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Environmental Stress Screening Tutorial Publisher: Accolade Engineering Solutions Overview: This paper provides an overview of environmental stress screening technology, and describes the developmental aspects of an effective environmental stress screening process. The study begins by describing the purpose of any environmental stress screening (ESS) regimen and discussing the most common mathematical models for quantifying stress screening programs, also called the empirical stress screen equations. The different phases of environmental stress screening technology such as the product profiling phase, also called the HALT (Highly Accelerated Life Test) of ESS executed by the designers engineering, and screen development phase of ESS implementation executed by manufacturing are analyzed. The type of stimulus and the screening parameters to determine the type of thermal cycling equipment to be used, are also covered. Finally, this paper concludes that the environmental stress screening programs must ensure that they properly stimulate the types of defects that are expected to be found in production and in the field. View Company Profile View Engineering & Consulting Suppliers View Engineering & Consulting Guides View Instruments & Controls Suppliers View Instruments & Controls Guides View Process Equipment Suppliers View Process Equipment Guides Format: PDF Date: 2008-11-26 View all Accolade Engineering Solutions White Papers TABLE OF CONTENTS 1. Introduction 2 2. References 3 3. Definitions 4 3.1. Bathtub Curve 4 3.2. Burn-In Test 4 3.3. Creep 4 3.4. Coffin-Manson Model 4 3.5. Corrective Action 4 3.6. Cyclic Differential Expansion 4 3.7. Cyclic Temperature Range or Swing 4 3.8. Destruct Limit 4 3.9. Detection Screen 4 3.10. Environmental Stress Screening 4 3.11. Highly Accelerated Stress Screen 4 3.12. Infant Mortality 5 3.13. Latent 5 3.14. Maximum Cyclic Strain Range 5 3.15. NAVMAT P-9492 Random Vibration Profile 5 3.16. Operating Limit 5 3.17. Patent 5 3.18. Precipitate 5 3.19. Precipitation Screen 5 3.20. Proof of Screen 5 3.21. Random Vibration 5 3.22. Sine Vibration 5 3.23. Solder Attachment 5 3.24. Step Stress Approach 5 3.25. Stress Relation 5 3.26. Thermal Cycling 6 3.27. Thermal Shock 6 3.28. Vibration 6 4. Background 7 5. Solder Joint Failure Mechanisms and Environmental Stimuli 12 6. Introduction of Mathematical Models 14 6.1. The Arrhenius Reaction Rate Model 14 6.2. The RADC Models 15 6.2.1. The RADC Constant Temperature Model 15 6.2.2. The RADC Thermal Cycling Model 16 7. Product Profiling 19 7.1. Documentation 19 7.2. Selection of Stimuli 19 7.3. Determination of Product Limits 20 7.4. Product Changes to Improve Margins 20 8. Screen Development 21 8.1. Selection of Stimuli 21 8.2. Magnitude of Precipitation Stimuli 21 8.2.1. Voltage 22 8.2.2. Vibration 22 8.2.3. Thermal Cycling 22 8.2.4. Power Cycling 22 8.3. Duration of Applied Stimuli 22 8.4. Proof of Screen 23 8.5. Testing During the Precipitation Screen 24 8.6. Detection Screens 24 8.6.1. Voltage 24 8.6.2. Vibration 24 8.6.3. Thermal Cycling 24 8.6.4. Elevated Temperature 25 8.7. Root Cause Analysis 25 8.8. Optimizing the ESS Process 25 8.9. Corrective Action 26 8.10. Re-Screening Product 27 9. Thermal Screening Equipment 28 10. Conclusions 30 11. Figures 8 11.1. IES Survey of Screening Effectiveness 8 11.2. French ESS Task Team ESS Effectiveness Survey 9 11.3. Stress Strain Curves for Solder Joints 12 11.4. Solder Joint Lifetime as a Function of Thermal Cycling Temperature Range 13 11.5. Arrhenuis Acceleration Plot as Function of Temperature 15 11.6. RADC Model for Screening Strength of Constant Temperature Screen 16 11.7. Screening Strength as a Function of Number of Thermal Cycles 17 11.8. Number of Thermal Cycles as a Function of Rate of Temperature Change 17 11.9. Screening Strength as a Function of Time 18 11.10. Single Zone Chamber Layout 29 11.11. 2 Zone Air-to-Air Chamber 29 12. Tables 8 12.1. Summary of Electrical Burn-in Results 8 12.2. Baseline Regimen for Organizations Lacking ESS Experience 9 12.3. IC Failure Mechanism and the Best Screens for Precipitation or Detection 11 12.4. Screening Time and Temperature Rate of Change 18

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