Abstract Highly accelerated life testing (HALT) is a test method used to expose design weaknesses at early stages of product development cycle by testing products under elevated stresses. Similarly, highly accelerated stress screening (HASS) is a widely accepted production test derived from HALT used to detect manufacturing defects jeopardizing product reliability. Despite wide usage of HASS, there is no clear way of deriving HASS from HALT for printed wire assemblies (PWA). Practitioners develop HASS by experimenting with 50% of HALT shock loads and 80% of thermal limits then reduce shock level until PWA pass at least twenty profiles. Such process is cost and time consuming. In this article, a more efficient and safe method to plan HASS is proposed and demonstrated using a real life case study. Successful implementation of the proposed method will enable practitioners to predict and determine how many profiles a PWA can survive under different loading conditions, which will reduce testing, time and cost. The proposed method is derived from the physics of failure and statistical modeling of solder joint strain range. The physical basis of the model is provided by Minor's rule of damage accumulation and Coffin-Manson and Basquin total strain model. Strain amplitude of solder joint is modeled using a power model in terms of vibration load and temperature. The proposed method is demonstrated using a gauge acquisition PWA used for oil & gas equipment. Results of case study suggest that proposed method is able to predict number of HASS profiles to failure with reasonable 3% prediction error.

中文翻译：

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基于HALT的印制线组件HASS型材开发

摘要 高加速寿命测试 (HALT) 是一种测试方法，用于在产品开发周期的早期阶段通过在升高的应力下测试产品来暴露设计弱点。同样，高度加速应力筛选 (HASS) 是一种广泛接受的生产测试，源自 HALT，用于检测危及产品可靠性的制造缺陷。尽管 HASS 被广泛使用，但没有明确的方法可以从印刷线组件 (PWA) 的 HALT 中导出 HASS。从业者通过试验 50% 的 HALT 冲击载荷和 80% 的热限制来开发 HASS，然后降低冲击水平，直到 PWA 通过至少 20 个配置文件。这样的过程既费钱又费时。在本文中，提出了一种更有效、更安全的 HASS 计划方法，并使用实际案例研究进行了演示。所提出方法的成功实施将使从业者能够预测和确定 PWA 在不同负载条件下可以存活的配置文件数量，这将减少测试、时间和成本。所提出的方法源自失效物理学和焊点应变范围的统计建模。该模型的物理基础是由Minor 损伤累积规则和Coffin-Manson 和Basquin 总应变模型提供的。焊点的应变幅度使用振动载荷和温度方面的功率模型进行建模。使用用于石油和天然气设备的仪表采集 PWA 演示了所提出的方法。案例研究的结果表明，所提出的方法能够以合理的 3% 的预测误差预测失效的 HASS 配置文件的数量。