp. 44
4.1 Plan Program Subprocess (A)p. 44
4.1.1 TASK 1: Form Team and Develop AST Strategyp. 44
4.1.2 TASK 2: Review and Issue AST Strategyp. 46
4.1.3 TASK 3: Write the AST Planp. 47
4.1.4 TASK 4: Review and Issue AST Planp. 47
4.1.5 TASK 5: AST Tools Realizationp. 48
4.2 Baseline Product Subprocess (B)p. 50
4.2.1 TASK 1: Baseline Productp. 50
4.3 Take Corrective Action Subprocess (C)p. 51
4.3.1 TASK 1: Analyze AST Resultsp. 51
4.3.2 TASK 2: Suggest and Review Corrective Actionsp. 53
4.3.3 TASK 3: Develop AST Verification Plan for Corrective Actionp. 54
4.3.4 TASK 4: Issue Summary of Lessons Learnedp. 55
4.4 Develop Manufacturing Stress Testing Regimen Subprocess (D)p. 55
4.4.1 TASK 1: Determine the Form of Product to be Testedp. 55
4.4.2 TASK 2: Determine What Stress Stimuli Are Effectivep. 56
4.5 Demonstrate Safety of the Stress Testing Regimen Subprocess (E)p. 57
4.5.1 TASK 1: Develop AST Safety Strategyp. 58
4.5.2 TASK 2: Write AST Safety Qualification Planp. 58
4.5.3 TASK 3: Execute Safety Qualification Planp. 59
4.5.4 TASK 4: Analyze Safety Test Datap. 60
4.5.5 TASK 5: Certify Safety of Candidate AST Regimenp. 61
4.6 Perform Manufacturing Stress Testing Subprocess (F)p. 61
4.6.1 TASK 1: Execute AST Planp. 61
4.7 Optimize the Manufacturing Stress Testing Regimen Subprocess (G)p. 62
4.7.1 TASK 1: Analyze Manufacturing AST Regimen Datap. 62
4.7.2 TASK 2: Select Manufacturing AST Mode or Regimenp. 64
4.7.3 TASK 3: Develop Evaluation Plan for Trial AST Regimenp. 64
4.7.4 TASK 4: Conduct Evaluation of Trial AST Regimenp. 65
Chapter 5 Guidelines for Design and Manufacturing Stress Testingp. 66
5.1 AST Test Strategyp. 66
5.2 AST Planp. 68
5.3 Sample Size Selection for Design ASTp. 69
5.4 Typical Stress Stimuli and Associated Product Flawsp. 70
5.5 Recommended Stress Levelsp. 71
5.6 Baseline Product Test Proceduresp. 77
5.7 Failure Mode Analysis and Root Cause Analysisp. 83
5.7.1 Failure Types and Modes Found During Stress Testingp. 85
5.8 Corrective Action and Product Ruggedizationp. 87
5.8.1 Design AST Databasep. 87
Referencesp. 90
Part III Theoryp. 91
Chapter 6 Economics and Optimizationp. 93
6.1 Guidelines for Optimizing Manufacturing Stress Testingp. 93
6.1.1 Product Attributesp. 93
6.1.2 Environment for Stress Testingp. 94
6.1.3 The Optimization Processp. 95
6.1.4 Effectiveness of the Stress Regimenp. 96
6.1.5 A/B Comparisonsp. 97
6.2 Formulationp. 97
6.3 Reliability Objectivep. 98
6.4 Types of Failures Revisitedp. 98
6.5 Distribution of Environmental Stressesp. 98
6.6 Effect of Stress Testingp. 100
6.7 Reliability Requirementsp. 101
6.8 Requirement on Service-Life Fraction Failedp. 101
6.9 Requirement on Product Strength Distributionp. 102
6.10 Examplesp. 103
6.10.1 1 in 100 Service-Life Fraction Failed Requirementsp. 104
6.10.2 1 in 1000 Service-Life Fraction Failed Requirementsp. 104
6.11 Economic Issues and Optimizationp. 105
6.11.1 Reduction in Field Failure Ratep. 105
6.11.2 Potential Benefitsp. 105
6.11.3 Potential Costsp. 106
6.12 Net Benefitp. 106
6.13 Optimizationp. 107
6.14 Product Considerationsp. 108
6.15 Economic Summaryp. 108
Referencesp. 108
Chapter 7 Reliability Growthp. 109
7.1 What Is Reliability Growth?p. 109
7.2 How Many Units Must Be Tested?p. 110
7.2.1 Binomial Probabilitiesp. 110
7.3 Failure Mode Distributionp. 111
7.3.1 Mathematical Substantiationp. 113
7.3.2 Kuklinski Curvesp. 114
7.4 How Are These Units Acquired?p. 118
7.4.1 Prototype Productionp. 118
7.4.2 Final Product Productionp. 119
7.5 The Success of Failures Attained by Stress Testingp. 120
7.5.1 Generic Stressesp. 120
7.5.2 Product-Specific Stresses and Stress Levelsp. 120
7.5.3 Relevance of Stress Failuresp. 121
7.5.4 Addressing All Failure Modesp. 122
7.5.4.1 Design Defect Trackingp. 123
7.5.4.2 Failure Analysisp. 124
7.6 Resultsp. 124
7.7 Conclusionsp. 125
Acknowledgmentsp. 125
Referencesp. 126
Chapter 8 Overview of the Failure Analysis Process for Electrical Componentsp. 127
8.1 Definition of Failure Analysisp. 127
8.2 The Benefits of Performing Failure Analysisp. 127
8.3 Overview of the Failure Analysis Process for Electrical Componentsp. 128
8.3.1 Understand the Problemp. 128
8.3.2 Examine the Component Package with a Low-Power Microscopep. 128
8.3.3 Verify the Failurep. 128
8.3.4 Nondestructive Evaluationp. 128
8.3.5 Stop, Think, and Plan!p. 129
8.3.6 Decapsulate the Devicep. 129
8.3.7 Examine the Interior of the Package and the Die Surfacep. 129
8.3.8 Conduct a Physical Analysisp. 129
8.3.9 Evaluate the Data and Come to a Conclusionp. 129
8.3.10 Develop a Corrective Action Recommendationp. 129
8.3.11 Write and Issue a Report (as Required by the Customer)p. 130
8.3.12 Archive the Data and Samplesp. 130
8.3.13 Follow Up on Customer's Corrective Action Resultsp. 130
8.4 Tools for Component Failure Analysisp. 130
8.4.1 Basic (Tools that Every Lab Needs)p. 130
8.4.2 Additional Toolsp. 131
8.5 Personnel for Component Failure Analysisp. 131
8.6 Challenges Facing Failure Analysts in the Futurep. 131
8.7 What the Customer Can Do to Optimize the Failure Analysis Processp. 132
Referencesp. 132
Part IV Equipment and Techniquesp. 135
Chapter 9 Accelerated Stress Testing Equipment and Techniquesp. 137
9.1 Introductionp. 137
9.2 Thermal Equipmentp. 137
9.2.1 Operating Temperature Rangep. 138
9.2.2 Temperature Rate of Changep. 138
9.2.3 Mechanical Refrigeration versus Liquid Nitrogen (LN[subscript 2]) Coolingp. 140
9.2.4 LN[subscript 2] Implementationp. 141
9.3 Vibration Equipmentp. 142
9.3.1 Issues for Repetitive Shock Machines Using Pneumatic Vibratorsp. 144
9.3.2 Multi-Axial Considerations for Repetitive Shock Machinesp. 145
9.3.3 Table Resonances for Repetitive Shock Machinesp. 147
9.3.4 g[subscript RMS] versus Peak G Stressp. 147
9.4 Combined Thermal and Vibration Equipmentp. 147
9.5 Ancillary Mechanical Equipment for Stress Testingp. 148
9.5.1 Fixturing for Vibration Stressingp. 148
9.5.2 Printed Wiring Board Card Cages Used for Stress Testingp. 149
9.6 Environmental Analysis Equipment Used for Stress Testingp. 152
9.7 Electrical Test Equipment and Software Used for Stress Testingp. 153
9.7.1 AST Test Equipment Hardwarep. 153
9.7.2 AST Test Equipment Softwarep. 153
9.8 Other Stress Optionsp. 154
Chapter 10 Vibration and Shock Inputs Identify Some Failure Modesp. 155
10.1 Why Important?p. 155
10.2 Vibration Measurementsp. 155
10.2.1 Prior Knowledgep. 155
10.2.2 Vibration and Shock Measurement--Unitsp. 157
10.2.3 Vibration and Shock Sensors (Field and Laboratory)p. 159
10.2.3.1 Displacement Sensorsp. 159
10.2.3.2 Velocity Sensorsp. 160
10.2.3.3 Accelerometersp. 160
10.2.3.4 Force Sensorsp. 161
10.2.4 Signal Conditioningp. 162
10.2.5 Display and Recording Instrumentsp. 163
10.2.6 Sources of Sensor Errorp. 163
10.3 Controllable Sources of Vibration and Mechanical Shockp. 164
10.3.1 Electrodynamic (Electromagnetic) Shakersp. 164
10.3.1.1 Shaker Armaturep. 164
10.3.1.2 Magnetic Fieldp. 165
10.3.1.3 Alternating Current Generates Forcep. 165
10.3.1.4 Force Ratingsp. 165
10.3.1.5 Vertical or Horizontal Thrustingp. 167
10.3.1.6 Isolation from Buildingp. 167
10.3.2 Power Amplifiersp. 167
10.3.2.1 Delivering Adequate Alternating Current for Shaker Driver Coilp. 167
10.3.2.2 Momentary Power Peaksp. 168
10.3.2.3 Importance of Low Distortionp. 168
10.3.2.4 Direct Current for Shaker Field Windingp. 168
10.3.3 Controlsp. 168
10.3.3.1 Controls for Sine Vibration Testingp. 169
10.3.3.2 Controls for Random Vibration Testingp. 169
10.3.3.3 Tolerancesp. 169
10.3.3.4 Abort Limitsp. 169
10.3.3.5 Controls for Shock Testingp. 170
10.3.4 Test Fixturesp. 170
10.4 Characteristics of Shock, Sine, and Random Vibrationp. 170
10.4.1 Mechanical Shock Pulsep. 170
10.4.2 Sinusoidal Vibration and Its Effectsp. 172
10.4.3 Random Vibration and Its Effectsp. 173
10.4.4 Amplitude Probability Densityp. 174
10.4.5 Acceleration Spectral Densityp. 176
10.5 Multi-Axis Excitationp. 176
10.6 Repetitive Shock Machines for Multi-Axis Stress Testingp. 178
10.7 Using Random Vibration and Repetitive Shock for Stress Testingp. 178
10.7.1 What Spectrum?p. 179
10.7.2 What Intensity?p. 180
10.7.3 For How Long?p. 180
10.7.4 Is Our Production Screening Damaging Good Hardware?p. 180
Chapter 11 Relative Effectiveness of Thermal Cycling Versus Burn-Inp. 182
11.1 Introductionp. 182
11.2 Results for Thermal Cycling Alonep. 183
11.3 Intermittents and First Eventsp. 183
11.4 Thermal Cycling versus Burn-Inp. 185
11.5 Failure Mechanismsp. 186
11.6 Conclusionp. 187
Acknowledgmentsp. 188
Chapter 12 Accelerated Qualification of Electronic Assemblies Under Combined Temperature Cycling and Vibration Environments: Is Miner's Hypothesis Valid?p. 189
12.1 Introductionp. 190
12.2 Combined Temperature and Vibration Accelerated Life Testsp. 191
12.3 The Macroscopic Incremental Damage Superposition Approach (Macro-IDSA)p. 194
12.4 The Micromechanistic Incremental Damage Superposition Approach (Micro-IDSA)p. 197
12.5 Conclusionsp. 200
Acknowledgmentsp. 201
Referencesp. 201
Chapter 13 Liquid Environmental Stress Testing (Lest)p. 203
13.1 Advantages of Liquid Environmental Stress Testingp. 203
13.2 Liquid Environmental Stress Testing Facilityp. 204
13.2.1 Overview of LEST Facility Featuresp. 204
13.3 Thermal Considerations in Liquid Environmental Stress Testingp. 208
13.4 Conclusionsp. 214
Referencesp. 214
Chapter 14 Safety Qualification of Stress Testingp. 216
14.1 Stress Testing Safety Qualification Programp. 217
14.1.1 Generic Component Qualificationp. 219
14.1.1.1 IC Qualificationp. 219
14.1.1.2 Discrete Component Qualificationp. 220
14.1.2 Specific Code Qualificationp. 220
14.1.2.1 The Qualification Processp. 221
14.1.2.2 AST with Voltage Biasp. 221
14.1.2.3 THB Testingp. 222
14.1.2.4 Product Destruct Limit Testingp. 223
14.2 Safety Qualification Programs for Other Types of Stressesp. 223
Referencesp. 224
Part V Best Practices Case Studies in Computer, Communications, and Other Industriesp. 227
Chapter 15 Production Ast With Computers Using the Taguchi Methodp. 229
15.1 Introductionp. 229
15.2 Objectivesp. 230
15.3 Stress Overviewp. 230
15.4 Stress Screen Designsp. 230
15.4.1 Temperature Rangep. 230
15.4.2 Temperature Change Ratep. 231
15.4.3 Power Cyclingp. 231
15.4.4 Vibration Screen Determinationp. 231
15.4.5 Fixture Designp. 232
15.4.6 Vibration Stress Durationp. 232
15.4.7 Diagnostic Monitoringp. 232
15.5 Experiment Overviewp. 232
15.5.1 Test Process Product Flowp. 233
15.6 The Taguchi Methodp. 234
15.6.1 Sample Size Selectionp. 235
15.7 Response Variable Results and Conclusions of the Taguchi Experimentp. 236
15.7.1 Triaxial Random Vibrationp. 236
15.7.2 Temperature Cyclingp. 237
15.7.3 Power Cyclingp. 237
15.8 Intra-Experiment Summaryp. 237
15.9 Taguchi Method Conclusionp. 238
15.10 Termsp. 239
Acknowledgmentsp. 239
Referencesp. 239
Chapter 16 Design Ast With Vendor Electronicsp. 240
16.1 Introductionp. 240
16.2 The Test-Analyze-Correct-Verify Processp. 240
16.3 Accelerated Reliability Techniques (ART)p. 242
16.3.1 Stress Tool Boxp. 243
16.3.2 Broad Spectrum Stress Portfoliop. 243
16.4 Original Equipment Manufacturer (OEM) Power Supply Examplep. 244
16.5 Conclusionsp. 251
Acknowledgmentsp. 252
Referencesp. 252
Chapter 17 Design and Production Ast With Power Suppliesp. 253
17.1 Backgroundp. 253
17.1.1 Switching Power Suppliesp. 253
17.2 STRIFE in New Product Development (Design AST)p. 253
17.2.1 Vibrationp. 254
17.2.2 Thermal Testp. 255
17.2.3 Electrical Overstressp. 256
17.2.4 Power Cyclingp. 256
17.2.5 Resultsp. 256
17.2.6 Conclusions with STRIFE in Product Development (Design AST)p. 257
17.3 ESS in Manufacturing (Production AST)p. 257
17.3.1 Burn-Inp. 257
17.3.1.1 Burn-In Conditionsp. 258
17.3.1.2 Resultsp. 258
17.3.2 Vibration Screeningp. 259
17.3.2.1 Conditionsp. 259
17.3.2.2 Resultsp. 260
17.3.3 Conclusions with ESS in Manufacturing (Production AST)p. 260
17.4 Final Conclusionsp. 261
Acknowledgmentsp. 262
Chapter 18 Design and Production Ast With Computersp. 263
18.1 Backgroundp. 263
18.1.1 A Massively Parallel RISC-Based Serverp. 263
18.2 The ESS Programp. 263
18.2.1 Integrationp. 264
18.3 Conclusionsp. 268
Acknowledgmentsp. 268
Definitions and Acronymsp. 268
Referencep. 268
Chapter 19 Qualifications and Production Sampling Ast With Printed Circuit Boardsp. 269
19.1 Introductionp. 269
19.2 Proposed Test and Theoryp. 270
19.3 Ongoing Monitoring of the Production Processp. 271
19.4 Screen Developmentp. 273
19.5 Equipmentp. 274
19.6 Results of the Initial Testingp. 275
19.7 Conclusionsp. 278
Acknowledgmentsp. 280
Glossaryp. 280
Referencesp. 281
Chapter 20 Manufacturing Ast With Telecommunication Productsp. 282
20.1 Introductionp. 282
20.2 EST During Product Design (Design AST)p. 284
20.3 Production EST (AST)p. 285
20.3.1 Techniques of Production EST (AST)p. 286
20.3.2 FMA and Corrective Actionp. 287
20.4 Production EST (AST) Studies at ATandTp. 288
20.4.1 Facilities Hardware and Softwarep. 289
20.4.2 Thermal Profilep. 291
20.5 Results of the Thermal Cycling Studiesp. 291
20.5.1 Phase I Studyp. 292
20.5.2 Phase IIap. 292
20.5.3 Phase IIbp. 294
20.5.4 Phase IIIp. 294
20.5.5 Phase IVp. 296
20.5.6 Future Studiesp. 296
20.5.7 Conclusionp. 297
Acknowledgmentsp. 297
Referencesp. 298
Chapter 21 Production Ast With Computer Disksp. 300
21.1 Introductionp. 300
21.2 Growing Reliabilityp. 301
21.3 Problemp. 302
21.4 Case Studyp. 302
21.5 Product Flowp. 303
21.6 Profile Utilizedp. 304
21.7 A Look at the Failure Mechanismsp. 304
21.8 The Bottom Linep. 306
21.9 Conclusionp. 307
Referencesp. 307
Chapter 22 Benchmarkingp. 308
22.1 Introduction to Benchmarkingp. 308
22.1.1 Traditional Benchmarkingp. 310
22.1.2 Product Benchmarkingp. 313
22.1.3 AST Benchmarkingp. 316
22.2 The AST Benchmarking Processp. 317
22.3 Benchmarking Partnerships--Otis Elevator Company and United Technologies/3Com Corporation (U.S. Robotics)p. 325
22.4 Benchmarking AST Survey Datap. 327
22.5 Summaryp. 329
Acknowledgmentsp. 329
Referencesp. 329
Appendix A Environmental Stress Screening Questionnaire--1997p. 330
Appendix B Environmental Stress Screening Questionnaire--1996 and 1997 Resultsp. 333
Glossary of Stress Testing Terminologyp. 338
Bibliographyp. 340
Indexp. 365
Epiloguep. 369
About the Editorsp. 371