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Prognostics of Thermal Fatigue Failure of Solder Joints in Avionic Equipment
Saab AB, Sweden.
SP Technical Research Institute of Sweden, and Jönköping University.
2012 (English)In: IEEE Aerospace and Electronic Systems Magazine, ISSN 0885-8985, E-ISSN 1557-959X, Vol. 27, no 4, 16-24 p.Article in journal (Refereed) Published
Abstract [en]

A practical method has been suggested for solder joint thermal fatigue prognostics, which enables real-time fatigue calculations based on uncompressed temperature data embedded in a host system that performs safety-critical operations. The accuracy of the prognosticated remaining useful life depends on the level of details captured in the model, and the level of confidence from validation efforts.

Place, publisher, year, edition, pages
IEEE , 2012. Vol. 27, no 4, 16-24 p.
Keyword [en]
Thermal fatigue prognostics, physics-of-failure, electronics, avionics, solder joints.
National Category
Other Electrical Engineering, Electronic Engineering, Information Engineering
Identifiers
URN: urn:nbn:se:liu:diva-91900DOI: 10.1109/MAES.2012.6203714OAI: oai:DiVA.org:liu-91900DiVA: diva2:619545
Available from: 2013-05-04 Created: 2013-05-04 Last updated: 2017-12-06Bibliographically approved
In thesis
1. Thermal Fatigue Life Prediction of Solder Joints in Avionics by Surrogate Modeling: A Contribution to Physics of Failure in Reliability Prediction
Open this publication in new window or tab >>Thermal Fatigue Life Prediction of Solder Joints in Avionics by Surrogate Modeling: A Contribution to Physics of Failure in Reliability Prediction
2013 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Manufacturers of aerospace, defense, and high performance (ADHP) equipment are currently facing multiple challenges related to the reliability of electronic systems. The continuing reduction in size of electronic components combined with increasing clock frequencies and greater functionality, results in increased power density. As an effect, controlling the temperature of electronic components is central in electronic product development in order to maintain and potentially improve the reliability of the equipment. Simultaneously, the transition to lead-free electronic equipment will most probably propagate also to the ADHP industry. Compared to well-proven tin-lead solder, the knowledge about field operation reliability of lead-free solders is still limited, as well as the availability of damage evaluation models validated for field temperature conditions. Hence, the need to fill in several knowledge gaps related to reliability and reliability prediction of lead-free solder alloys is emphasized. Having perceived increasing problems experienced in the reliability of fielded equipment, the ADHP industry has suggested inclusion of physics-of-failure (PoF) in reliability prediction of electronics as one potential measure to improve the reliability of the electronic systems.

This thesis aims to contribute to the development of reliable ADHP systems, with the main focus on electronic equipment for the aerospace industry. In order to accomplish this, the thesis provides design guidelines for power distribution on a double-sided printed circuit board assembly (PBA) as a measure to improve the thermal performance without increasing the weight of the system, and a novel, computationally efficient method for PoF-based evaluation of damage accumulation in solder joints in harsh, non-cyclic field operation temperature environments.

Thermal fatigue failure mechanisms and state‑of‑the‑art thermal design and design tools are presented, with focus on the requirements that may arise from avionic use, such as low weight, high reliability, and ability to sustain functional during high vibration levels and high g-forces. Paper I, II, and III describes an in-depth investigation that has been performed utilizing advanced thermal modeling of power distribution on a double-sided PBA as a measure to improve the thermal performance of electronic modules.

Paper IV contributes to increasing the accuracy of thermal fatigue life prediction in solder joints, by employing existing analytical models for predicting thermal fatigue life, but enhancing the prediction result by incorporating advanced thermal analysis in the procedure.

Papers V and VI suggest and elaborate on a computational method that utilizes surrogate stress and strain modeling of a solder joint, to quickly evaluate the damage accumulated in a critical solder joint from non-cyclic, non-simplified field operation temperature profiles, with accuracy comparable to finite element modeling. The method has been tested on a ball grid array package with SnAgCu solder joints. This package is included in an extensive set of accelerated tests that helps to qualify certain packages and solder alloys for avionic use. The tests include -20°C to +80°C and -55°C to +125°C thermal cycling of a statistically sound population of a number of selected packages, assembled with SnAgCu, Sn100C, and SnPbAg solder alloys. Statistical analysis of the results confirms that the SnAgCu-alloy may outperform SnPbAg solder at moderate thermal loads on the solder joints.

In Papers VII and VIII, the timeframe is extended to a future, in which validated life prediction models will be available, and the suggested method is expected to increase the accuracy of embedded prognostics of remaining useful thermal fatigue life of a critical solder joint.

The key contribution of the thesis is the added value of the proposed computational method utilized in the design phase for electronic equipment. Due to its ability for time-efficient operation on uncompressed temperature data, the method gives contribution to the accuracy, and thereby also to the credibility, of reliability prediction of electronic packages in the design phase. This especially relates to applications where thermal fatigue is a dominant contributor to the damage of solder joints.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2013. 64 p.
Series
Linköping Studies in Science and Technology. Dissertations, ISSN 0345-7524 ; 1521
National Category
Other Electrical Engineering, Electronic Engineering, Information Engineering
Identifiers
urn:nbn:se:liu:diva-91903 (URN)978-91-7519-618-3 (ISBN)
Public defence
2013-06-11, K3, Kåkenhus, Campus Norrköping, Linköpings Universitet, Norrköping, 10:15 (English)
Opponent
Supervisors
Funder
The Knowledge Foundation
Available from: 2013-05-08 Created: 2013-05-04 Last updated: 2013-05-08Bibliographically approved

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Johansson, Jonas

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