march 15 - 18, 2015 hilton phoenix / mesa hotel mesa, arizona … · 2015-03-30 · march 15 - 18,...

BiTS 2015

March 15-18, 2015Burn-in & Test Strategies Workshop www.bitsworkshop.org

Proceedings

Archive – Session 4

March 15 - 18, 2015

Hilton Phoenix / Mesa Hotel

Mesa, Arizona

© 2015 BiTS Workshop – Image: BCFC/iStock

BiTS 2015


ProceedingsBiTS Workshop 2015 Schedule

Session

Session Chair

Performance DayTuesday March 17 8:00 am

Material Magic

"Reliability and Failure over Time"Mike Gedeon - Materion

"Using Cold Heading Technology and Deutsch Coat to Produce Test Probes & Spring Contacts "

Jimmy L. Johnson - Tyco Electronics

"APEX Glass for Burn-In and Test Sockets"Jeb H. Flemming & Tim Foster - 3D Glass Solutions, Inc.

"C3 Coating : Solution for IC Testing"Bert Brost & Valts Treibergs - Xcerra Corporation

Nakaya Katsura - Kobelco Research Institute, Inc.

4Rafiq Hussain

Approved/BiTS2015s4p1Gedeon.pptx

Approved/BiTS2015s4p2Johnson.pptx

Approved/BiTS2015s4p3FlemmingR2.pptx

Approved/BiTS2015s4p4Brost.pptx

BiTS 2015


Proceedings

Copyright Notice

The presentation(s)/paper(s) in this publication comprise the Proceedings of the 2015 BiTS Workshop. The content reflects the opinion of the authors and their respective companies. They are reproduced here as they were presented at the 2015 BiTS Workshop. This version of the papers may differ from the version that was distributed in hardcopy & softcopy form at the 2015 BiTS Workshop. The inclusion of the presentations/papers in this publication does not constitute an endorsement by BiTS Workshop or the workshop’s sponsors.

There is NO copyright protection claimed on the presentation content by BiTS Workshop. However, each presentation is the work of the authors and their respective companies: as such, it is strongly encouraged that any use reflect proper acknowledgement to the appropriate source. Any questions regarding the use of any materials presented should be directed to the author(s) or their companies.

The BiTS logo and ‘Burn-in & Test Strategies Workshop’ are trademarks of BiTS Workshop. All rights reserved.

Material Magic - Materials and fabrication processesBiTS 2015Session 4 Presentation 1


Reliability and Time-

Dependent Failure

Mike Gedeon

Materion Performance Alloys

2015 BiTS Workshop

March 15 - 18, 2015Conference Ready

mm/dd/2014



“Riddles in the Dark”

• “This thing all things devours: birds,

beasts, trees, flowers;

Gnaws iron, bites steel;

Grinds hard stones to meal;

Slays king, ruins town, and beats high

mountain down.” - Gollum

J.R.R. Tolkien – The Hobbit

Reliability and Time-Dependent Failure 2



The Answer

• Time




The Bathtub Curve


Time

Fa

ilure

Ra

te Burn

In

Wear

Out -

EOLUseful

Life



Stress-Strain Curve


0.0% 1.0% 2.0% 3.0% 4.0% 5.0%

Fo

rce

, S

tre

ss

Deflection, Strain

A = Proportional Limit

B = 0.2% OYS

C = UTS

D = Elastic Limit

X = Fracture Point

A

B

C

Slope O-A = Elastic Modulus

(Young's Modulus)

D

X

O



Fo

rce

, S

tre

ss

Deflection, Strain

Normal Loading and Unloading

σ-ε Curve

Loading Curve

Unloading Curve

Stress-Strain Curve

• Plastic Behavior


Permanent

Set



0

500

1000

1500

0 200 400

Elevated Temperature Properties


Temperature (°C)

Yie

ld S

tre

ng

th

(MP

a)



Creep (Heat Deflection)


Fo

rce

, S

tre

ss

Deflection, Strain

σ-ε Curve

Loading Curve

Creep Over Time

Unloading After Creep



Stress Relaxation


Fo

rce

, S

tre

ss

Deflection, Strain

σ-ε Curve

Loading

σ Relax Over Time

Unloading After Relaxation



Stress Relaxation Resistance




Stress Relaxation Resistance


90%

92%

94%

96%

98%

100%

0 500 1000

Pe

rce

nt

Str

es

s

Re

ma

inin

g

Hours

Alloy 190 XHM - 100°C

100% of 0.2% OYS - 155 ksi

75% of 0.2% OYS - 116 ksi

50% of 0.2% OYS - 77.5 ksi

50% of 0.01% OYS - 58.5 ksi



Thermal Runaway

• Steady state or infinite loop?

• Conductivity dependent


HeatCurrent Resistance



Avoiding Thermal Failures

• Sufficient elevated temperature yield

strength/heat deflection temperature

• Stress relaxation resistance

• Sufficient conductivity




Fatigue

• Accumulated damage over time at low

stress

• Slow process, imperceptible each cycle

• Sudden, catastrophic failure




Fatigue Failure – Fracture Surface




Typical Fatigue Data


0

20

40

60

80

100

120

140

1.E+03 1.E+05 1.E+07 1.E+09

Ma

xim

um

Str

es

s

(ks

i)

Cycles to Failure

Test Data

1% Failure Rate

10% Failure Rate

50% Failure Rate



All Cycled Loading Susceptible

• Tension

• Torsion

• Bending

• Compression




Avoiding Fatigue Failures

• High fatigue strength material

• Sufficiently ductile, uniform material

• Smooth surface, edges

• Minimize stress concentration

• Avoid corrosion (low stress plating)




Corrosion

• Deterioration caused by chemical or

electrochemical reaction of the metal with

its environment. – ASM Metals

Handbook Desk Edition

• “Corrosion is a natural process that tries

to reverse the chemical action of the

refining process.” – Donald J. Wulpi

Understanding how Components Fail




Some Types of Corrosion

• General Corrosion*

• Pore Corrosion*

• Creep Corrosion*

• Galvanic Corrosion

• Fretting Corrosion

• Stress-Corrosion

Cracking

• Dealloying

• Crevice Corrosion

• Corrosion Fatigue

• H2 Embrittlement

• Liquid Metal

Embrittlement


*Likely to be found in BiTS World



General Corrosion

• Slow, uniform attack of entire surface

• Least prone to catastrophic failure

• Ways to reduce general corrosion:

– Use a more noble metal

– Use coating

– Let the part erode –

maybe more economical




Pore Corrosion

• Pores – Defects in plating

– Exposes base metal

• Ways to reduce:

– Increase plating thickness

– Use underplating of less porous metal




Pore Corrosion




Pore and Creep Corrosion Control


creeping corrosion products

Au plating

Cu alloy base metal

Au plating

Ni underplate

Cu alloy base metal

protective Ni oxide in pores

creeping corrosion products

protective Ni oxide on edge

Pore Corrosion Corrosion Migration

“ACTIVE”

PORES

“PASSIVE”

PORES



Adhesive & Abrasive Wear

• Adhesive Wear - softer material transfers

onto harder surface

– e.g. solder onto crown

• Abrasive Wear - Hard particles plow

across surface and remove volume

– e.g. oxide particles




Adhesive & Abrasive Wear

• Surfaces in Contact


Cold Welded Asperities

Wear Particles



Avoiding Corrosion and Wear Issues

• Plate (sufficiently thick) to avoid

corrosion

• Clean to remove corrosion product &

wear debris

• Re-plate to enhance service life




Mechanical Hysteresis

• Stress-strain behavior over time




Strain Softening


• Softening behavior over time

– No cracks

– No elevated

temperature

required



Strain Softening

• Usually occurs around knee of stress-

strain curve


Yield

Strength

Elastic

Limit



Avoiding Hysteresis Issues

• Sufficient elastic limit in Material

• Know strain hardening behavior

• Keep stresses in safe zone




Final Thought

• “All we have to do is decide what to do

with the time that is given to us.” -

Gandalf

J.R.R. Tolkien – The Lord of the Rings


march 15 - 18, 2015 hilton phoenix / mesa hotel mesa, arizona … · 2015-03-30 · march 15 - 18,...

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