Demarcation Mapping: Initial Design of Accelerated Tests
Demarcation Mapping: Initial Design of Accelerated Tests
2
Demarcation Mapping:
Initial Design of Accelerated Tests
However, both for the development of screens that do not reduce the remaining
life significantly, and for reducing risk of a priori unknown failure modes, it is
necessary to have in place a theory from which it is possible to infer reliability
from the initial failure and degradation-free periods in accelerated testing.
This chapter provides an introduction to some theory and methods nec-
essary for inferring reliability from failure and degradation-free periods. The
statistical theory underlying this development was begun in Complements
1.6.3 and 1.6.4. The physical theory and the integration of the two occupy
most of this chapter and Chapter 4. In this chapter we introduce the notion
of demarcation maps, both analytic (LuValle et al., 1998; LuValle, 2000) and
computational (LuValle et al., 2002). In conjunction with this development,
we show how demarcation maps can be used to accomplish the following:
the approximation and the stress conditions, we can divide the set
into two regions. One region is where all the potential reactions are
essentially completed (the region of potential failure modes) and the
other where they are not. By comparing these maps for two different
stress trajectories, an accelerated stress trajectory, and an operating
trajectory, four regions are identified: (a) a region where the potential
reactions are not complete for either stress condition, (b) another
where they are complete for accelerated test conditions but not for
operating life conditions (the region of potential artificially generated
failure modes), (c) another where they are complete for operating life
but not for accelerated test conditions (a region of potential failure
modes not uncovered by the accelerated test), and (d) a region where
they are complete for both stress conditions.
2. Computational demarcation maps: The concept is the same as that of
the analytical, but rather than make analytical approximations to
determine when reactions are complete, the extent of potential reac-
tions is calculated for each stress trajectory and compared directly
at each point. The dominating trajectory is indicated at that point
by symbol or color choices.
The latter is, in fact, more flexible and lends itself to both more complex
kinetic processes, and more complex statistical analysis. However, it also
requires more sophisticated software for doing the calculations. The former
is more easily calculated, and offers surprisingly useful insights. We will begin
this chapter studying the tools and theory of analytical demarcation maps.
Although at present it seems impossible to make a detailed map of this
sort for all chemical reactions, it is possible to construct a fairly conservative
map for a moderate-sized set of chemical reactions (LuValle et al., 1998, 2000).
The theory supporting the conservative nature is fairly involved, but the
basic idea is straightforward and is provided in the next section. Following
that are examples for several kinds of degradation processes, listed below.
The first three are based on the assumption of simple, one-step processes or
empirical models. The fourth example uses computational demarcation map-
ping with more complicated kinetic processes.
For simplicity, in the first seven sections of this chapter, where the physical
theory of demarcation mapping is developed, we ignore the question of
sample size and statistical interpretation. We return to statistical theory in
Sections 2.8 and 2.9.
−E
k 1 = ν exp a (2.1)
kT
(1 − exp(−k t)) 1
(2.2)
An interesting thing happens if, for a given time and temperature, we plot
the value of Equation 2.2 given Equation 2.1 across activation energies, and
compare that to the approximation:
0, k t < 1
∆( k 1 , t) = 1 (2.3)
1, k 1t ≥ 1
Figure 2.1 shows the result (actually plotting 1 − exp( −k 1t) and ∆( k 1 , t) for
a given temperature and time against activation energy). The center vertical
line is the approximation. The circles are the exponential functions at each
activation energy. The two outer vertical lines correspond to values of ν two
orders of magnitude off. The bounds shown by the outer lines are important
in the following discussion. Relationships 2.1 and 2.3 give the formal approx-
imation:
Ed = kT ln( νt) (2.4)
1.0
0.8
reaction extent
0.6
0.4
0.2
0.0
FIGURE 2.1
Extent of reaction vs. activation energy plotted over the demarcation approximation.
or
T2
t1 =
( νt )
2
T1
(2.6)
ν
which implies that, after a step in temperature, Equation 2.4 can be re-
expressed:
T1
Ed = kT2 ln ν t2 +
( νt 1 ) T2
(2.7)
ν
A key practical issue is how low the value of ν can be. As far as we have
found, there is no scientific reason to presume a lower bound. Diffusion
processes using this approximation can be expected to reach very low values.
However, for the one-step processes, quoted values typically range from 106
to 1018 Hz. Based on our experience with glasses and polymers, we have
chosen to use 10–5 Hz as a lower bound, but some careful thought needs to
be used. Even with this uncertainty, the maps provide significant information
on the relative efficacy of different accelerated tests. A reasonable, conserva-
tive alternative for thermal demarcation maps is to extend the maps to low
enough values of ν so that the corresponding Ed is 0 in all experiments and
life. In the example below this would be to 10–10.
To illustrate how demarcation mapping works, consider an operating life
consisting of a 4-h bake at 180°C, followed by 25 years at 50°C. We compare
this to an accelerated test with a 4-h bake at 180°C followed by 1 h at 260°C
in Figure 2.2. (Figure 2.2 and Figure 2.3 were produced using the code in
the complement to this chapter in Splus.) The shaded region (horizontal
20
1 2
1 2
1 2
1 2
1 2
15
1 2
1 2
1 2
1 2
1 2
10
1 2
1 2
1 2
log nu
12
12
5
12
12
12
12
12
0
12
12
12
12
12
-5
12
1
2
1
2
1
2
1
2
-10
1
2
0 1 2 3 4
Ea
FIGURE 2.2
Demarcation map of 180°C 4 h + 50°C 25 year life vs. 180°C 4 h + 260°C 1 h experiment.
lines) represents the region of reactions corresponding to life (it does not
include the burn-in as that occurs before the customer sees the device, and
failures in that part of the space will be eliminated by the burn-in). The space
between the lines labeled with 1s and that labeled with 2s represents the
region of reactions corresponding to the accelerated test. We note that the
accelerated test contains all reactions occurring during life only for values
of ν greater than 104.5 Hz. The vertical line is at 0 eV, representing the limit
of “reasonable” reactions. If we have reason to regard any reaction with
ν less than this to be an improbable contributor to failure, we can regard
survival of the accelerated test without failure as a basis for acceptance of
the product. If the value of ν might actually be close to 104 Hz, we may wish
to use the bounds on the approximation given by the outer lines in Figure
2.1 to guide us. Thus, we might wish to use an experiment such that the
accelerated test region contains all reactions occurring during life for values
of ν greater than 102 Hz. Figure 2.3 shows an experiment doing this. How-
ever, instead of having to extend the time on test by a factor of 100, we only
had to test at 260°C for 10 h, rather than 1 h.
A schema for an Excel spreadsheet is supplied as Table 2.1. The first six
rows are adjustable parameters; the remaining rows are formulae for columns.
We can also note for these diagrams that the accelerated tests include many
reactions not included during life. Thus, we see with this particular scheme
that there is a fair danger of seeing an artificial failure or degradation mode
20
1 2
1 2
1 2
1 2
1 2
15
1 2
1 2
1 2
1 2
1 2
10
1 2
1 2
1 2
log nu
1 2
1 2
1 2
5
1 2
1 2
1 2
1 2
0
12
12
12
12
12
-5
12
12
12
12
12
-10
12
0 1 2 3 4
Ea
FIGURE 2.3
Demarcation map of 180°C 4 h + 50°C 25 year life vs. 180°C 4 h + 260°C 10 h experiment.
during accelerated testing that would have nothing to do with service life
failure. The demarcation maps can be used to design tests with more specificity
as well, trading off time on test, with coverage, and the possibility of a false
alarm by using different time-stress trajectories. The maps can even be used to
design tests that peel back degradation or failure modes that analysis indicates
are artificial so we can look for failure mechanisms they may be masking. A
prior publication (LuValle, 1998) provides an example of this in a real problem.
Here we continue this example to show in principle how this could work.
Suppose that exposures of 4 h at 180°C and 10 h at 260°C result in several
failures, and that repeating the experiment with the second exposure at
300°C also results in failures. Suppose further that we have recorded the
times of these failures and find that they correspond to a process with an
activation energy of ~2.0 eV and a ν value of 1015 Hz. Because a failure mode
with these parameters will not occur during service life, the standard
assumption applied in accelerated testing is that we now have proved the
device reliable, because the only failure we have seen is one that will never
occur during life. However, the map points out that our accelerated tests
have not gotten close to a number of (Ea, ν) pairs that may be active during
life. The high-stress failure mode could be masking it in these tests. Thus,
what we want to do is to perform a test that minimally activates the (2.0,
1015) failure mode, but that emphasizes some of the lower values we have
missed. Such a test is described below.
TABLE 2.1
Adjustable Terms Variable Name Example Value
Operating temperature OT 85
Operating time Otime (h) 24*365*25
Experimental temperature ET 260
Experimental time Etime (h) 1
Bake temperature BT 180
Bake time Btime (h) 4
Column Name/Symbol Column Formula Example Value
Log10(ν) lν 5
ν 10lν 100000
( 273+ BT )
Equivalent time under operating
conditions, tbO (ν × Btime × 3600) ( 273+ OT ) 1077.3
ν × 3600
( 273+ BT )
Equivalent time under experimental
conditions, tbE (ν × Btime × 3600) ( 273+ ET ) 0.1688
ν × 3600
20 1 2
3
1 2
3
1 2
3
1 2 3
1 23
15
1 23 F
1 23
1 23
1 23
1 23
10
12 3
12 3
12 3
log nu
12 3
12 3
5
1
2 3
1
2 3
1
2 3
1
2 3
1
2 3
0
1
2 3
1 3
2
1 3
2
1 3
2
1 3
2
-5
1 3
2
1 3
2
1 3
2
1 3
2
1 3
2
-10
1 3
2
0 1 2 3 4
Ea
FIGURE 2.4
Demarcation map of 180°C 4 h + 50°C 25 year life vs. 180°C 4 h + 320°C 15 s + 170°C 500 h
experiment.
of stress test would be impossible for a device with high thermal mass and
low surface area to volume. The map also points out that some potential
failure modes are economically untestable (very low ν values).
This section has illustrated some of the basic concepts of the demarcation
map, using the demarcation approximation derived from the Arrhenius rela-
tionship. In the next section, we look more closely at the particular problem
of developing an acceptance test for Arrhenius-driven failure modes.
20 1
1
1
1
1
15
1
1
1
1
1
10
1
1
1
log nu
1
1
1
5
1
1
1
1
0
1
1
1
1
1
-5
1
1
1
1
1
-10
FIGURE 2.5
Demarcation map of 40°C 30 year life vs. 90°C 100 h experiment.
the minimum value of ν where the accelerated test contains all the processes
occurring during life. This is the simplest use of demarcation mapping to
design accelerated tests that will arguably reach end of life. A conservative
value of ν for the purpose of including both processes running totally to
completion and some more complex processes (LuValle, 2000) is a value
three orders of magnitude lower than the lowest value for a simple single-
step chemical process in the materials under consideration.
Suppose the device to be life-tested is assembled using a low-melting-point
solder (e.g., indium–tin with a melting point of 110°C). We believe that the
device, which will see a maximum temperature of 40°C during manufactur-
ing and life, may have a thermally activated failure model. If we would like
to check whether the device could survive for 30 years, while testing at no
more than 90°C, how long will we have to test?
Constructing a demarcation map using the theory provided above, we can
construct a demarcation map for 40°C for 30 years (no bake) and plot over
it the demarcation map for 90°C 100 h.
The shaded region in Figure 2.5 contains the (Ea, ν) pairs that can be
expected to react during life, for those values of ν in the range of 10–10 to
1020. The region to the left and above the line marked with “1”s is the
corresponding region for the experiment. We see that the value of ν for which
the activation energies activated during the experiment are exactly those
activated during life is 1016. This is fairly high, as many common chemical
20 1
1
1
1
1
15
1
1
1
1
1
10
1
1
1
log nu
1
1
1
5
1
1
1
1
0
1
1
1
1
1
-5
1
1
1
1
1
-10
FIGURE 2.6
Demarcation map of 40°C 30 year life vs. 90°C 500 h experiment.
reactions have ν values below 1016 Hz. A good moderately conservative value
would be 103 or lower.
Plainly, to have a more conservative test we need to lengthen the time at
90°C. If we change the time at 90°C to 500 h we obtain Figure 2.6, with a
crossover of approximately 1010.5. The reader can continue with trial and
error. Alternatively, the reader can complete the following exercises.
Exercise 2.2.1
Determine how to identify for fixed operating time and temperature and
experimental temperature the exact time needed to obtain equivalent
times at a given value of ν.
Exercise 2.2.2
Prove that for fixed temperature experiments, with the experiment at a
higher temperature than the operating temperature, this experiment will
be conservative for all values of ν larger than that found in 1.
Exercise 2.2.3
An alternative approach used in reliability engineering is to find the
smallest activation energy such that, for every activation energy above
−E
k 1 = νf ( RH , T) exp a (2.8)
kT
where
(RH)β [PL]
f ( RH , T) = (Vapor _ Pr essure)
β
[VP] (2.9)
β
RH
[BHT]
1 − RH
depending on the physics. The bottom expression was derived to model the
number of monolayers of gas adsorbed on a surface (Braunauer et al., 1938;
Klinger, 1991), and has been found to be useful in modeling reactions rates
occurring at material interfaces. The other two are used often, although
careful derivations of which situations are most appropriate for which model
are not available. As remarked in Complement 1.6.2, the first and second
representations are not statistically identifiable when coupled with the
Arrhenius relationship. Equation 2.8 results in a definition of demarcation
energy with the form:
( )
Ed = kT ln νf ( RH , T)t (2.10)
From this we can derive a similar result to that given in Equations 2.5, 2.6,
and 2.7, so that after a step in stress, the demarcation energy may be calcu-
lated:
T1
Ed = kT2 ln ν t2 +
( )
νf ( RH 1 , T1)t1 T2
(2.11)
νf ( RH 2 , T2 )
0.4389
VP = RH * exp 13.653 − .
kT
For the power law it is clear that we have not reached the goal proposed
above. The reader can input the software in the complement, and proceed
by trial and error until a solution is found, or the reader can perform the
following exercises:
Exercise 2.4.1
Determine how to identify for fixed humidity function operating time
and temperature, relative humidity, β, and experimental temperature and
relative humidity the exact time needed to obtain equivalent times at a
given value of ν.
Exercise 2.4.2
Prove that for fixed stress experiments, with the experiment at a higher
temperature than the operating temperature, this experiment will be
conservative for all larger values of ν found in 1. What happens for the
humidity functions?
20
20
20
15
15
15
10
10
10
log nu
log nu
log nu
5
5
0
0
-5
-5
-5
-10
-10
-10
0.0 0.5 1.0 1.5 2.0 0.0 0.5 1.0 1.5 2.0 0.0 0.5 1.0 1.5 2.0
Ea Ea Ea
20
20
15
15
15
10
10
10
log nu
log nu
log nu
5
5
0
0
-5
-5
-5
-10
-10
-10
0.0 0.5 1.0 1.5 2.0 0.0 0.5 1.0 1.5 2.0 0.0 0.5 1.0 1.5 2.0
Ea Ea Ea
FIGURE 2.7
Array of temperature/humidity demarcation maps of life consisting of 85°C 85% RH screen followed by 20
years at 40°C 42% RH vs. an experiment of 90°C 90% RH for 500 h.
Exercise 2.4.3
What advantages do the plots have over the crossover points in terms
of information about artificial and uncovered failure mechanisms in ac-
celerated tests?
Exercise 2.4.4
Check the crossover point for the vapor pressure and power law curves.
Which is more conservative? Why?
ε p = MN zf (2.12)
1=
( M N ) ⇔ 1 = 1 log( M
1/z
f 1/z
)
Nf (2.13)
z log( ε )
(ε )
1
z p
p
The equation on the left of Equation 2.13 corresponds to Equation 2.4. From
this the step stress criterion to go from plastic strain ε p1 to ε p2 is
( )
log ε p 2
1z
M Nf
( )
log ε p 1
N f 2* = 1
(2.14)
z
M
Miner’s rule (Miner, 1945) gives empirical support to the use of Equations
2.13 and 2.14 to construct demarcation maps with varying amounts of plastic
( ) (
strain. Our implementation of a demarcation map plots log10 M 1 Z vs. − 1 z . )
In this way, the plot can be interpreted the same way as the thermal demar-
cation map, with values above and to the right of the drawn line values that
will occur during the stress trajectory.
[ ( )(
The maps are drawn in the log10 M 1 z , − 1 z )] plane. However, the value
of z = −1 2 is marked with a red line to aid in interpreting the plot in line
with the diffusion hypothesis. Understanding other values of z would
require additional theoretical analysis.
0 1 2 3 4
-1/z
FIGURE 2.8
Coffin–Manson demarcation maps of life consisting of 10-cycle screen at 1e–3 plastic strain
followed by 2 years of hourly cycles at 1e–4 plastic strain vs. an experiment of a 10-cycle screen
at 1e–3 plastic strain followed by 100-cycle “safety test” at 1e–3 plastic strain.
The map, given in Figure 2.8, shows that even if we consider only the
( )
value of − 1 z corresponding to diffusion, the “safety experiment” of 100
thermal cycles has not tested to end of life, so does not indicate if we will
see any serious increase in failure due to this testing or not. The line without
“+” is the line representing the screen followed by life, while the lower line
with “+” is the screen followed by the safety test; the top line is the screen.
The vertical line is the value of − 1 z = 2 . ( )
As two alternatives, we can consider thermal cycles with identical strain
as the screen, and thermal cycles at a lower strain level than the screen.
Figure 2.9 runs the test to 170 cycles. Now the safety test at 1e–3 plastic strain
does reach end of life under the diffusion hypothesis, but not for more
conservative values of –1/z. Figure 2.10 shows what happens if we drop the
plastic strain in the safety test to 3e–4 for 500, 2500, and 5000 cycles (respec-
tively, the second, third, and fourth lines with “+” from the top).
Exercise 2.6.1
Determine algebraically how many cycles are required in the safety ex-
periment to ensure no failures by end of life assuming a – 1/z value of
2, and of 1, for a plastic strain value of 3e–4.
0 1 2 3 4
-1/z
FIGURE 2.9
Coffin–Manson demarcation maps of life consisting of 10-cycle screen at 1e–3 plastic strain
followed by 2 years of hourly cycles at 1e–4 plastic strain vs. an experiment of a 10-cycle screen
at 1e–3 plastic strain followed by 170-cycle “safety test” at 1e–3 plastic strain.
10^-2 10^0 10^2 10^4 10^6 10^8 10^10
M^(1/z)
10^-5
0 1 2 3 4
-1/z
FIGURE 2.10
Coffin–Manson demarcation maps of life consisting of 10-cycle screen at 1e–3 plastic strain
followed by 2 years of hourly cycles at 1e–4 plastic strain vs. an experiment of a 10-cycle screen
at 1e–3 plastic strain followed by 3e–4 plastic strain at 500, 2500, and 5000 cycles.
where
(
E − stress.coef × T − T )
( )
pow a 0 +
k f = fluence ν exp − (2.16)
kT
and
(
E + stress.coef × T − T )
( )
pow a 0 +
kb = fluence ν exp − (2.17)
kT
T0 is the temperature where the film and the underlying material are at 0
stress, the notation ( z) denotes we are setting the value as z if it is positive,
+
and 0 if it is negative. We could take an arbitrarily complex kinetic model if
we wished, but this is sufficiently complex. This model could be used as a
combined model of electromigration and stress voiding, with fluence denot-
ing current density. We assume there is no fluence effect. Then in the simplest
version of the real problem, there are four unknown parameters to cause us
( )
concern: ν, Ea , stress.coef , T0 , and there is a moderately complex relation-
ship based on Equations 2.15 through 2.17.
() (
log10 ν = −4, 0, 4, 8, 12, 16, 20 )
E = (0.3, 0.6, 0.9, 1.2, 1.5)
a
stress.coef = (1e − 6, 1e − 5, 1e − 4, 1e − 3, 1e − 2)
T0 varies through 200, 350, and 500 for the values in life. In six experiments
it follows this variation, and in the remaining experiments it is set to 600.
This allows us to examine the effect of T0 both if it is uncontrolled (but
constant through manufacture), and if it can be used as an experimental
variable for acceleration.
Figure 2.11 is a demarcation map comparing storage life at 50°C for 5 years
to an accelerated experiment at 150°C for 5000 h. Each graph in the plot
corresponds to the values of pow (the exponent of the fluence term = 0
identically), T0, and stress.coef being fixed to the values shown above that
graph for the life stress. In this case the T0 values changed in the experiment
in a corresponding fashion. The horizontal axis of each graph is the activation
TABLE 2.2
Evaluation of Potential Experiments
Number
Temperature Time T0 (of 525 possible)
100 5000 h 200,350,500 372
150 5000 h 200,350,500 363
100 2 years 200,350,500 357
150 2 years 200,350,500 350
200 2 years 200,350,500 405
300 2 years 200,350,500 413
50 2 years 600 196
100 2 years 600 194
150 2 years 600 195
200 2 years 600 269
100* 1000 h 600 218
250* 1000 h 600 270
Combo (two above*) 190
energy (Ea) in electron volts, and the vertical axis is log 10 ( ν) . An L in a spot
means that life will result in more depletion in the first five compartments
than the experiment, so the experiment cannot be thought of as having
reached end of life. An E implies that the experiment will result in more
depletion, implying that for the parameter values corresponding to that
position we have reached beyond the end of life degradation in the experi-
ment. (A key assumption here is that end of life is controlled only by the
function of the state vector we are examining, and the environment influ-
ences end of life only through that state vector).
A very simple crude measure of the efficiency of an experiment is the
number of points in the map where life dominates experiment. For a fixed
map, such as here, the fewer points dominated by life, the more likely the
experiment is to identify regions where failure can occur. Although this
actually must be weighed by the likelihood of each parameter point, for the
interest of simplicity we start with the simple measure and allow Chapter 4
to consider more sophisticated measures. Table 2.2 shows the experiments
tried vs. the number of points where life dominates.
There are several points of interest that can be derived from this table.
First, if T0 can be controlled, it makes a far more effective accelerant than
temperature for probing for this phenomenon. Second, increasing T0 shifts
the optimal temperature for achieving high coverage. Finally, combining
experiments cleverly can result in significant shortening of the time required
to attain a certain level of coverage.
The particular coverage by the 2-year experiment at 100°C with a T0 of
600°C is shown in Figure 2.12 and can be contrasted to the coverage shown
in Figure 2.13 for the combined experiment run at 1000 h each. The differ-
ences are actually slight, although they do exist.
20
20
20
20
20
L L L L L L L L L L L L L L L L L L L L L L L L L
L L L L E L L L L E L L L L E L L L L L L L L L L
15
15
15
15
15
L L L L E L L L L E L L L L E L L L L E L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
L L L E E L L L E E L L L E E L L L E E L L L L L
5
L L E E E L L E E E L L E E E L L E E E L L L L L
0
0
L E E E E L E E E E L E E E E L L E E E L L L L L
L E E E L L E E E L L E E E E L L E E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
0 350 1e-006 0 350 1e-005 0 350 0.0001 0 350 0.001 0 350 0.01
20
20
20
20
20
L L L L L L L L L L L L L L L L L L L L L L L L L
L L L L E L L L L E L L L L E L L L L L L L L L L
15
15
15
15
15
L L L L E L L L L E L L L L E L L L L E L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
L L L E E L L L E E L L L E E L L L E E L L L L L
5
5
L L E E E L L E E E L L E E E L L L E E L L L L L
0
0
L E E E E L E E E E L E E E E L L E E E L L L L L
L E E E L L E E E L L E E E E L L E E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
0 500 1e-006 0 500 1e-005 0 500 0.0001 0 500 0.001 0 500 0.01
20
20
20
20
20
L L L L L L L L L L L L L L L L L L L L L L L L L
L L L L E L L L L E L L L L E L L L L L L L L L L
15
15
15
15
15
L L L E E L L L E E L L L L E L L L L L L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
L L L E E L L L E E L L L E E L L L L E L L L L L
5
5
L L E E E L L E E E L L E E E L L L E E L L L L L
0
0
L E E E E L E E E E L E E E E L L L E E L L L L L
L E E E L L E E E L L E E E E L L L E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
FIGURE 2.11
Computational demarcation map of stress voiding, comparing life at 50°C for 5 years vs. an experiment
at 150°C for 5000 h. L means that the reaction extent for life dominates the reaction extent for the experiment
at that combination of parameters. E means the reverse.
20
20
20
20
20
E E E E E E E E E E E E E E E E E E E E L L L L L
E E E E E E E E E E E E E E E E E E E E L L L L L
15
15
15
15
15
E E E E E E E E E E E E E E E E E E E E L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
E E E E E E E E E E E E E E E E E E E E L L L L L
5
0 E E E E E E E E E E E E E E E E E E E E L L L L L
0
E E E E E E E E E E E E E E E E E E E E L L L L L
E E E E L E E E E L E E E E L E E E E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
0 350 1e-006 0 350 1e-005 0 350 0.0001 0 350 0.001 0 350 0.01
20
20
20
20
20
E E E E E E E E E E E E E E E E E E E E L L L L L
E E E E E E E E E E E E E E E E E E E E L L L L L
15
15
15
15
15
E E E E E E E E E E E E E E E E E E E E L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
E E E E E E E E E E E E E E E E E E E E L L L L L
5
5
E E E E E E E E E E E E E E E E E E E E L L L L L
0
0
E E E E E E E E E E E E E E E E E E E E L L L L L
E E E E L E E E E L E E E E L E E E E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
0 500 1e-006 0 500 1e-005 0 500 0.0001 0 500 0.001 0 500 0.01
20
20
20
20
20
L L L L L L L L L L L L L L L L L L L L L L L L L
L L L L E L L L L E L L L L E L L L L L L L L L L
15
15
15
15
15
L L L E E L L L E E L L L L E L L L L L L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
L L L E E L L L E E L L L E E L L L L E L L L L L
5
5
L L E E E L L E E E L L E E E L L L E E L L L L L
0
0
L E E E E L E E E E L E E E E L L E E E L L L L L
E E E E L E E E E L E E E E L L E E E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
FIGURE 2.12
Computational demarcation map of stress voiding, comparing life at 50°C for 5 years vs. an experiment at
100°C for 2 years, with T0 = 600°C.
20
20
20
20
20
E E E E E E E E E E E E E E E E E E E E L L L L L
E E E E E E E E E E E E E E E E E E E E L L L L L
15
15
15
15
15
E E E E E E E E E E E E E E E E E E E E L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
E E E E E E E E E E E E E E E E E E E E L L L L L
5
E E E E E E E E E E E E E E E E E E E E L L L L L
0
0
E E E E E E E E E E E E E E E E E E E E L L L L L
E E E E E E E E E E E E E E E E E E E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
0 350 1e-006 0 350 1e-005 0 350 0.0001 0 350 0.001 0 350 0.01
20
20
20
20
20
E E E E E E E E E E E E E E E E E E E E L L L L L
E E E E E E E E E E E E E E E E E E E E L L L L L
15
15
15
15
15
E E E E E E E E E E E E E E E E E E E E L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
E E E E E E E E E E E E E E E E E E E E L L L L L
5
5
E E E E E E E E E E E E E E E E E E E E L L L L L
0
0
E E E E E E E E E E E E E E E E E E E E L L L L L
E E E E E E E E E E L E E E E E E E E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
0 500 1e-006 0 500 1e-005 0 500 0.0001 0 500 0.001 0 500 0.01
20
20
20
20
20
L L L L L L L L L L L L L L L L L L L L L L L L L
L L L L E L L L L E L L L L E L L L L L L L L L L
15
15
15
15
15
L L L E E L L L E E L L L L E L L L L L L L L L L
10
10
10
10
10
Diff0
Diff0
Diff0
Diff0
Diff0
L L L E E L L L E E L L L E E L L L L E L L L L L
5
5
L L E E E L L E E E L L E E E L L L E E L L L L L
0
0
L E E E E L E E E E L E E E E L L E E E L L L L L
L E E E E L E E E E L E E E E L L E E E L L L L L
0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4 0.4 0.6 0.8 1.0 1.2 1.4
Ea Ea Ea Ea Ea
FIGURE 2.13
Computational demarcation map of stress voiding, comparing life at 50°C for 5 years vs. combined experiment
100°C for 1000 h, and another experiment of 250°C for 1000 h, both with T0 = 600°C.
Γ (α + β)
1
α α
∫ ∫ P Γ (α)Γ (β) P α −1
(1 − P) β−1
dPdπ( φ) =
α +β ∫ dπ(φ) = α + β (2.18)
H 0 H
1
( ) P 1− P
Γ α +β
∫ ∫ Γ (α)Γ (β + n) ( ) ()
β + n− 1
α −1
P dPdπ θ
E 0
Γ (α + β)
1
∫ ∫ Γ (α)Γ (β) P (1 − P) ()
β−1
α −1
+ P dPdπ θ
L 0 (2.19)
α α
=
α +β+n ∫ dπ(θ) + α + β ∫ dπ(θ)
E L
=
α
α +β+n
×πE +
α
α +β
()
× 1− π E ( ( ))
From the final portion of Equation 2.19 we see that the best experiment
(disregarding costs) is the one with the highest prior probability on the points
where the experiment will dominate life. Thus, the best experiment to reduce
the risk associated with assuming no failures will occur during life is the
experiment most likely to disprove the hypothesis that no failures will occur
during life. This result is important enough to emphasize it.
Assume that at each point φ a beta prior is specified for p( φ, Ei ) and assume
that it is the same beta prior at all φ.
{ (
Define Sij = φ p( φ , Ei ) ≥ p φ , E j )} , and Θ θ as the set of all the φ in the neigh-
borhood of θ that we wish to consider. Define an estimate determined from
( )
Ei for p φ, E j to be a strongly determined upper estimate only if φ ∈Sij .
Then we have:
LEMMA
Under the assumptions, and assuming ni ≡ n , the experiment that, with a
null result (no observable degradation or failure), minimizes risk using
strongly determined upper estimates is that experiment for which π Siρ is ( )
maximized.
PROOF
1
( )
R(Ei ) = E Lθ ( φ) Ei = nρ
∫ ∫ dpp(φ, E )β(α , β E , φ)dπ(φ)
Θθ 0
ρ i
(2.20)
α α
( )
R Ei = nρ
α + β + n
d
∫ ()
π φ +
α + β
d
∫ ()
π φ
Siρ Θθ \Siρ (2.21)
α
= nρ
α
( )
π Siρ +
α + β + n
( ( ))
1 − π Siρ
α + β
2.10 Summary
In this chapter a radically different approach to the extrapolation of acceler-
ated tests has been described. This theory is based on the following notion:
The information on reliability (for ultrahigh-reliability devices) in an accelerated
test is in the failure and degradation free periods prior to any observable degradation
or failure. We have provided a theoretical basis for using this approach assum-
ing that tests can be constructed in which no failures are expected to occur
given the existing models of failure, and assuming that the failure modes
are described by a rather simple one-step kinds of kinetic models.
The complement to this chapter provides instructions for using the down-
loadable computer code in Splus for analytical demarcation mapping.
In Chapter 4, we extend the notion of demarcation mapping to considering
more complex (but still first-order) chemical kinetic processes as possible
alternatives to whatever model currently fits the failure and degradation
data obtained.
Pk = IS i
binary( k , i )
iρ
1= ∑p
i =1
i
Ignoring for the moment that devices come in whole numbers, we can
apply elementary calculus. Define from the constraint
m −1
pm = 1 − ∑p i =1
i
∂
∂p i
(
expected posterior probability of failure = )
binary( m , i) × α × π Pk ( )
k∑ m
2
α + β +
∑( binary( k , i) × Np i )
i =1
N
binary( k , i) × α × π Pk( )
−
∑ m
2
∑( )
k
α + β + binary ( k , i) × Np i
i =1
FIGURE 2.14
GUI for thermal demarcation map function in Splus.
Temperature
vector for life
(°C)
Title of plot
(in quotes)
FIGURE 2.15
Annotated GUI for thermal demarcation map function in Splus, filled in to produce Figure 2.4.
As configured, left-clicking with the mouse on the apply button causes the
function to execute, producing Figure 2.4 and bringing up the “report”
window in Splus, where the numerical output is dumped. The numerical
output is a list, printed below. Note that vectors in the input use the usual
Splus notation beginning with a c(…).
$order.1.life:
matx mat.ret vec.ret
[1,] -5 -0.07571782 0.2499654
[2,] -4 0.01424706 0.3141129
[3,] -3 0.10421194 0.3782609
[4,] -2 0.19417682 0.4424103
[5,] -1 0.28414170 0.5065632
[6,] 0 0.37410657 0.5707249
[7,] 1 0.46407145 0.6349086
[8,] 2 0.55403633 0.6991479
[9,] 3 0.64400121 0.7635266
[10,] 4 0.73396608 0.8282502
[11,] 5 0.82393096 0.8938027
[12,] 6 0.91389584 0.9612132
[13,] 7 1.00386072 1.0322211
[14,] 8 1.09382560 1.1086037
[15,] 9 1.18379047 1.1906019
[16,] 10 1.27375535 1.2766537
[17,] 11 1.36372023 1.3649038
[18,] 12 1.45368511 1.4541597
[19,] 13 1.54364999 1.5438388
[20,] 14 1.63361486 1.6336898
[21,] 15 1.72357974 1.7236094
[22,] 16 1.81354462 1.8135564
[23,] 17 1.90350950 1.9035141
[24,] 18 1.99347437 1.9934762
[25,] 19 2.08343925 2.0834400
[26,] 20 2.17340413 2.1734044
$order.1.expt:
matx mat.ret vec.ret vec.ret
[1,] -5 -0.07571782 -0.07568411 0.1107292
[2,] -4 0.01424706 0.01430510 0.1987238
[3,] -3 0.10421194 0.10431185 0.2867194
[4,] -2 0.19417682 0.19434876 0.3747162
[5,] -1 0.28414170 0.28443745 0.4627144
[6,] 0 0.37410657 0.37461487 0.5507146
[7,] 1 0.46407145 0.46494374 0.6387176
[8,] 2 0.55403633 0.55552947 0.7267251
[9,] 3 0.64400121 0.64654624 0.8147398
[10,] 4 0.73396608 0.73827349 0.9027669
[11,] 5 0.82393096 0.83113808 0.9908161
[12,] 6 0.91389584 0.92574114 1.0789056
[13,] 7 1.00386072 1.02282347 1.1670707
[14,] 8 1.09382560 1.12311511 1.2553813
[15,] 9 1.18379047 1.22708066 1.3439780
[16,] 10 1.27375535 1.33470647 1.4331434
[17,] 11 1.36372023 1.44550735 1.5234262
$crossover:
[1] 0.8400869 0.4496849
FIGURE 2.16
Annotated GUI for temperature/humidity demarcation map function in Splus, filled in to
produce Figure 2.7.
Left-clicking the apply button with the mouse produces the plot below, as
well as assigning the numerical output to the name “dum.” The output is
printed below.
The numerical output is a list; at the highest level it has two components,
corresponding to each exponent. Within each list is a sublist with compo-
nents BHT (the Teller model RH/(1-RH)), VP (the vapor pressure model),
and PL (the power law in relative humidity model). Even though there is
no numerical difference between the last two if a translation is made for
activation energy and ν, both are shown because there is a possibility that
one is interpretable when the other is not because, for example, one results
in a negative activation energy. Each of the sublists has a cc component and
a matrix component. CC shows the crossover value of log 10 ( ν) ; while the
matrix is similar to that for temperature, only the life matrix and experiment
matrix are shown side by side. The column of log 10 ( ν) values is repeated
at the beginning of both matrices, life first.
> dum
[[1]]:
[[1]]$BHT:
[[1]]$BHT$cc:
[1] 3.250845
[[1]]$BHT$mat:
matx mat.ret vec.ret matx vecx
[1,] 2 0.5907987 0.6745286 2 0.6639237
[2,] 3 0.6618967 0.7381145 3 0.7360148
[3,] 4 0.7329948 0.8018350 4 0.8081058
[4,] 5 0.8040929 0.8657280 5 0.8801969
[5,] 6 0.8751910 0.9298391 6 0.9522880
[6,] 7 0.9462890 0.9942218 7 1.0243790
[7,] 8 1.0173871 1.0589357 8 1.0964701
[8,] 9 1.0884852 1.1240441 9 1.1685611
[9,] 10 1.1595832 1.1896091 10 1.2406522
[10,] 11 1.2306813 1.2556852 11 1.3127433
[11,] 12 1.3017794 1.3223126 12 1.3848343
[12,] 13 1.3728775 1.3895116 13 1.4569254
[13,] 14 1.4439755 1.4572791 14 1.5290164
[14,] 15 1.5150736 1.5255895 15 1.6011075
[[1]]$VP:
[[1]]$VP$cc:
[1] 3.78138
[[1]]$VP$mat:
matx mat.ret vec.ret matx vecx
[1,] 2 0.5148744 0.5953111 2 0.5803748
[2,] 3 0.5859725 0.6589516 3 0.6524659
[3,] 4 0.6570705 0.7227423 4 0.7245569
[4,] 5 0.7281686 0.7867244 5 0.7966480
[5,] 6 0.7992667 0.8509471 6 0.8687391
[6,] 7 0.8703648 0.9154666 7 0.9408301
[[1]]$PL:
[[1]]$PL$cc:
[1] 9.711457
[[1]]$PL$mat:
matx mat.ret vec.ret matx vecx
[1,] 2 0.5322204 0.6585367 2 0.5918326
[2,] 3 0.6033184 0.7217828 3 0.6639237
[3,] 4 0.6744165 0.7850594 4 0.7360148
[4,] 5 0.7455146 0.8483762 5 0.8081058
[5,] 6 0.8166126 0.9117461 6 0.8801969
[6,] 7 0.8877107 0.9751859 7 0.9522880
[7,] 8 0.9588088 1.0387170 8 1.0243790
[8,] 9 1.0299069 1.1023669 9 1.0964701
[9,] 10 1.1010049 1.1661696 10 1.1685611
[10,] 11 1.1721030 1.2301669 11 1.2406522
[11,] 12 1.2432011 1.2944085 12 1.3127433
[12,] 13 1.3142991 1.3589513 13 1.3848343
[13,] 14 1.3853972 1.4238571 14 1.4569254
[14,] 15 1.4564953 1.4891895 15 1.5290164
[[2]]:
[[2]]$BHT:
[[2]]$BHT$cc:
[1] NA
[[2]]$BHT$mat:
matx mat.ret vec.ret matx vecx
[1,] 2 0.6443588 0.6751473 2 0.7327161
[2,] 3 0.7154569 0.7411473 3 0.8048071
[3,] 4 0.7865550 0.8076939 4 0.8768982
[4,] 5 0.8576530 0.8748106 5 0.9489892
[5,] 6 0.9287511 0.9424978 6 1.0210803
[6,] 7 0.9998492 1.0107327 7 1.0931714
[7,] 8 1.0709472 1.0794733 8 1.1652624
[8,] 9 1.1420453 1.1486638 9 1.2373535
[9,] 10 1.2131434 1.2182418 10 1.3094446
[10,] 11 1.2842415 1.2881442 11 1.3815356
[11,] 12 1.3553395 1.3583119 12 1.4536267
[12,] 13 1.4264376 1.4286923 13 1.5257177
[13,] 14 1.4975357 1.4992406 14 1.5978088
[14,] 15 1.5686337 1.5699198 15 1.6698999
[[2]]$VP:
[[2]]$VP$cc:
[1] NA
[[2]]$VP$mat:
matx mat.ret vec.ret matx vecx
[1,] 2 0.4925103 0.5188190 2 0.5656183
[2,] 3 0.5636084 0.5852944 3 0.6377094
[3,] 4 0.6347064 0.6523382 4 0.7098004
[4,] 5 0.7058045 0.7199536 5 0.7818915
[5,] 6 0.7769026 0.7881209 6 0.8539825
[6,] 7 0.8480006 0.8568001 7 0.9260736
[7,] 8 0.9190987 0.9259368 8 0.9981647
[8,] 9 0.9901968 0.9954691 9 1.0702557
[9,] 10 1.0612948 1.0653337 10 1.1423468
[10,] 11 1.1323929 1.1354707 11 1.2144378
[11,] 12 1.2034910 1.2058267 12 1.2865289
[12,] 13 1.2745891 1.2763559 13 1.3586200
[13,] 14 1.3456871 1.3470203 14 1.4307110
[14,] 15 1.4167852 1.4177892 15 1.5028021
[[2]]$PL:
[[2]]$PL$cc:
[1] 7.424668
[[2]]$PL$mat:
matx mat.ret vec.ret matx vecx
[1,] 2 0.5272022 0.6350115 2 0.5885339
[2,] 3 0.5983002 0.6983460 3 0.6606250
[3,] 4 0.6693983 0.7617391 4 0.7327161
[4,] 5 0.7404964 0.8252093 5 0.8048071
[5,] 6 0.8115945 0.8887802 6 0.8768982
[6,] 7 0.8826925 0.9524812 7 0.9489892
[7,] 8 0.9537906 1.0163494 8 1.0210803
[8,] 9 1.0248887 1.0804294 9 1.0931714
[9,] 10 1.0959867 1.1447735 10 1.1652624
[10,] 11 1.1670848 1.2094409 11 1.2373535
[11,] 12 1.2381829 1.2744946 12 1.3094446
[12,] 13 1.3092810 1.3399970 13 1.3815356
[13,] 14 1.3803790 1.4060041 14 1.4536267
[14,] 15 1.4514771 1.4725584 15 1.5257177
dum
$life:
matx mat.ret
[1,] 1e-005 -1.3333333 -0.18911360
[2,] 1e-004 -1.0000000 0.06088972
[3,] 1e-003 -0.6666667 0.31089688
Corresponding
vector of plastic
Name of object that numerical strains during
output is assigned to experiment
Name for
Vector of cycles plot (in
during life quotes)
Corresponding
vector of plastic
strains during
life Vector of M1/2
values for plot
Vector of cycles
during experiment Maximum value of –1/z for plot
FIGURE 2.17
GUI for Coffin–Manson demarcation map function in Splus for mechanical and thermal cycling,
filled in to produce Figure 2.8.
$expt:
matx mat.ret
[1,] 1e-005 -1.3333333 -0.98620244
[2,] 1e-004 -1.0000000 -0.65286910
[3,] 1e-003 -0.6666667 -0.31953577
[4,] 1e-002 -0.3333333 0.01379756
[5,] 1e-001 0.0000000 0.34713090
[6,] 1e+000 0.3333333 0.68046423
[7,] 1e+001 0.6666667 1.01379756
[8,] 1e+002 1.0000000 1.34713090
[9,] 1e+003 1.3333333 1.68046423
[10,] 1e+004 1.6666667 2.01379756
[11,] 1e+005 2.0000000 2.34713090
[12,] 1e+006 2.3333333 2.68046423
[13,] 1e+007 2.6666667 3.01379756
[14,] 1e+008 3.0000000 3.34713090
[15,] 1e+009 3.3333333 3.68046423
[16,] 1e+010 3.6666667 4.01379756
>
The first column of both the life and the expt. matrices are the vectors of
M 1 z values; the remaining columns are the –1/z values computed from the
demarcation equations.