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Accelerated Stress Testing Handbook Guide for Achieving Quality Products

Best in textbook rentals since 2012!

ISBN-10: 0780360257

ISBN-13: 9780780360259

Edition: 2001

Authors: H. Anthony Chan, Paul J. Englert

List price: $245.95
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Description:

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…    
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Book details

List price: $245.95
Copyright year: 2001
Publisher: John Wiley & Sons, Incorporated
Publication date: 5/25/2001
Binding: Hardcover
Pages: 372
Size: 7.03" wide x 10.57" long x 1.04" tall
Weight: 1.804
Language: English

Foreword
Preface
Acknowledgments
Overview
Introduction
Synopsis of Reliability Trends and Aim of Book
Background of Military and Industrial Stress Testing Practices
Overview of the AST Handbook
References
Principles of Stress Testing
Rationale for Stress Testing
Product Robustness
AST and Accelerated Testing
AST and the Bath-Tub Curve
Bimodal Product Strength Distribution
Relevance of AST Failures
Types of Stress Failures
Stress Testing Technical and Implementation Issues
Modes of AST
Other Forms of Stress Testing
Stress Stimuli and Flaws Precipitated by Them
Stress Stimuli Selection
Stress Level Determination
Safety Testing
Fault Simulation and Detection Issues
Form of Product to Test
Economic Issues
Benefits
Cost of AST
Optimizing the Application of AST
References
Process and Guidelines
Stress Testing Program: Generic Processes
Overview of the Stress Testing Strategy
Select AST Options
Design Stress Testing (D-AST)
Plan Program (A)
Baseline Product (B)
Take Corrective Action (C)
Manufacturing Qualification Stress Testing (MQ-AST)
Plan Program (A)
Baseline Product (B)
Take Corrective Action (C)
Develop Manufacturing AST Regimen (D)
Demonstrate Safety of the AST Regimen (E)
Perform Manufacturing AST (F)
Periodic Qualification Stress Testing (PQ-AST)
Production Sampling Stress Test (PS-AST)
Plan Program (A)
Develop Manufacturing AST Regimen (D)
Perform Manufacturing AST Regimen (F)
Take Corrective Action (C)
Optimize Manufacturing AST Regimen (G)
Full Production Stress Testing (FP-AST)
Stress Testing Program Subprocesses
Plan Program Subprocess (A)
TASK 1: Form Team and Develop AST Strategy
TASK 2: Review and Issue AST Strategy
TASK 3: Write the AST Plan
TASK 4: Review and Issue AST Plan
TASK 5: AST Tools Realization
Baseline Product Subprocess (B)
TASK 1: Baseline Product
Take Corrective Action Subprocess (C)
TASK 1: Analyze AST Results
TASK 2: Suggest and Review Corrective Actions
TASK 3: Develop AST Verification Plan for Corrective Action
TASK 4: Issue Summary of Lessons Learned
Develop Manufacturing Stress Testing Regimen Subprocess (D)
TASK 1: Determine the Form of Product to be Tested
TASK 2: Determine What Stress Stimuli Are Effective
Demonstrate Safety of the Stress Testing Regimen Subprocess (E)
TASK 1: Develop AST Safety Strategy
TASK 2: Write AST Safety Qualification Plan
TASK 3: Execute Safety Qualification Plan
TASK 4: Analyze Safety Test Data
TASK 5: Certify Safety of Candidate AST Regimen
Perform Manufacturing Stress Testing Subprocess (F)
TASK 1: Execute AST Plan
Optimize the Manufacturing Stress Testing Regimen Subprocess (G)
TASK 1: Analyze Manufacturing AST Regimen Data
TASK 2: Select Manufacturing AST Mode or Regimen
TASK 3: Develop Evaluation Plan for Trial AST Regimen
TASK 4: Conduct Evaluation of Trial AST Regimen
Guidelines for Design and Manufacturing Stress Testing
AST Test Strategy
AST Plan
Sample Size Selection for Design AST
Typical Stress Stimuli and Associated Product Flaws
Recommended Stress Levels
Baseline Product Test Procedures
Failure Mode Analysis and Root Cause Analysis
Failure Types and Modes Found During Stress Testing
Corrective Action and Product Ruggedization
Design AST Database
References
Theory
Economics and Optimization
Guidelines for Optimizing Manufacturing Stress Testing
Product Attributes
Environment for Stress Testing
The Optimization Process
Effectiveness of the Stress Regimen
A/B Comparisons
Formulation
Reliability Objective
Types of Failures Revisited
Distribution of Environmental Stresses
Effect of Stress Testing
Reliability Requirements
Requirement on Service-Life Fraction Failed
Requirement on Product Strength Distribution
Examples
1 in 100 Service-Life Fraction Failed Requirements
1 in 1000 Service-Life Fraction Failed Requirements
Economic Issues and Optimization
Reduction in Field Failure Rate
Potential Benefits
Potential Costs
Net Benefit
Optimization
Product Considerations
Economic Summary
References
Reliability Growth
What Is Reliability Growth?
How Many Units Must Be Tested?
Binomial Probabilities
Failure Mode Distribution
Mathematical Substantiation
Kuklinski Curves
How Are These Units Acquired?
Prototype Production
Final Product Production
The Success of Failures Attained by Stress Testing
Generic Stresses
Product-Specific Stresses and Stress Levels
Relevance of Stress Failures
Addressing All Failure Modes
Design Defect Tracking
Failure Analysis
Results
Conclusions
Acknowledgments
References
Overview of the Failure Analysis Process for Electrical Components
Definition of Failure Analysis
The Benefits of Performing Failure Analysis
Overview of the Failure Analysis Process for Electrical Components
Understand the Problem
Examine the Component Package with a Low-Power Microscope
Verify the Failure
Nondestructive Evaluation
Stop, Think, and Plan!
Decapsulate the Device
Examine the Interior of the Package and the Die Surface
Conduct a Physical Analysis
Evaluate the Data and Come to a Conclusion
Develop a Corrective Action Recommendation
Write and Issue a Report (as Required by the Customer)
Archive the Data and Samples
Follow Up on Customer's Corrective Action Results
Tools for Component Failure Analysis
Basic (Tools that Every Lab Needs)
Additional Tools
Personnel for Component Failure Analysis
Challenges Facing Failure Analysts in the Future
What the Customer Can Do to Optimize the Failure Analysis Process
References
Equipment and Techniques
Accelerated Stress Testing Equipment and Techniques
Introduction
Thermal Equipment
Operating Temperature Range
Temperature Rate of Change
Mechanical Refrigeration versus Liquid Nitrogen (LN[subscript 2]) Cooling
LN[subscript 2] Implementation
Vibration Equipment
Issues for Repetitive Shock Machines Using Pneumatic Vibrators
Multi-Axial Considerations for Repetitive Shock Machines
Table Resonances for Repetitive Shock Machines
g[subscript RMS] versus Peak G Stress
Combined Thermal and Vibration Equipment
Ancillary Mechanical Equipment for Stress Testing
Fixturing for Vibration Stressing
Printed Wiring Board Card Cages Used for Stress Testing
Environmental Analysis Equipment Used for Stress Testing
Electrical Test Equipment and Software Used for Stress Testing
AST Test Equipment Hardware
AST Test Equipment Software
Other Stress Options
Vibration and Shock Inputs Identify Some Failure Modes
Why Important?
Vibration Measurements
Prior Knowledge
Vibration and Shock Measurement--Units
Vibration and Shock Sensors (Field and Laboratory)
Displacement Sensors
Velocity Sensors
Accelerometers
Force Sensors
Signal Conditioning
Display and Recording Instruments
Sources of Sensor Error
Controllable Sources of Vibration and Mechanical Shock
Electrodynamic (Electromagnetic) Shakers
Shaker Armature
Magnetic Field
Alternating Current Generates Force
Force Ratings
Vertical or Horizontal Thrusting
Isolation from Building
Power Amplifiers
Delivering Adequate Alternating Current for Shaker Driver Coil
Momentary Power Peaks
Importance of Low Distortion
Direct Current for Shaker Field Winding
Controls
Controls for Sine Vibration Testing
Controls for Random Vibration Testing
Tolerances
Abort Limits
Controls for Shock Testing
Test Fixtures
Characteristics of Shock, Sine, and Random Vibration
Mechanical Shock Pulse
Sinusoidal Vibration and Its Effects
Random Vibration and Its Effects
Amplitude Probability Density
Acceleration Spectral Density
Multi-Axis Excitation
Repetitive Shock Machines for Multi-Axis Stress Testing
Using Random Vibration and Repetitive Shock for Stress Testing
What Spectrum?
What Intensity?
For How Long?
Is Our Production Screening Damaging Good Hardware?
Relative Effectiveness of Thermal Cycling Versus Burn-In
Introduction
Results for Thermal Cycling Alone
Intermittents and First Events
Thermal Cycling versus Burn-In
Failure Mechanisms
Conclusion
Acknowledgments
Accelerated Qualification of Electronic Assemblies Under Combined Temperature Cycling and Vibration Environments: Is Miner's Hypothesis Valid?
Introduction
Combined Temperature and Vibration Accelerated Life Tests
The Macroscopic Incremental Damage Superposition Approach (Macro-IDSA)
The Micromechanistic Incremental Damage Superposition Approach (Micro-IDSA)
Conclusions
Acknowledgments
References
Liquid Environmental Stress Testing (Lest)
Advantages of Liquid Environmental Stress Testing
Liquid Environmental Stress Testing Facility
Overview of LEST Facility Features
Thermal Considerations in Liquid Environmental Stress Testing
Conclusions
References
Safety Qualification of Stress Testing
Stress Testing Safety Qualification Program
Generic Component Qualification
IC Qualification
Discrete Component Qualification
Specific Code Qualification
The Qualification Process
AST with Voltage Bias
THB Testing
Product Destruct Limit Testing
Safety Qualification Programs for Other Types of Stresses
References
Best Practices Case Studies in Computer, Communications, and Other Industries
Production Ast With Computers Using the Taguchi Method
Introduction
Objectives
Stress Overview
Stress Screen Designs
Temperature Range
Temperature Change Rate
Power Cycling
Vibration Screen Determination
Fixture Design
Vibration Stress Duration
Diagnostic Monitoring
Experiment Overview
Test Process Product Flow
The Taguchi Method
Sample Size Selection
Response Variable Results and Conclusions of the Taguchi Experiment
Triaxial Random Vibration
Temperature Cycling
Power Cycling
Intra-Experiment Summary
Taguchi Method Conclusion
Terms
Acknowledgments
References
Design Ast With Vendor Electronics
Introduction
The Test-Analyze-Correct-Verify Process
Accelerated Reliability Techniques (ART)
Stress Tool Box
Broad Spectrum Stress Portfolio
Original Equipment Manufacturer (OEM) Power Supply Example
Conclusions
Acknowledgments
References
Design and Production Ast With Power Supplies
Background
Switching Power Supplies
STRIFE in New Product Development (Design AST)
Vibration
Thermal Test
Electrical Overstress
Power Cycling
Results
Conclusions with STRIFE in Product Development (Design AST)
ESS in Manufacturing (Production AST)
Burn-In
Burn-In Conditions
Results
Vibration Screening
Conditions
Results
Conclusions with ESS in Manufacturing (Production AST)
Final Conclusions
Acknowledgments
Design and Production Ast With Computers
Background
A Massively Parallel RISC-Based Server
The ESS Program
Integration
Conclusions
Acknowledgments
Definitions and Acronyms
Reference
Qualifications and Production Sampling Ast With Printed Circuit Boards
Introduction
Proposed Test and Theory
Ongoing Monitoring of the Production Process
Screen Development
Equipment
Results of the Initial Testing
Conclusions
Acknowledgments
Glossary
References
Manufacturing Ast With Telecommunication Products
Introduction
EST During Product Design (Design AST)
Production EST (AST)
Techniques of Production EST (AST)
FMA and Corrective Action
Production EST (AST) Studies at ATandT
Facilities Hardware and Software
Thermal Profile
Results of the Thermal Cycling Studies
Phase I Study
Phase IIa
Phase IIb
Phase III
Phase IV
Future Studies
Conclusion
Acknowledgments
References
Production Ast With Computer Disks
Introduction
Growing Reliability
Problem
Case Study
Product Flow
Profile Utilized
A Look at the Failure Mechanisms
The Bottom Line
Conclusion
References
Benchmarking
Introduction to Benchmarking
Traditional Benchmarking
Product Benchmarking
AST Benchmarking
The AST Benchmarking Process
Benchmarking Partnerships--Otis Elevator Company and United Technologies/3Com Corporation (U.S. Robotics)
Benchmarking AST Survey Data
Summary
Acknowledgments
References
Environmental Stress Screening Questionnaire--1997
Environmental Stress Screening Questionnaire--1996 and 1997 Results
Glossary of Stress Testing Terminology
Bibliography
Index
Epilogue
About the Editors
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