Zuverlässigkeitsuntersuchungen. Transienten Thermischen Analyse

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1 In-Situ Measurements of the Relative Thermal Resistance: Highly Sensitive Method von to LED-Modulen Detect Crack Propagation mit Hilfe der in Solder Joints Zuverlässigkeitsuntersuchungen Transienten Thermischen Analyse 4. VDI-Konferenz: Lebensdauer und Zuverlässigkeit in der LED-Beleuchtung, 10. und 11. Juni 2015, Düsseldorf

2 Introduction Agenda / Outline / Overview Outline Introduction Reliability of LEDs Detection of Structural Integrity Transient Thermal Testing Standard Method Relative Thermal Resistance k-factor and Thermal Load Independent Failure Mode Separation Experimental Example Temperature Cycle Test Comparing Ceramic LED Packages Soldered with Innolot and SAC Solder Analysis by Transient Finite Element Simulations Summary & Conclusions

3 Introduction LED Modules Under Severe Conditions: Automotive Example Car Live Automotive front lighting LED head lamp module Mission profile Temperature (*) Probability (*) Air Temperature in Headlamp No dimming for standard operating condition up to 65 C!

4 Introduction Temperature and Drive Current Dependent Failure Rate Typical test data of a high power LED specified for 1A drive current Heat Sink Temperature T HS ( C) Culminated Failure in Accelerated Tests (after 5000hrs) T HS = % T HS = % 86.36% T HS = % 21.05% 75.00% Current (ma) % T HS =110 C T HS =140 C Altilon HTOL Tb=110C, 1A 50.00% Altilon HTOL Tb=140C, 1A 25.00% 25.00% Delta LOP (%) 0.00% 10.00% Delta LOP (%) 0.00% 10.00% % % % % % %

5 Introduction Detection of Structural Integrity Measurement Method of Solder Joint Failure 1. Light On Test 2. Acoustic-Microscopy (CSAM) 3. 3D-Xray 4. Shear strength measurement 5. Electrical resistance measurement V f measurements (static / transient thermal testing) Example: Solder Joint Failure Correlation with Cross Section

6 Introduction Thermal Resistance 70%-80% of heat is generated Heat Transfer Channel: Conduction Die Package Board Crack / Delamination Heat Delamination Delamination T J R th_ real TJ T P HS thermal Heatsink T HS Voids, gaps, cracks and delamination increase the thermal resistance

7 Transient Thermal Analysis Transient Thermal Measurement V f of a diode is temperature dependent: V f Transient thermal test method: V f (t) is measured time resolved to determine R th of a package Measurement Principle k T C Initially a large drive current (ID) is applied (region A) sufficient long time to ensure thermal equilibrium Afterwards a small sense current (IS) is applied (region B) and the temperature dependent V f (t) is measured V f (t) is measured during system transfers to thermal equilibrium V f [V] A ms - min I drive V f at I drive B ms - min I sense V f at I sense Time [seconds]

8 Transient Thermal Analysis Transient Thermal Theorie Thermal system is physically described by a Cauer network Transformation between FOSTER to CAUER and vice versa is possible FOSTER type FOSTER CAUER RC network CAUER type Transfer function of a Foster network can be solved analytically and time dependent solution is obtained: V f ( t) T( t) k Total thermal resistance is obtained by: R P k th N i 1 th( junction case) R (1 e i t R C i i ) Where th P T ( t 0) T ( t ) P th P electrical V f P optical ( t 0) V To calculate thermal resistance k-factor and thermal load need to be measured Power step (thermal load) and k-factor are simple scaling factors for T(t) P th k f ( t ) Introduction of relative thermal resistance to describe and analyze changes in thermal resistance

9 Transient Thermal Analysis Transient Thermal Data time derivation d/dz (z=ln(t)) Scaling: k P th Scaling: k P th Scaling: 1/k P th Numerical unfolding to calculate R( ), Foster- Cauer transformation Relative R Zuverlässigkeitsuntersuchungen von LED-Modulen mit Hilfe der Transienten Thermischen th methode Analyse

10 Relative R th Method Relative Thermal Resistance The time dependent thermal impedance Z th T ( v) n ( t) R (1 exp( / )) i 1 i t i P th Substitution z=ln(t) calculation of derivation d/dz d a( z) Zth( z) dz d dz T ( z) P th V f k T C a( z) k 1 P th d dz V f z Transfer of factor 1 k P th to axis offset: d B( z) log[ a( z) ] log[ V ( z) ] log[ kpth dz ]

11 Relative R th Method Data Processing Red: 800mA Black:700mA Blue: 600mA Red: 800mA Black:700mA Blue: 600mA Red: 800mA Black:700mA Blue: 600mA z normalization point / interval for least square fit shift perpendicular to time axis z

12 Relative R th Method Example 1W LED Measured Data Derivative of temp. rise [ C/-] Logarithmic time derived temperature (au) T3Ster Mas ter: Derivative m 700mv 50mv range 40s led2 25C - Ch. 1 m2 350mv 50mv range 40s led2 25C - Ch. 1 m4 350mv 50mv range 40s led2 55C - Ch. 1 m2 700mv 50mv range 40s led2 25C - Ch mA / 25 C 700mA / 25 C 350mA / 25 C 350mA / 55 C Logarithmic time derived temperature (logarithmic plot and normalized) (au) After Normalization 0 1e-6 1e-5 1e time [s] Time [s]

13 Relative R th Method Advantage Compared with Structural Function 1.E+08 1.E+06 1.E+04 1.E+02 1.E+00 1.E A 1A 1.E+08 1.E+06 1.E+04 1.E+02 1.E A 1A Derivative of temp. rise [ C/-] T3Ster Master: Derivative Alt_T1_hiPow_SR_0,5TIM_Tein.aver - Ch. 0 Alt_T1_loPow_SR_0,5TIM_Tein.aver - Ch. 0 1.E-04 1.E E R th_el [K/W] 1.E R th_el [K/W] 0 1e-6 1e-5 1e time Time [s] [s] 1.E+08 1.E+06 1.E+04 1.E+02 1.E+00 1.E A 1A 1.E+08 1.E+06 1.E+04 1.E+02 1.E A 1A 1.E-04 1.E-02 1.E R th_real [K/W] 1.E R th_real [K/W] time [s]

14 Relative R th Method Data Normalization Normalization at an chosen time interval, i.e. when heat flows through the die By least square fit B( z) log[ an_ cycle( z) ] fitted to B( z) log[ a 0 _ cycle( z)] for the normalization time interval is Changes in linear factors are normalized under the assumption that thermal pass doesn t change within the normalization time interval Assumption is checked by analyzing the residuum within the time interval of normalization By reference samples absolute R th_real can be calculated

15 Relative R th Method Application Reliability Testing

16 Relative R th Method Failure Mode Analysis For some LED types variation of 0-hour transient signals can be observed Application: Quality of LED module can be accessed

17 Experimental Application Reliability Testing Reliability Testing by Relative R th Measurement Ceramic LED packages on Al-IMS Vacuum soldered to realize void free interconnects SAC and improved SAC+ solder (Innolot) in test 1s measurement time is sufficient Increasing peak height indicates the degradation of solder joint

18 Experimental Application Reliability Testing Correlation with Solder Joint Degradation

19 Experimental Application Reliability Testing Comparison SAC versus Innolot Failure criteria: Increase of peak height by 0.05 (i.e. thermal resistance increase of 0.8 C/W) Weibull plot of Innolot and SAC. 24 of 40 samples were cycled to 1500 cycles. Red cross indicates 100% failure for both SAC and Innolot samples. Weibull Plot SAC and Innolot

20 Finite Element Simulation Failure Mode Analysis by Transient FE Modeling Approach for transient FE simulation Initial steady state simulation with heat load switched on Temperature field of steady state simulation is taken as input for transient cooling down simulation without heat load Advantage Simulation of 3D physical model and direct access on physical parameters Information of transient time responds from Transient Thermal Testing is used to extract structural information from failure modes

21 Finite Element Simulation Model Set-Up Ceramic LED package on Al-IMS Geometry is based on CAD file Thermal capacity and conductivity taken from literature For specific material of EPI and phosphor coating material data from basic bulk material have to taken, a realistic range is defined and data are adjusted within the simulation

22 Finite Element Simulation Simulation of 0-Hour Data Transient Thermal Measurement (blue) Transient FE Simulation (red)

23 Finite Element Simulation Simulation of Cracks in Solder Joint Homogeneous cracks (very fine voids) simulated by reducing the thermal conductivity of the SAC solder from nominal 56W/mK stepwise to 5.6W/mK Realistic cracks for cracked area infinite thermal resistance is defined Circular crack propagation from the corner (maximum stress)

24 Finite Element Simulation Peak Hight, Rth and Cracked Area Estimation of crack length for failure criteria: 300µm external cracks (33%) 70% area cracked for homogeneous distributed cracks Failure criteria for Weibull plot

25 Summary & Conclusions Relative R th measurement is non-invasive approach of thermal resistance and structural degradation of LEDs High sensitivity early prediction of failures failure mode separation Measurement effort is significantly reduced (no light output measurement, no k-factor measurement) Short measurement time (less than 2s, package dependent) Suited for In-situ reliability testing Automatic data processing, suitable to replace light on test and for testing within production

26 Acknowledgements Thank you for your attention!

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