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3,...5 62% 6b 7 8. I.0 Ar: exaalp!e of hydrated aluminaemanating from dissimilar metal contacts , .? ~ ~ . /I 19 An example of hydrated aluminaforming in the center of an aluminum

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Page 1: 3,...5 62% 6b 7 8. I.0 Ar: exaalp!e of hydrated aluminaemanating from dissimilar metal contacts , .? ~ ~ . /I 19 An example of hydrated aluminaforming in the center of an aluminum
Page 2: 3,...5 62% 6b 7 8. I.0 Ar: exaalp!e of hydrated aluminaemanating from dissimilar metal contacts , .? ~ ~ . /I 19 An example of hydrated aluminaforming in the center of an aluminum

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Page 3: 3,...5 62% 6b 7 8. I.0 Ar: exaalp!e of hydrated aluminaemanating from dissimilar metal contacts , .? ~ ~ . /I 19 An example of hydrated aluminaforming in the center of an aluminum

The authors wish to gratefui!y acknowledge the assistance

and encouragement of W R h i n e ., TC Michaels a n d M Holzman

of N~~~+l MS@ RASPO/MIT The authors also wish to acknowledge

the help of L E-Iaworth and his staff of Raytheon Sudbury for ac-

cum-&ating some of the data of Table 1% and G ~~‘layo cf MIT/IL

for helpful suggesti OHS.

This report was prepared undex- DSR Prqect 55-191

sponsored by the Manned Spacecraft Center of the National

Aeronautics and Space Adminic-’Jiration through contract NASS -153

The publ.ication of th.~’J report does llot constitute z?,pproval

by the Nationa.1 Aerona.utics and Space Administ-;ation of the find-

ings or the conciusions contained thereir; it is published only

for the exchange and stimulation of ideas.

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5

62%

6 b

7

8.

I.0

Ar: exaalp!e of hydrated alumina emanating

from dissimilar metal contacts , . ? ~ ~ . / I 19

An example of hydrated alumina forming

in the center of an aluminum interconnect . . 19

An example of an open created at a scratch

after l.ong time operation because of sus-

pected hydrated alumina formation . S . u 23

An example af a3 open and xneltir;g created at

at scratch after long time operation because

oi’ a suspec ted a luminum. co r ros i on D d I I S 23

An example of an open at a sc.ratcb over an

oxide step due to aluminum melting 1 S , . , 23

An exa.rnple of shorting due -trJ aluminum

scratching and smearing. . a D l B a S . . 23

An example of a bond made too close to un-

thermally oxidized silicon . * 9 a 1 , . a * 2 5

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Page 8: 3,...5 62% 6b 7 8. I.0 Ar: exaalp!e of hydrated aluminaemanating from dissimilar metal contacts , .? ~ ~ . /I 19 An example of hydrated aluminaforming in the center of an aluminum

tllc end goal must be con-L’j’c’ l.<><i i‘ L+ ‘: ; r:il it :~oclate;i c0nstralnt.S For military and space

app!icatio:- i,h i (: r, :~c;llab:ii; q; 15 an extrtmely Important goal which

is often o-erlookcd during tl.-e initial design of the system Tl1e

seiec!:m of com,ponents p:moducibility, circuit packaging and

thermal ciC!Sigil Tni:s,-f all be included in the initial design of a re-

iiLlLiil? s:,r3trrn In addition proving the high reliabilit; l)ric;r $0

‘~clti use has bccomc a majur problem By proven reliability we

mean actual demonstration of reliability To prove the high re-

iiabllity oiljecttves of space and military applications many tens

of millions of element operating hours with no operating failures

a r e requ:red If large samples are not available, the accumu-

lated time required to prove high reliability exceeds the time

after which the system parts or processing of parts become

obsolete There have been methods proposed and used to cir-

cum\ient these problems They are

A 1Jse of Mathematical Models for Reliability Prediction

Mathematical models have been developed by fit-

ting a failure frequency distribution to past failure experienceand .so determine future failure rates as a function of time EX-

amples of fitted failure frequency distributions are the exponen-

tial function gaussian and ‘ilieibull distributions If the failure

frequency distribution is assumed for a new system without priorkno?vledge of how parts assembly of l,.?rts and therefore sys-

tems fail and under what conditions they fail the technique is

highly questionable If one considers the multitude of time and

stress dependencies of various failure modes occurring in vari-

ous parts oi assembly of parts and the fact that these failure

modes mu.st. be weighted in order of frequency of occurrence a

general mathematical model does not appear promising Should

a potentially applicable n- iathematicsl model be developed the

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jc, .oLQi<* i i !: t\ 1 i:-A.,- ] ’i A ‘- r’ 1 % & * -:ia!]ijard~;# ‘&ti;j;-*

- __^--.. e-

r”,r; appr~klch -ihic:h xjll h+p asslure end reliaijliitv is theL -’desig:1 (If tilt: r. ’ -’-T, “-CC ir, with n?inknizCatioli of the Ri:rnber of differ-

er:t romporIent * ‘This I~pproach kils several advantages. First,

31: aspr,t of -f-E’ Eabllity which is often overlooked is the fabrica-

tion of parts into a system, Standardization minimizes the

number GE different components which greatly simplifies the

13roCPSLs11-- _ control for production !ir!es. For example, the use of

one packaged integrated ,:circuit with no components external

to it allows for ease of fabrication and handling which in turn

cl e c i‘ e a s e s errors and damage dL:rjng fabrication. Second, no

assilmptions as to how parts fall have to be made, since proven

reliability caa be developed and maintained if a large volume of

a relatively simple device can be produced. The development

of a reliable device must be stressed, Even if at the start of a

program a device is not sufficiently reliable or its reliability

has not been demonstrated, large volumes allow both reliability

improveme& a.P;d demonstration,

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technological de-velopment coupied with reliability goals that

require successful operation for several years, A compromise

must often be made between the use oLf new technoiogy and high.

reliability oh j ectives i With judicious planning this colmpromise

can be iristituted effectively, For example, integrated circuits1 -using planar technology have made new objectives possrbie by

reducing the size and weight of a system while introducing an

important future reliability gain. Because of very similar pro-

cessing, the development of the inhe,rent planar integrated circurt

reliability to the levels of the already proven high reliability of

planar transistors appeared inevitable* This exciting concept

mean-t that one planar integrated circuit, with a combination of

active and passive components, using a potentially careful!,y

controlled interconnect process, packaged in a hermeticallysealed enclosure, could achieve the failure rates.of a single

planar tranexceed the

with assocr

connects

SiStOr. Therefore, the integrated circuit could

reliability of a circu,*it consisting of several transistors

ated diodes or resistors plus al? the external. inter-

Once the compcnent part has been selected, rellabri:ty can

be developed by determrnmg techniques to detect ali possible

farlures, by studying the fariure modes of the part, and by deter-

minmg contributmg factors to faliures, thus correctrng faults

orrgrnating in the production of the part. Reliability can be

maintained by determinfng vendor qualrfication lrsts whrch allow

parts to be purchased from a selected group of vendors with

proven hrstory of quality and reiiabillty Relrabiiity 1s further

maintained by developrng lot rejectron criterra following pre-

determfned testmg procedures for known failure mode,c: such that

the entire lot can be returned to the vendor when a certam per-centage of fa ilures 1s d e t e c t e d , Lot rejection by fa Ilure modes

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and i~erci-‘ntages cf failure s institutes a contin~uous monitoring

prOCdUW. Since rellabilitv is built into a device, testing an--t

screening cannot <:reate a mon‘c reliable device, but testing and

screening can eliminate a poor device or suspected troublesome

lots of dcvicecL, , Reliab3ility depends on vendor control over

proven processes l,vith rapid feedback to the vendor- when new

failure modes are detected.

Purchasing of large volumes of a part aids in the development

and maintenance of high reliability. Purchasing of large quantities

results in 10lqjeT prices M’hich allow funds to be allocated into

evaluation, testing and monitoring, Large volumes allow a con-

tinuous production flow where ma.nufacturing control is facilitated.

Large samples become avaiia.b!e for rapid ex.tended life testing

and provide extensive vendor history.

Th<> standardization approach, which is particularly

adaptable to computers, has been demonstrated with the Polaris

flight computer and extended with jntegrated circuits to the Apollo

Guidance Computer. Both computers were designed to use a

three input Nor gate as the only logic element. All logic functions

are generated by interconnecting th e three input Nor gate with no

additional logrc blocks, resistors,or capacitors I At first glance,

it appears that using only one type of logic block greatly increases

the number of blocks required for the computer. Bu?,, by ludicrous

selecting and organizing the logic functions it is quickly apparent

that few additional blocks are necessary. The few additional units

required are greatly counter balanced by the increased reliability

gain during both the manufacturing of co-mponents and fabrication

of the components into modules.

The integrated circuit for which all of the following data

is to be presented is the th.ree input Nor gate as shown in Fig, 1.

This circuit is used at 3V and 15 mw, but is rated at 8V and 100 mw,

Unpowered temperature rati’ng is 150°C. The basic simplici-ty of

the three input gate aids an effecti\ e screening process, All tran-

Page 13: 3,...5 62% 6b 7 8. I.0 Ar: exaalp!e of hydrated aluminaemanating from dissimilar metal contacts , .? ~ ~ . /I 19 An example of hydrated aluminaforming in the center of an aluminum

-.-__-----mm-_ I__ ___ - .-. - ..-

l--------lI 2it

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13

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I, A n exampie o f open bonds due to the goi+ aiunl-

inum eutectic formation i”pusp?e plague”) is shown

i n Fig, 2 . In most ca3cs, fai2wes due to ‘tpurplen

plague” have been traced back to uncontrolled t~ond-

ing procedures. The failures may be triggered by

mechanical shock, ther-maI shock, acceleration, or

vibration testing. “Purple plague” does not a;,pear

to be created during txtendcd bakes at 200°C or iess,

This tentative conclusion is based on the fact that

when a populatisn of integrated circuits exhibits

plague problems after baking, the plague problems

are also detected after mechanical stresses prior to

baking I Visual internal inspection, accompanied by

bond probing of integrated circuits from the popula-

tion prior to any stressing has indicated that a weak-

ened bond already exists,

2. An exampl,c of oper, bonds due to poor aluminuln

adhesion to the silicon dioxide is shown in Fig, 3.

‘rhj.s failure type has always been found tG be tr:~(.:‘crcc! by

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Fig. 2 An example of the gold-al~~minum e~ltectic formationYpurpie plague").

Fig. 3 An example of poor aluminum adhesion to the si!icorrdioxide.

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Fig. 3 An example of poor aluminum adhesion to the siiicondioxide.

15

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has been produced. ‘The “disappearing” aluminum ‘v: Ith

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Fig. 6a An examp!e of hydrate,d alumina emanating f$on~dissimilar metal. contacts,

Fig. 6b An example of hydrated alumina forming in 21center of ar, alumin-urn int?rconnect.

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01: ;I~~~qcrs ~,herc rt was known that the aluminum was

present initially. The regions of aluminum absence

are usually found emanating from bonds and they art’

often deteceed after baking.

It is interesting to note that Fig, 8 shows a very

ioca.lized aiuminum melting such that the melt ran

doTV+-nhill at the oxide step. Preliminary studies using

a thermal plotter have indicated that extreme localized

heating, even in the base mterconnects, can occur at

scratches and at oxide steps in the interconnects of a

powered device. For the type of failure shown in

Fig, 8, it is suspected that the localized heating has

accelerated a corrosion mechanism which in turn

generates more localized heating as the resistance

increases. Electrical overstressing for this failure

type is improbable since the melting of a base inter-

connect without melting of a collector or emitter

interconnect has never been detected after overstress

conditions, Also for this failure, circuit operation

was continuously maintained until time of failure,

It is interesting to note that unless excessive moisture (in

the order of vapor pressures which allow condensation) is present

within the package ambient, any corrosion phenomena seem to

occur only at scratches or oxide steps for at least a year’s oper-

ation at normal conditions. It should also be mentioned that sev-

eral corrosion phenomena have also been observed on thin film

powered and unpowered circuits using other than aluminum metal

systems.

4, Figure 9 indicates that scratches contribute to

opens even w-hen the corrosion phenomena is not ob-

served. En this case overstressing was possible al-

though not certain, and it can be argued that severe

scratching can markedly decrease the tolerance of a

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1, F’ifp’” 11. shows i,haT. even thCXlgh the bond appears

to make eorltact, -to the silic12r-l frcm the surface view,

the devices exhIbiCng this f&lure ty-pe are kn.oivi, r:Oi.

to have sh0r.t~ ‘:o the s:Llicc:; at or,e i.;me durilzg the

testing procedure, ~‘-l,gure 12 depjcis ;?, c;r()ss-se(-;t.;on-i_-

al representation w~here the oxide si.ep is sho\,vr~ ta-

pering. Shorting could OCCL~P by expansion of thegold through the distance, a. Perhaps equally possible

is shorting thr-ougt the silicur dioxide r’dis-tance hj,

Since the oxide thickness at b is capable of being much

thir,ney 1 a decreased d.ielectTic strerigth Is possible.

or added strains could resul.!, such that evmt:Li rup-

ture with or without applied vcltage may occur, This

particular failure type may be elimicated by r,o-t a!-lewing pattern layouts which wll1 pver;tlaliy cause the

described failures,

2 4

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F i g . 1 1 A n e x a m p l e o f a bind m a d e t o o c l o s e t o unbhermallyo x i d i z e d s i l i c o n .

A u B A L L RON@

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1-i j Surface problerrls CVCII l.~lth the “;ITLss:~,~~~~” Spr~i :c::fT;-

*d,uc:or occ~sjonal‘!y cause fa~lurcs although they LY‘C usually P;c?! o1’

A ca?as”rophic r;at~~re, Any 1r~lpurl?lcs at t:1c sillcoi?-si:?co;: :?:o::ld:~

?nterface> m or on tiic s~llcon clloxldc whch have my trxlsi~!Lol~al

or rotational freedom may become moblle in Ihe i,mprcssed clecX-

trical fleZd at the surEace of a Junction, or during vz. rrat tor,s m

thermal stressing, This then causes correDpoEdmg changes in

the eiectncai characterxstlcs C This has been the sub?ect of many

;1 few of wh:ch are referenced. 6 -9,papers and ~111 not be covered

ir del,al! here S[3eClfiCLllly for th? iI?lC,,-atefJ clrcui?s under study

the predornlnant suri‘~.~f-e f;illure mode is the dcgradatlon o! ~hc

gain an d ieakage currents under rerierse bias j The degr;Ldai 1011

under re-gerse hlas IS azded by the appilcatlon of elevated temp-cratures D The clectrlcai characteristics may be recovered by

bakmg \v?thout voltage stressing. This dcgradatlon 1s mLmmlzcd

or elzminaled through changes m surface !)reparailon, Some of

the techniques are discussed In refcrrncc 6-9,

P, Figure 14 indicates an occasiomi failure due to cracks

in the silicon die, Most of the chips which are susceptible +o crac&ng

duri.ng mechanical stressing or thermal shocking are those where

st,rains have been set up during die attach procedures, Most notab r:

are poor die at.tach procedures not using the si.licon-gold cu!ect:c:

altholwugh good die attaching has been observed using &her than the

standard technique,

7ti I Many types of shorts have been cclused by ir.terr;al ledd

wires and the method of making contact from the z;luminum pads on

the chip surface to the posts 0: the package,

1, Figure 15 shows the shorting of a gold lea6 io the

edge of Ihe silicon ch:p9 The possjbjl.lt,y of’ this type

of shorting is enhanced by the fact that the cor,tact +O

26

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2” Extra ior_g lead Wires may shor, _* to the i:d oi the^package, the bot,:om of rhe p&ckage- t,he surface cr

edge oi the chip, or to orte anoTher, Exampies are

given 1~: Figs, I.6 ard 17, Kate -iha: F’ig, 17 a;so S~C~J:S

‘;he ro+atior, of the chip such ih,t, cor,nect~cr, +o ?te post

necessitates long loopmg leads,

K, Opens can occur in lead wires because of fault>

handling, bonding and subsequent processing, Nicks and cuts in

lead wires have been known to break open durmg mechanical stressing. If bonds are made such that an extreme thinning of the wire

is forced, or the wire constricted, the wire IS extremel:j suscept

ble to breaking open during the slightest of mechanical stressmg

such as handling. The latter failure tJ.pe has been observed at ‘;hc

post of the package where wedge or capillary bonds rather than

nail head bonds are made,

L. Loose material and particles within a package are

always a potential cause cf failures, Excessive ‘!pigtails” Iex.-

cess of a lead after the lead is broken off when a bond is madej

have created shorts. The presence of free conducting materials

(metallic or otherwise) within a package is a most troublesome

cause of failure, Non conduct,ing free particles can cause mechan-

28

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Fig. 15 An example of a lead sho’tiing to we edge of the chi

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ical damage.

The packaging of a se,miconductor device will not be dis-

cussed in this report even though the package plaJ,s an important

role in the reiiabGty of the device. The failure or success of apackage to -meet the hermetic and mechanicall;, strong enclosure

of an electrical component is subject to study and testing as are

integrated circuiis, and is the subject of another report.

31

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The Lst of failure modes g’lver: III the prevtous sect?or-

might make appear impossible the task of de>elopir:g a highly

rel;able integrated circuit. It must be poted that exc!udkg poor

design, all the ipdlcated failure modes are the result of pocr

process control or the vendor’s lack of complete iechr,icai iirLo\,%-

ledge of his process. A “dynamic srate-of-the-art” process wiii

be subject to Inadvertent process changes. As a result, attempts

to legislate reliabXty through fixed processing documents al-C,

by themselves, ineffective. A program must be established to

detect new failure modes, determine ccn!ribw;ng causes and

finally eliminate or minimize faiiures. Ellmmatk~g or mir,i-

mizirg failure modes implies controlled process changes. ~o;L-tinous effective momtoring must be performed to zssure t5aT

no process changes occur other than for reifabrllsy improvemer,:

and that the vendor can maintain a high degree of quality a;nd reL-

abliity from lot to lot throughout the entire progra-m. The fur,c-

tional aspects of the reliability program for the Apollo Guidai:ce

ar;d Navigational system are the prequalification tests, The

screer: and burn-in testing, and extended life tests a+ use cc:-.di-Cot--s ~

The foliowirlg is a brief description of t.he approach ulsed

for detecting, eliminating., and moni.toring of faJures,

The vendor prequalificatlon tests consist of small sampies

of devices which are subjected to a combiriation of mechanic&l,

thermal, and power stressing at normai and accelerated stresses,

These tests are performed to detect many of the exist,r_g fa;lure

modes, ar,d must be backed up by thorough f’a;;ure ar-alysis pw-

tlculariy when accelerated stressing is performed. The pre-

quaiifica:ion studfes are coupled wiih thorough bisuai ir.spectlor:

of submltted samples and complete electrical characteris!.ic

studies ~ I<now;!edge of the device processkg acd any re:;ab:k*y

h’story accumulated by the vendor :s alsc k~corporared. A it hoiigil

3 2

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i+‘,?ili;:-e ri2()!--<::; may :?ow genera.liy bc c?,;s.;lfie:? as those

whi.ch can be e!imina,.tc.1~’ 1 through specification; those whi.ch lendc

themselves to being eliminated through a series of mechanical,

t h e r m a l , y,~o!tage, and power stressing; and those which can be

i?etected nrtly oc:casior~ally after var ied stressing. The latter

?ornpriSe ciie group of so cai!ed troublesome or long time de

pendent failure modes. The easiest failure modes to eliminate

are those \x:hich mav be specified out. For example, any design-

ing, processing, or packaging of devices which is found to create

or aggravate known or new failure modes can he eliminated througli

spec i f i ca t i on , E!eC b:rica! anomalies may be rernoved by electri -

cal characteris tic specification. Many of the failure modes given

in the previous section fall into this category, Next, faillirc modes

which occur early in time or are mechanically stress dependent

(time independent and mechanical fatigue failures) are easily re-

moved through a 100% non--destructive combination of stresses

commonly referred to as screen and burn-in. Additionaily, a

properly designed screen and burn-in procedure allows for

f;J.rther detection of failure modes at realistic stress conditions,

particularly those which are no-t easily “weeded out” (troublesome

fail-ure modes) i

The screen and burn-in procedure if properly designed

establishes a con’linuous vendor qualifical Len and monitoring pro-

cedure. Once most if not all of the failure modes have been de-

termined, -vendor evaluation on large samples at realistic stress

conditions can be maintained, Vendors can be rated with respect

to:

1-e Xumber of failure modes,

2. Frequency of failure modes; i, e., how often a given

failure mode appears.

33

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3. Seriousness of failure modes. The seriousness of a

failure mode depends upon how difficult it is to weed

out or detect a given failure mode. Failure modes

which are easily weeded out or detected can be toler-

ated in reasonable number but indicate a measure of

the vendor’s quality control. The more serious (long

time dependentjfailure modes are intolerable and in-dicate that a vendor does not fully understand his

process f

4 . How rapidly a vendor can eliminate or minimize

failure modes. Feedback information is provided to

the vendor such that vendor action for corrective pro-

cedures can be established and contributmg factors to

failure modes be determined and reported.

The screen and burn-in procedure then provides extensive vendor

history from several points of view and provides cont.inuous moni-

toring of lots from a given vendor. The monit,oring assures that

q.uality and reliability be maintained. If an unrealistic number of

failures or failure modes is detected or if non “specoutable” or

“weedoutable” failure modes occur, the lot can be rejected for use

in critical high reliability systems.

Any test or qualification procedures which are designed to

eliminate failures must be self correcting. If failures occur after

a screen procedure, the complete screening and qualification pro-

cedures must be scrutinized. The failures and the lot from wl-$ich

they come must be studied. Simultaneously, as data is accumu-

lated, failure mode and mechanism studies continue. Modifica-

tions may then occur in vendor qualification, the screen and

burn-in procedure, and/or lot rejection criteria.

3 4

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The success of the :standa.rdization approach can only be

demonstrated by its effectiveness, Table I provides a summary

of the data, by vendors, a~ccumulated up to 10 October, 1964.

The following gives sa.mple sizes, failure definitions, and fur-

ther explanations as needed:

1 The prequalification te st i were performed with sam-

ples of 100 to 200 devices for each vendor. The failure defini-

tion is an inoperable device in our computer circuits.

2, The screen and burn-in tests were performed with

sample sizes ranging from 20, 000 to 60, 000 devices for each

vendor, The screen and burn-in results are divided into two

sections; the total fallout, and the fallout after baking, centri-

fuge, and power operating at room temperature. The latter is

referred to as the second and third electrical results, The fail-

ure defi.nitions for the second and third electrical results are:’

inoperable devices, any devices drifting out of the electrical

specification, and any device exhibiting a maximum allowable

percentage drift. The total fallout results include the same fail-

ure definitions as the second and third electrical results and also

include incoming visual and electrical inspection fallouts, lead

stressing, and hermeticity fallouts ~

3% The failure rates at use conditions were determined

wi.th sample sizes ranging from 5, 000 to 18, 000 devices for each

vendor. The failure definition is an inoperable device.

The data of Table I presents extremely interesting results, not

only in showing the achievablt= reliability and the variation among ven-

dors, but also in showing how the vendor maintains his respective

position throughout the entire evaluation procedure. At the outset,

the prequalification testing indicated an order of magnitude differ-

ence in the extremes. Just as significant were the failure types

generated among vendors. Vendor A exhibited no serious failure modes

3 5

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‘The COI~~E?iati~r! 0’ t,IlP pre”l’~“lifil^iCation Tes’dltS to the

Screeri 3nd liUr:l-ii? r e s u l t s i s a m a z i n g . Co-mparing the prequalifi-

cation percentage failures to the ;::cond and third electrical per-

centage failures, it is see9 t’hat in both cases there is a factor

of 5 difference between Venc!or A and B, while there is approxi-

mately a factor of 10 difference between Vendor A and C. .Again

Vendor ii did not exhibit the serious failure modes throughout

the extensive screen and burn- in testing. Vendors B and C ex-

hibited .the same failure modes detected during orequalification

testing with some additional ones.

The most interesting and applicable comparison is that of

the failure rates during computer use. It is interesting to noteithat although a smaii percentage fallout for the best vendor oc-

curs during -the stress testing of sscreen and burn-in, over 50 x 13

element hours were accumulated with no operational failures.

The lower failure rates of Vendors B and C are partly reflected

in the fewer accumulated element hours t-2, 000, 000). However,

the failure modes detected at use conditions are an indication of

things to come. The chance that Vendor B will accumulate6anotker 98 .\ 10’ element hours for the same population without

an additional failure is improbable. These additional element

hours are needed for Vendor 13 to compete with Vendor A. The

serious time dependent failure mode described in Section III; C,

~constitates the two failures of Vendor R. As far as Vendor C is

concerned, the situation appears hopeless for the same population

of devices. It does not appear that Vendor C will ever accumulate

su.ffi.ci.ent device hours to bc; competitive with Vendor A, The de-

tected failure modes at use conditions for Vendor C were a com-

bination of interconnect c orrosion. oxide breakdown, and failure

modes due to generally poor quality control.

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Without the demonsirated high reliabilit>- of iiltegratcd cir-

cuits other methods of ac’hieving the reliability goal through design

would be required to satisfy the Apollo mission, Since failures

arc not random but are a1wax.s based on cause and effect princi-

ples, passive rcdundanc;,, would not have cfficientlb- achieved the

required mission life time. The alternative was to consider forms10of active rctlundancv. One solution was infiight sparing and0

maintenance S The maintenance would be accomplished by inter-

changing modules with the aid of the computer system and self

test procedures, With respect to any redundancy technique, the

inflight sparing concept minimized the system weight, power, and

volume. The disadvantages were a requirement for additional

crew tasks in case of failure and the possibility of a time critical

failure which could not be repaired. Also packaging to allow for

inflight repair was a serious restriction on the design and in itsej.f

introduced reliability risks. Alternatively, at a higher cost in

weight, power,and volume,two a-rtive computers could be provided.

This concept allowed for computer switching via the operator at

any time during the flight, thus reducing the possibility of the

time critical failures when there would be no time for repair,

Both computers were required to be operating only during the

time critica. phase of the mission and switch over would be ac-

complished by electronically gating out the output commands of

one of the two computers, Because of the proven reliability of

the integrated circuits, redundancy becomes unnecessary with the

resultant use of a single computer and no inflight repair,

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1.

2

?L >

4

5 .

6,

7

8,

3 .

10

P art.L-idgc, J. “On the Extrapolation of Accelerated StressCondit.ions to Norma! Stress Conditions of Germanium Transis -tars, ” Physics of Failures in Hlectronics, Vol, 2, Ed, by icl. 17.i _-____-- --__----l-_l_-Goldberg a n d J. V a c c a r o , pi 208,

L’on Neumann

p: i,4 ‘3

“Probabilistic Logics and the Synthesis offrom Unreliable Components, ” Automa-____

Press , Pr ince ton , N. J, (19561,

Longo, T a A and Selikson, a. , “Aluminum ‘A’ire Bonding ofSilicon Transistors, Ii Semiconductor Products Nov. 1963,11_____1___-. Ip* 2 7 :

Wortrnan, Jo J, alid Eurger, K” ICI , “A Fundamental FailureD/Iechnnism in Thin Film Metal Dielectric Stlucturos Observn-ble as a Generated Voltage, ‘I Physics of Failures in F~lectron-its--’ Vol. 2, F:d. b y M, F’. G o l d b e r g a n d J, V a c c a r o , p 173.

Schafft. and J.. C, French, “Second I-‘jreakdown in TransistorBs, ”IRE Transactions of Electron Devices, ILlarch. 1962, pi 129,^-_II-

Metz, E, u, , “Silicon Transistor Failure Mechanisms Causedby Surface Charge Separation, ” PjhJsics of tl‘ailures in Elec-__-&ronics, V o l , 2 , E d . b y &‘I. 1;‘. Goldberg and J. Vaccaro,p* 163,

Schnabl.e, G; L . , S c h l e g e l , Ei S, , a n d K e e n , H, S. , “Fa i lureMechanisms in Keverse-Biased Oxide Passiirated SiliconDiodes, Ii presented at the 3rd Annual Symposium of Piiysicsof F’ai!ures in Electronics, Sept. 29-30, 1964, Chicago, Ill.

Hali, ,J; I Ba i rd , S, S , , and Wi l l i ams , I<, P, , “Kesults o fHigh Temperature and Impressed Voltage on Transi.stor Dev i ces , ” presented at the Electrochemical Society Meeting,M a y q-10, i962,

Partridge] +J and Rorofsky.. A. J. ) !!Some Reversible andMore Permanent Effects of Moisture on the Electrical Charac--teristics of Germanium Transistors Following Stress, ” Clean-.ing and Processing Electronic and Space Apparatus, 1962,_II__- -ASTM STP 3 4 2 , p, :65,

Wallmark, J, T. !‘Basic Considerations in Microelectronics, ”Microelectronics Ed, by E,. Keonjian, Cha.pter IT section_ _ . )2-5,

30

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E- 1673

DIS?‘KIRU’I”TON I,IST

-A* I Ilopkins

F H o u s t o n

I, I3 J o h n s o n

A Koso

M. Kramer

W. K u p f e r

D. L a d d

A. LaPoint e

,T Larsen

L L a r s o n

<J. Lawrence (MIT/GREG)

1‘. MS Lawton (MIT/MSC)

G. M a y o

j. McNeil

.John Mi l ler

J, Xevins

J Nugent

E, O isson

P. Sarmanian

I’: ) Schwa rm

J) Sciegicnny

N. Sears

13. Shansky

W ~ Shotwell (iLLIT /ACSP,)

T. Shuck

J. S i tomcr

%, Stamcris

W. Tanner

R ~ Therrien

vi, Tot11

M , Tragcs er

R. Weatherbee

L . Wil!i

R. Woodbury

W, W r i g l e y

Apollo Library : 2 J

MIT/II, L,ibrary !G:

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