Vibration-Induced Failures in Automotive Electronics: Knowledge-Based Qualification Perspective

2018 ◽  
Vol 140 (2) ◽  
Author(s):  
Karumbu Meyyappan ◽  
Milena Vujosevic ◽  
Qifeng Wu ◽  
Pramod Malatkar ◽  
Charles Hill ◽  
...  
Keyword(s):  
Failure Modes ◽  
Field Performance ◽  
Test Methods ◽  
Automotive Electronics ◽  
Automotive Market ◽  
Damage Models ◽  
Knowledge Based ◽  
Industry Standards ◽  
Solder Joint Fatigue ◽  
Test Requirements

This paper intends to address an important gap between reliability standards and the physics of how components respond to real use conditions using a knowledge-based qualification (KBQ) process. Bridging the gap is essential to developing test methods that better reflect field performance. With the growth in importance of automotive market and the wide usage of electronics in this market, vibration-induced failures was chosen for this study. MIL-STD-810G and ISTA4AB are couple of industry standards that address the risk of shipping finished goods to a customer. For automotive electronic products that are exposed to vibration conditions all through their life, USCAR-2 and GMW3172 are more relevant. Even though the usage models and transportation duration for shipping fully packaged systems is different from automotive electronics, the source of energy (road conditions), driving the risks, are similar. The industry standards-based damage models appear to be generic, covering a wide variety of products and failure modes. Whereas, the KBQ framework, used in this paper, maps use conditions to accelerated test requirements for only two failure modes: solder joint fatigue and socket contact fretting. The mechanisms were chosen to be distinct with different damage metric and drivers. The process is intended to explain how industry standards reflect field risks for two of the risks relevant for automotive electronics.

Knowledge Based Qualification Process to Evaluate Vibration Induced Failures in Electronic Components

2017 ◽  
Author(s):  
Karumbu Meyyappan ◽  
Milena Vujosevic ◽  
Qifeng Wu ◽  
Pramod Malatkar ◽  
Charles Hill ◽  
...  
Keyword(s):  
Autonomous Vehicles ◽  
Failure Modes ◽  
Damage Model ◽  
Automotive Electronics ◽  
Electronic Components ◽  
Standard Requirement ◽  
Reliability Models ◽  
Knowledge Based ◽  
Industry Standards ◽  
Solder Joint Fatigue

Electronic products used in autonomous vehicles can be subjected to harsh road conditions. Transportation induced vibration is one such reliability risk to be addressed as part of qualification. Vibration use data and reliability models are very extensively studied for fully packaged systems exposed to vibration risks during shipping. MIL-STD-810G and ISTA4AB are some of the industry standards that address these risks. On the other hand, USCAR-2 and GMW-3172 are couple of standards that may be more relevant for electronics used in automotive applications, where electronic components are exposed to vibration risks during their entire lifetime. Even though the usage model and duration for fully packaged systems in shipping and automotive electronics are different, the source of energy (road conditions), driving the risks are similar. The industry standards based damage model appear to be generic, covering a wide variety of products. In this paper, a knowledge based qualification (KBQ) framework, is used to map use conditions to accelerated test requirements for two failure modes: solder joint fatigue and socket contact fretting. The mechanisms chosen are distinct with different damage metric and drivers. The KBQ obtained qualification requirements were discussed relative to standard requirement with the objective to verify how well industry standard models reflect field reliability risks. For the chosen failure mechanisms and use condition data, it was observed that the industry standards lead to erroneous conclusions about vibration risk in the field.

Failure Mechanisms and Energy Absorption in Composite Elements under Axial Crush

2011 ◽  
Vol 488-489 ◽  
pp. 638-641 ◽  
Author(s):  
Alastair F. Johnson ◽  
Matthew David
Keyword(s):  
Energy Absorption ◽  
Composite Structures ◽  
High Speed ◽  
Failure Modes ◽  
Test Methods ◽  
Interface Fracture ◽  
Static Tests ◽  
Failure Initiation ◽  
Damage Models ◽  
Axial Crush

Test methods are presented to determine failure modes and energy absorption properties of composite crash structural elements from quasi-static tests on chamfered carbon fabric/epoxy tube segment specimens under axial compression loads. High speed film and CT scans of failed specimens are used to identify trigger mechanisms, failure mode evolution at the crush front and failure processes during steady crushing. FE models of failure were developed which could be the basis for materials selection and design procedures for crashworthy composite structures. These are based on meso-scale composites ply damage models combined with cohesive interfaces to represent delamination failures, which damage and fail when the interface fracture energy is reached. The models are implemented in an explicit FE code and parameters for the ply damage and delamination models were obtained from related materials test programmes. The FE models were applied to simulate axial crushing in tube segments and C-channels, showing good predictions of measured peak forces at failure initiation, steady crush forces and total energy absorption.

Effect of Alloy Composition and Aging on the Survivability of Leadfree Solders in High Temperature Vibration in Automotive Environments

2017 ◽  
Author(s):  
Pradeep Lall ◽  
Vikas Yadav ◽  
Di Zhang ◽  
Jeff Suhling
Keyword(s):  
High Temperature ◽  
Failure Modes ◽  
Elevated Temperatures ◽  
Automotive Electronics ◽  
Reliability Models ◽  
Solder Interconnects ◽  
Current Trends ◽  
Lane Departure ◽  
Solder Joint Fatigue ◽  
Lead Free Solders

Current trends in the automotive industry point to increasing role of electronics for vehicle control, safety, efficiency and entertainment. Examples include lane-departure warning systems, collision avoidance systems, vehicle stability systems, and drive assist systems. Many of the automotive electronics systems are located under the hood of the vehicle mounted directly on engine or on transmission with sustained exposure to temperatures greater than 150°C in conjunction with vibration. Solder joint fatigue is a dominant failure modes under high-temperature vibration. Industry migration to lead-free solders has resulted in a proliferation of a wide variety of solder alloy compositions many of which are based on formulation of Sn, Ag and Cu. While it is well known that solder interconnects, accrue damage much faster when vibrated at elevated temperatures, the models for assessment of life under simultaneous temperature and vibration are scarce. State-of-art reliability models for solder joints focus on single stresses of vibration or thermal cycling. There is need for models for evaluating the survivability of leadfree solder assemblies to ensure 10-years, 100,000 miles life in automotive environments. In this paper, a new model has been proposed for life prediction of electronics under simultaneous temperature-vibration.

Cumulative Damage Mechanics: Characterization, Modeling, and Interpretation of Progressive Failure in Ceramics and Composites

2004 ◽  
Author(s):  
Michael G. Jenkins ◽  
Paul E. Labossie`re ◽  
Jonathan A. Salem
Keyword(s):  
Damage Mechanics ◽  
Progressive Failure ◽  
Ceramic Matrix Composites ◽  
Test Methods ◽  
Cumulative Damage ◽  
Material Behavior ◽  
Matrix Composites ◽  
Damage Models ◽  
Novel Design ◽  
Nonlinear Energy

Ceramic matrix composites (CMCs) have evolved to exhibit inherent damage tolerance through nonlinear energy absorption mechanisms while retaining the desirable attributes of their monolithic structural ceramic counterparts. Mathematical (analytic and numeric) models together with experimental measurements of this damage absorption have aided in understanding the thermomechanical behavior of CMCs. This understanding has led to improved test methods, better predictive modeling of material behavior, appropriate processing methods, and finally novel design methodologies for implementing CMCs. In this paper, background on CMC damage is presented, damage measurement and damage models are discussed and finally probabilistic aspects of constituent materials that can be used to illustrate the cumulative damage behavior of CMCs are described.

A Validated Methodology to Establish Structural Capacities for Subsea Connector Families

2021 ◽  
Author(s):  
Michael John Stephens ◽  
Simon John Roberts ◽  
Derek James Bennet
Keyword(s):  
Failure Modes ◽  
Bending Moment ◽  
Full Scale ◽  
Structural Testing ◽  
Combined Loading ◽  
Test Sequence ◽  
Fea Model ◽  
Analysis Methodology ◽  
Industry Standards ◽  
Physical Testing

Abstract Understanding the structural limits of subsea connectors used in offshore environments is critical to ensure safe operations. The latest industry standards establish the requirement for physical testing to validate analysis methodologies for connector designs. In this paper, an analysis methodology, compliant with the latest API 17G standard, is presented for calculating structural capacities of non-preloaded connectors. The methodology has been developed for complex combined loading scenarios and validated using full-scale physical testing for different connector families. Detailed 3-D, non-linear, finite element models were developed for three different non-preloaded connections, which consisted of threaded and load shoulder connectors. A comprehensive set of combined tension and bending moment structural capacities at normal, extreme and survival conditions were calculated for each connection. The calculated capacities were validated for each connection by performing a test sequence using full-scale structural testing. A final tension or bending to failure test was also completed for each test connection to validate the physical failure mode, exceeding the latest API 17G requirements. For all connections tested, capacities calculated using the methodology were validated from the successful completion of the test sequences. The physical failure modes of the test connections also matched the predicted failure modes from the FEA, and the tensile or bending moment loading at physical collapse exceeded that predicted by the global collapse of the FEA model. Using the validated approach described in this paper significantly reduces the requirement of physical testing for connector families, establishing confidence in the structural limits that are critical for safe operations.

HPHT Subsea Connector Verification and Validation Using an API 17TR8 Methodology

2021 ◽  
Author(s):  
Barry Stewart ◽  
Sam Kwok Lun Lee
Keyword(s):  
Failure Modes ◽  
Production Systems ◽  
Three Dimensional ◽  
Full Scale ◽  
Verification And Validation ◽  
Combined Loading ◽  
Load Path ◽  
Capacity Curves ◽  
Industry Standards ◽  
Full Scale Tests

Abstract Wellhead connectors form a critical part of subsea tree production systems. Their location in the riser load path means that they are subjected to high levels of bending and tension loading in addition to internal pressure and cyclic loading. As more fields continue to be discovered and developed that are defined as High Pressure and/or High Temperature (HPHT) these loading conditions become even more arduous. In order to ensure the integrity of HPHT components, industry requirements for components are setout in API 17TR8. This technical report provides a design verification methodology for HPHT products and some requirements for validation testing. The methodology provides detail on the assessment of static structural and cyclic capacities but less detail on how to assess the functional and serviceability criteria for wellhead connectors. Similarly, API 17TR8 does not include prescriptive validation requirements for wellhead connectors and refers back to historical methods. This paper describes a practical application of the API 17TR8 methodology to the development of a 20k HPHT connector and how it was implemented to verify and validate the connector design through full scale tests to failure. A methodology was developed to meet the requirements of the relevant industry standards and applied to the connector to develop capacity charts for static combined loading. Verification was carried out on three dimensional 180° FEA models to ensure all non axi-symmetric loading is accurately captured. Connector capacities are defined based on API 17TR8 criteria with elastic plastic analysis (i.e. collapse load, local failure and ratcheting), functionality/serviceability criteria defined through a FMECA review and also including API STD 17G criteria including failure modes such as lock/unlock functionality, fracture based failure, mechanical disengagement, leakage and preload exceedance. These capacities are validated through full scale testing based on the requirements of API 17TR7 and API STD 17G with combined loading applied to the Normal, Extreme and Survival capacity curves (as defined by "as-built" FEA using actual material properties). Various test parameters such as strain gauge data, hub separation data, displacements, etc. were recorded and correlated to FEA prediction to prove the validity of the methodology. Further validation was carried out by applying a combined load up to the FEA predicted failure to confirm the design margins of the connector. Post-test review was carried out to review the suitability of the requirements set out in API 17TR8 and API STD 17G for the verification and validation of subsea connectors. The results build on previous test results to validate the effectiveness of the API 17TR8 code for verification and validation of connectors. The results show that real margins between failure of the connector and rated loads are higher than those defined in API 17TR8 and show that the methodology can be conservative.

scholarly journals Biodegradability standards for carrier bags and plastic films in aquatic environments: a critical review

2018 ◽  
Vol 5 (5) ◽  
pp. 171792 ◽  
Author(s):  
Jesse P. Harrison ◽  
Carl Boardman ◽  
Kenneth O'Callaghan ◽  
Anne-Marie Delort ◽  
Jim Song
Keyword(s):  
Degradation Products ◽  
Toxicity Testing ◽  
Test Methods ◽  
Ecological Impacts ◽  
Aquatic Environments ◽  
Natural Ecosystems ◽  
Marine Habitats ◽  
Industry Standards ◽  
Plastic Bag ◽  
Chemical Conditions

Plastic litter is encountered in aquatic ecosystems across the globe, including polar environments and the deep sea. To mitigate the adverse societal and ecological impacts of this waste, there has been debate on whether ‘biodegradable' materials should be granted exemptions from plastic bag bans and levies. However, great care must be exercised when attempting to define this term, due to the broad and complex range of physical and chemical conditions encountered within natural ecosystems. Here, we review existing international industry standards and regional test methods for evaluating the biodegradability of plastics within aquatic environments (wastewater, unmanaged freshwater and marine habitats). We argue that current standards and test methods are insufficient in their ability to realistically predict the biodegradability of carrier bags in these environments, due to several shortcomings in experimental procedures and a paucity of information in the scientific literature. Moreover, existing biodegradability standards and test methods for aquatic environments do not involve toxicity testing or account for the potentially adverse ecological impacts of carrier bags, plastic additives, polymer degradation products or small (microscopic) plastic particles that can arise via fragmentation. Successfully addressing these knowledge gaps is a key requirement for developing new biodegradability standard(s) for lightweight carrier bags.

Developing Measurement Science to Verify and Validate the Identification of Robot Workcell Degradation

2019 ◽  
Author(s):  
Brian A. Weiss
Keyword(s):  
Failure Modes ◽  
Performance Metrics ◽  
Health Assessment ◽  
Test Methods ◽  
Data Sets ◽  
Robot Arm ◽  
Performance Targets ◽  
Manufacturing Operations ◽  
Measurement Science ◽  
Manufacturing Competitiveness

Abstract Robot systems have become more prevalent in manufacturing operations as the technology has become more accessible to a wider range of manufacturers, especially small to medium-sized organizations. Although these robot technologies have become more affordable, easier to integrate, and greater in functional capability, these advanced systems increase workcell complexity leading to the presence of more fault and failure modes. Given increasing manufacturing competitiveness, maximizing asset availability and maintaining desired quality and productivity targets have become essential. The National Institute of Standards and Technology (NIST) is developing measurement science (e.g., test methods, performance metrics, reference data sets) to monitor the degradation within a manufacturing workcell that includes a six-degree-of-freedom robot arm. Numerous components of the workcell influence the accuracy of the robot’s tool center position. Identifying the component(s) responsible for process degradation prior to the process performing out of specification will provide manufacturers with advanced intelligence to maintain or maximize their performance targets and asset availability. NIST’s research in robot workcell health promotes workcell component health characterization and develops methods and tools to verify and validate this approach. This paper presents the overall research plan and the efforts to date in developing appropriate test methods, identifying key sources of workcell degradation, and presenting baseline performance data that is leveraged for health assessment.

Review of material test standardization status for the material qualification of laminated thermosetting composite structures

2020 ◽  
pp. 073168442095810
Author(s):  
Sang Yoon Park ◽  
Won Jong Choi
Keyword(s):  
Composite Materials ◽  
Material Properties ◽  
Composite Structures ◽  
Failure Modes ◽  
Laminated Composite ◽  
Test Methods ◽  
Test Method ◽  
Experimental Comparison ◽  
Laminated Composite Materials ◽  
Design Values

This paper presents a review of recent literature related to the static mechanical testing of thermoset-based carbon fiber reinforced composites and introduces a material qualification methodology to generate statistically-based allowable design values for aerospace application. Although most test methods have been found to be effective in determining the specific material properties by incorporating them into the material qualification and quality control provisions, a full validation to clarify the behavior of thermoset-based laminated composite materials is currently lacking, particularly with regard to the characterization of compressive, in-plane, interlaminar shear, and damage tolerance properties. The present study obtains information on the different types of test method that can be employed within the same material properties, and makes an in-depth experimental comparison based on the past literatures. A discussion on the scope of theoretical analysis involves a description of how the proposed test method can be adequate for obtaining more accurate material properties. This discussion is directly applicable to the assessment of material nonlinearity and the geometrical effect of specimens. Finally, the resulting failure modes and the effect of each material property are studied to aid the understanding of the load distribution and behavior of laminated composite materials.

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