AEC Q101 Rev E Base Document
AEC Q101 Rev E Base Document
March 1, 2021
TABLE OF CONTENTS
Appendix 6: Plastic Package Opening for Wire Bond Testing and Inspection
Attachments
AEC-Q101-006: Short Circuit Reliability Characterization of Smart Power Devices for 12V
Systems
AEC - Q101 - Rev - E
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Automotive Electronics Council
Component Technical Committee
Acknowledgment
Any document involving a complex technology brings together experience and skills from many sources. The
Automotive Electronics Council would especially like to recognize the following significant contributors to the
revision of this document:
NOTICE
AEC documents contain material that has been prepared, reviewed, and approved through the AEC Technical
Committee.
AEC documents are designed to serve the automotive electronics industry through eliminating
misunderstandings between manufacturers and purchasers, facilitating interchangeability and improvement of
products, and assisting the purchaser in selecting and obtaining with minimum delay the proper product for use
by those other than AEC members, whether the standard is to be used either domestically or internationally.
AEC documents are adopted without regard to whether or not their adoption may involve patents or articles,
materials, or processes. By such action AEC does not assume any liability to any patent owner, nor does it
assume any obligation whatever to parties adopting the AEC documents. The information included in AEC
documents represents a sound approach to product specification and application, principally from the
automotive electronics system manufacturer viewpoint. No claims to be in Conformance with this document
shall be made unless all requirements stated in the document are met.
Inquiries, comments, and suggestions relative to the content of this AEC document should be addressed to the
AEC Technical Committee on the link http://www.aecouncil.com.
This document may be downloaded free of charge, however AEC retains the copyright on this material. By
downloading this file, the individual agrees not to charge for or resell the resulting material.
Copyright © 2021 by the Sustaining Members of the Automotive Electronics Council. This document may be
freely reprinted with this copyright notice. This document cannot be changed without approval from the AEC
Component Technical Committee.
AEC - Q101 - Rev - E
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Component Technical Committee
Unless otherwise stated herein, the date of implementation of this standard for new
qualifications and re-qualifications is as of the publish date above.
1. SCOPE
This document defines minimum stress test driven qualification requirements and references test
conditions for qualification of discrete semiconductors (e.g. transistors, diodes, etc.). This document
does not relieve the supplier of their responsibility to meet their own company's internal qualification
program. Additionally, this document does not relieve the supplier from meeting any user requirements
outside the scope of this document. In this document, "user" is defined as any company developing or
using a discrete semiconductor part in production. The user is responsible to confirm and validate all
qualification and assessment data that substantiates conformance to this document.
1.1 Purpose
The purpose of this specification is to determine that a part is capable of passing the specified stress
tests and thus can be expected to give a certain level of quality / reliability in the application.
Current revision of the referenced documents will be in effect at the date of agreement to the
qualification plan. Subsequent qualification plans will automatically use updated revisions of these
referenced documents.
1.2.1 Military
1.2.2 Industrial
UL-STD-94 Test for Flammability of Plastic Materials of Parts in Devices and Appliances.
JEDEC JESD-22 Reliability Test Methods for Packaged Devices
J-STD-002 Solderability Tests for Component Leads, Terminations, Lugs, Terminals and Wires.
J-STD-020 Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount
Devices
JESD22-A113 Preconditioning of Nonhermetic Surface Mount Devices Prior to Reliability Testing
JEDEC/IPC J-STD-035 Acoustic Microscopy for Nonhermetic Encapsulated Electronic Components
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1.2.3 Automotive
1.2.4 Other
IATF 16949
1.2.5 Decommissioned
1.3 Definitions
Successful completion and documentation of the test results from requirements outlined in this
document allows the supplier to claim that the part is “AEC-Q101 qualified”. The supplier, in agreement
with the user, can perform qualification at sample sizes and conditions less stringent than what this
document requires. However, that part cannot be considered “AEC-Q101 qualified” until such time that
the unfulfilled requirements have been successfully completed. Note that there are no "certifications"
for AEC-Q101 qualification and there is no certification board run by AEC to qualify parts.
The minimum ambient temperature range for discrete semiconductors per this specification shall be -
40°C to +125°C operational.
Any parts being qualified with Cu wire must follow the requirements in AEC-Q006. The test
requirements in AEC-Q006 supersede what is in this document. All other tests are performed to AEC-
Q101 (see note 3 in Table 2).
"Approval" is defined as user approval for use of a part in their application. The user’s method of
approval is beyond the scope of this document.
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1.3.3 Terminology
In this document, “part” refers to the same entity as would “device” or “component” (i.e., a singulated
diode, transistor, varistor, etc.) with the die molded in a plastic mold compound or unmolded (i.e. metal
can transistors, glass diodes, etc.) with solderable terminations for board attachment. Discrete
products delivered as bare die or in wafer form are still qualified to Q101 using appropriate carriers or
surrogate packages.
2. GENERAL REQUIREMENTS
In the event of conflict in the requirements of this specification and those of any other documents, the
following order of precedence applies:
For the part to be considered qualified per this specification, the purchase order and/or individual part
specification cannot waive or detract from the requirements of this document.
2.2 The Use of Generic Data to Satisfy Qualification and Re-qualification Requirements
The use of generic (family) data to simplify the qualification/re-qualification process is encouraged. To
be considered, the generic data must be based on the following criteria:
Appendix 1 defines the criteria by which parts are grouped into a qualification family for the purpose of
considering the data from all family members to be equal and generically acceptable to the qualification
of the part in question.
With proper attention to these qualification family guidelines, information applicable to other parts in the
family can be accumulated. This information can be used to demonstrate generic reliability of a part
family and minimize the need for part-specific qualification test programs. This can be achieved through
qualification of a range of parts representing the “four corners” of the qualification family (e.g.,
highest/lowest voltage, largest/smallest die, etc.). Sources of generic data should come from supplier-
certified test labs, and can include internal supplier's qualifications, user-specific qualifications and
supplier's in-process monitors. The generic data to be submitted must meet or exceed the test
conditions specified in Table 2. Table 1 provides the requirements showing how the available part test
data may be applied to reducing the number of lots required for qualification. Electrical characterization
to the individual user part specification must be performed for each part submission, generic
characterization data is not allowed. The user(s) will be the final authority on the acceptance of
generic data in lieu of specific part test data.
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New part, no applicable generic data. Lot and sample size requirements per Table 2.
A part in a family is qualified. The part to be Only part specific tests as defined in section 4.2
qualified is less complex and meets the Family are required. Lot and sample size requirements
Qualification Definition per Appendix 1. per Table 2 for the required tests.
Review Section 2.2 above to determine
A new part that has some applicable generic
required tests from Table 2. Lot and sample
data.
sizes per Table 2 for the required tests.
Review Table 3 to determine which tests from
Part process change. Table 2 should be considered. Lot and sample
sizes per Table 2 for the required tests.
Table 2 defines a set of qualification tests that must be considered for both new part qualifications and
re-qualification associated with a design or process change.
Table 3 defines a matrix of appropriate qualification tests that must be considered for any changes
proposed for the part. Table 3 is the same for both new processes and requalification associated with
a process change. This table is a superset of tests that the supplier and user should use as a baseline
for discussion of tests that are required for the qualification/requalification in question. It is the
supplier’s responsibility to present and document rationale for why any of the highlighted tests
need not be performed.
Sample sizes used for qualification testing and/or generic data submission must be consistent with the
specified minimum sample sizes and acceptance criteria in Table 2. If the supplier elects to submit
generic data for qualification/requalification, the specific test conditions and results must be reported.
Existing applicable generic data should first be used to satisfy these requirements and those of Section
2.3 for each test requirement in Table 2. Part specific qualification testing should be performed if the
generic data does not satisfy these requirements.
• The supplier must perform any combination of the specific part to be qualified and/or an
acceptable generic part(s) that totals a minimum of 3 lots x 77 pcs/lot.
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There are no time limits for the acceptability of generic data as long as the appropriate reliability data
is submitted to the user for evaluation. Use the diagram below for appropriate sources of reliability data
that can be used. This data must come from the specific part or a part in the same qualification family,
as defined in Appendix 1. Potential sources of data could include any user specific data (withhold user
name), process change qualification, and periodic reliability monitor data (see Figure 1).
History Present
Process Change
Process Change
Customer #2
Qualification
Qualification
Qualification
Specific
Supplier Internal
Characterization
Periodic Reliability
Internal Device
Supplier Start
of Production
Monitor Tests
Qualification
Note: Some process changes (e.g., die shrink) will affect the use of
generic data such that data obtained before these types of
changes will not be acceptable for use as generic data.
All pre- and post-stress test parts must be tested to the electrical characteristics defined in the individual
user part detail specification at room temperature.
Test failures are defined as devices exhibiting any of the following criteria:
a. Parts not meeting the electrical test limits defined in the first user's part specification or
appropriate supplier part specification. Minimum test parametric requirements shall be as
specified in Appendix 5.
b. Parts not remaining within ± 20% of the initial reading of each test after completion of
environmental testing. For leakages below 100nA, tester accuracy may prevent a post stress
analysis to initial reading.
o For IOL, PTC and TC tests on products with RDSon 2.5 mOhm max, the allowed value
for the shift of RDSon is 0.5 mOhm.
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o For breakdown voltage only, a shift of >20% of the initial measured value is a failure only
if the final reading is within 20% of the datasheet maximum value.
c. The allowed leakage limits which are not to exceed 10 times the initial value for moisture tests
and 5 times the initial value for all others.
o For MOSFETs only, for 0h test values <10nA (IGSS and IDSS), the allowed value after
stressing is 100nA for moisture tests and 50nA for other tests.
d. Any part exhibiting external physical damage attributable to the environmental test.
Parts exceeding these requirements must be justified by the supplier and approved by the user. If the
cause of failure is agreed (by the manufacturer and the user) to be due to mishandling or ESD, the
failure shall be discounted, but reported as part of the data submission.
Passing all appropriate qualification tests specified in Table 1, either by performing the tests
(acceptance of zero failures using the specified minimum sample size) on the specific part or
demonstrating acceptable family generic data (using the family definition guidelines defined in Appendix
1 and the total required lot and sample sizes), qualifies the part per this document.
Parts that have failed the acceptance criteria of tests required by this document require the supplier to
satisfactorily determine root cause, implement and verify the corrective action to assure the user that
the failure mechanism is understood and contained. The part shall not be considered as passing stress-
test qualification until the root cause of the failure is determined and the corrective and preventive
actions are confirmed to be effective. If generic data contains any failures, the data is not usable as
generic data unless the supplier has verified corrective action for the failure condition. Upon
qualification data submission, the user may request the supplier to demonstrate the effectiveness of
the corrective actions.
Any unique reliability tests or conditions requested by the user and not specified in this document shall
be agreed upon between the supplier and user requesting the test, and will not preclude a device from
passing stress-test qualification as defined by this document.
Any deviation from the test requirements and conditions listed in Table 2 are beyond the scope of this
document. Deviations (e.g., accelerated test methods) must be demonstrated to the AEC for
consideration and inclusion into future revisions of this document.
See Appendix 7: AEC-Q101 and the Use of Mission Profiles for more information.
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Stress test requirements and corresponding test conditions for a new part qualification are listed in
Table 2. For each qualification, the supplier must present data for ALL of these tests, whether it is
stress test results on the specific part or acceptable generic family data. A review is to be made of
other parts in the same generic family to ensure that there are no common failure mechanisms in that
family. Justification for the use of generic data, whenever it is used, must be demonstrated by the
supplier and approved by the user. For each part qualification, the supplier must present Certificate of
Design, Construction and Qualification to the requesting user. See Appendix 2.
Re-qualification of a part is required when the supplier makes a change to the product and/or process
that impacts (or could potentially impact) the form, fit, function, quality and/or reliability of the part (see
Table 3 for guidelines).
The supplier will meet mutually agreed upon requirements for product/process changes.
As a minimum, any change to the product, as defined above, requires performing the applicable tests
listed in Table 2, using Table 3 to determine the re-qualification test plan. Table 3 should be used as
a guide for determining which tests need to be performed or whether equivalent generic data can be
submitted for the test(s).
All requalification failures shall be analyzed for root cause, with corrective and preventive actions
established as required. The part and/or qualification family may be granted “qualification status” if, as
a minimum, proper containment is demonstrated and approved by the user, with corrective and
preventive actions established and verified, normally via requalification.
A change may not affect a part’s operating temperature grade, but may affect its performance in an
application. Individual user authorization of a process change shall be based on a contract between
Supplier and User, and is outside the scope of this document.
The supplier is requested to initiate a discussion with each user (as needed) resulting in completion of
a signed Qualification Test Plan agreement as soon as possible after supplier selection for new parts,
and at the time of notification (see Section 3.2.2) prior to process changes. The Qualification Test Plan,
as defined in Appendix 3, shall be used to provide a consistent method of documentation supporting
what testing will be performed as required by Tables 2 & 3.
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4 QUALIFICATION TESTS
Test flows are shown in Figure 2 and test details are given in Table 2. Not all tests apply to all parts.
For example, certain tests apply only to hermetically packaged parts, others apply only to power
MOSFET parts, and so on. The applicable tests for the particular part type are indicated in the "Note"
column and the "Additional Requirements" column of Table 2. The "Additional Requirements" column
of Table 2 also serves to highlight test requirements that supersede those described in the referenced
test.
The following tests must be performed on the specific part (i.e., family data is not allowed for these
tests):
b. Parametric Verification (Table 2, E2) - The supplier must demonstrate that the part is capable
of meeting parametric limits detailed in the individual user part specification.
Data to be submitted to the user are classified in three types (Data Type column in Table 2):
Data (generic or specific) from these tests should be formatted as defined in Section 4.4 and included
in each qualification submission.
Package specific data that should not be included with each qualification submission (except where the
package is new). In place of this data the supplier can submit a "Document of Completion" that
references successful completion of the specific test previously performed, provided no significant
changes have been made. For Test C2 (Physical Dimensions), the Document of Completion should
be completed referencing the appropriate user packaging specification.
Re-qualification data should be included in the qualification submission as required by Table 3. For
new parts, data should be included in the qualification submission as required by Table 2. These tests
shall be considered by the supplier during re-qualification plan development as useful tools to provide
supporting rationale for new part qualification (including new packages) and/or process changes. It is
the supplier's responsibility to present rationale for why any of these tests need not be performed.
A data summary shall be submitted as defined in Appendix 4. Raw data and histograms shall be
submitted to the individual user upon request. All data and documents (e.g., justification for non-
performed tests, etc.) shall be maintained by the supplier in accordance with IATF 16949 requirements.
The supplier shall follow the requirements of AEC-Q005 Pb-Free Test Requirements for all parts whose
plating material on the leads/terminations contains <1000ppm by weight of lead (Pb).
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NOTE: “alt” indicates an option to perform either/or of the same test number.
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* Note: All electrical testing before and after the qualification stresses (including pre-conditioning) are performed to the limits detailed in the individual
user specification at room temperature only. For generic qualifications, the supplier’s standard specification limits at room temperature may be used.
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Table 2A: Timing Requirements for Intermittent Operational Life (Test A5) or Power Temperature Cycling (Test A5alt)
Example 1: A package capable of 2 minutes on/4 minutes off would require 10,000 cycles [60,000/(2+4)] at TJ
100oC or 5,000 cycles at TJ 125°C.
Example 2: A package capable of 1 minute on/1 minute off would require 15,000 cycles at TJ 100oC or 7,500
cycles at TJ 125°C.
X = the minimum amount of time it takes for the part to reach the required Tj from ambient temperature.
Y = the minimum amount of time it takes for the part to cool to ambient temperature from the required Tj.
The method of instrumentation, part mounting and heat sinking on the test board will influence x and y per
package.
Table 2B: Solderability Requirements (Test C10) for SnPb Plated Terminations per J-STD-002
Steam Age
Type Test Method Solder Temperature
Category
245+/-5°C reflow:
Leaded Through-Hole A or A1 215+/-5°C Pb-free C or E
backward compatibility
SMD Standard Process S or S1 215-230°C C or E
SMD Dissolution of Metals test D 260+/-5°C C or E
* Note: Refer to AEC-Q005 Pb-Free Test Requirements for solderability requirements of Pb-free terminated parts.
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(previous) 9 8/ 10/ 5/
7 7ab 6 12 13 23 24 25 14 15 20 22 21 16 17 18 19 27 3 4 11 26 28
Rev D Test # alt/a alt alt abc
Test Name
Parametric Verification
HTRB / ACBV / SSOP
Physical Dimensions
Thermal Resistance
Wire Bond Strength
UHAST / Autoclave
Temperature Cycle
TC Hot / TC Delam
Mechanical Shock
Resist to Solvents
Terminal Strength
Dielectric Integrity
Wire Bond Shear
Unclamp. Induct.
Characterization
Whisker Growth
Constant Accel.
External Visual
HAST / H3TRB
Short Circuit
Solderability
Hermeticity
ESD Char.
Die Shear
IOL / PTC
Vibration
NOTES
Switch
Change
DESIGN
Wafer Thickness x F
Wafer Diameter
Die Size E M F
Layout 3 3 E M
Field Termination E M
WAFER FAB
Wafer Source 9,M R
Lithography 6,7 4 4 1 P
Diffusion 6 6 5,6 5 6 M PR
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The qualification of a particular process will be defined within, but not limited to, the categories listed
below. The supplier will provide a complete description of each process and material of significance.
There must be valid and obvious links between the data and the subject of qualification.
For parts to be categorized in a qualification family, they all must share the same major process and
materials elements as defined below. For each qualification test, two or more qualification families can
be combined if the reasoning is technically sound (i.e., supported by rationale clearly detailing
similarity). All parts using the same process and materials are to be categorized in the same
qualification family for that process and are acceptable by association when one family member
successfully completes qualification with the exception of the device specific requirements of Section
4.2.
Prior qualification data obtained from a part in a specific family may be extended to the qualification of
subsequent parts in that family provided the supplier can insure no process changes have been made.
For broad changes that involve multiple attributes (e.g., site, material(s), process(es)), refer to Section
2.3 that allows for the selection of worst-case test vehicles to cover all the possible permutations.
Each process technology (e.g., Power MOS, Bipolar, Zener, etc.) must be considered and subjected to
stress-test qualification separately. No matter how similar, processes from one fundamental fab
technology cannot be used for the other.
Family requalification with the appropriate tests is required when the process or a material is changed.
The important attributes defining a qualification family are listed below:
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A1.1.2 Wafer Fab Process - consisting of the same attributes listed below:
• Process flow
• Layout design rules
• Number of masks
• Cell Density (where applicable)
• Lithographic process (e.g., contact vs. projection, E-beam vs. X-ray, photoresist polarity)
• Doping process (e.g., diffusion vs. ion implantation)
• Passivation/Glassivation material and thickness range
• Oxidation process and thickness range (for gate and field oxides)
• Front/back metallization material, thickness range and number of levels
A1.1.4 Example:
3 lots of a FAB family in any package outline for the following Qualification tests:
• HTRB
• HTGB
• H3TRB / HAST
Example:
For a given FAB family of Gold doped fast efficient rectifiers with a NiAu metal:
All 3 of these for the 3 tests above would constitute the requirement as 3 die sizes within the
same FAB family under the same process controls.
The processes for each package type must be considered and subjected to stress-test qualification
separately. For parts to be categorized in a qualification family, they all must share the same major
process and material elements as defined below. Family requalification with the appropriate tests is
required when the process or a material is changed. The supplier must submit technical justification to
the user(s) to support the acceptance of generic data with package type, die sizes, paddle sizes and
die aspect ratios different than the device being considered for stress-test qualification. The important
attributes defining a qualification family are listed below:
• Range of paddle (flag) size qualified for the die size/aspect ratio under consideration.
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A1.2.4 Example
3 lots of a package family using any die structure that has the same die backside metallization will
suffice for the following Qualification tests. It is highly desirable that two of the lots come from the
maximum and minimum die size allowed by the package design rules.
• IOL / PTC
• TC
• AC / UHST
• H3TRB / HAST
When the specific product or process attribute to be qualified or re-qualified (i.e., via process, material
or site change) will affect more than one wafer fab family or assembly family, the qualification test
vehicles should be three lots of a single part type from each of the technology and package families
that are projected to be most sensitive to the changed attribute with sample sizes split to include a
minimum of 30 pieces from each of 3 assembly lots from each assembly / fab site.
Below is the recommended process for qualifying changes across many process and product families:
b. Identify the critical structures and interfaces potentially affected by the proposed change.
c. Identify and list the potential failure mechanisms and associated failure modes for the critical
structures and interfaces. Conduct a risk assessment into potential failure mechanisms. Note
that steps (a) to (c) are equivalent to the creation of an FMEA.
d. Define the product groupings or families based upon similar characteristics as they relate to
the technology process and package families and device sensitivities to be evaluated, and
provide technical justification to document the rationale for these groupings.
e. Provide the qualification test plan, including a description of the change, the matrix of tests and
the representative products, which will address each of the potential failure mechanisms and
associated failure modes.
f. Robust process capability must be demonstrated at each site (e.g., control of each process
step, capability of each piece of equipment involved in the process, equivalence of the process
step-by-step across all affected sites) for each of the affected process step(s).
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The following information is required to identify a part that has met the requirements of AEC-Q101. Submission of the
required data in the format shown below is optional. All entries must be completed; if a particular item does not apply,
enter "Not Applicable". This template can be downloaded from the AEC website at http://www.aecouncil.com.
This template is available as a stand-alone document that can be downloaded at
http://www.aecouncil.com
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22. Maximum Process Exposure Conditions: * Note: Temperatures are as measured on the center of
the plastic package body top surface.
a. MSL @ rated SnPb temperature: at C (SnPb)
b. MSL @ rated Pb-free temperature: at C (Pb-free)
Attachments: Requirements:
Die Photo
1. A separate Certification of Design, Construction
Package Outline Drawing & Qualification must be submitted for each part
number, wafer fab, and assembly location.
Die Cross-Section Photo/Drawing
Wire Bonding Diagram 2. Design, Construction & Qualification shall be
signed by the responsible individual at the supplier
Die Placement Diagram who can verify the above information is accurate
and complete. Type name and sign below.
Completed by: Date: Certified by: Date:
Typed or
Printed:
Signature:
Title:
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The supplier is requested to complete and submit the Discrete Semiconductor Qualification Test Plan as part
of the pre-launch Control Plan whenever qualification submission is required. Acceptance and subsequent
sign-off of the plan will establish a qualification agreement between the user and the supplier determining
requirements for both new parts and process changes prior to commencement of testing. Where "family" data
is being proposed, the plan will document how the reliability testing previously completed fulfills the
requirements outlined in this specification. An approved copy of the Qualification Test Plan shall be included
with each qualification submission.
The test plan section of the form should detail ONLY the testing that will be performed on the specific part
shown. For process change qualifications, multiple parts can be included on the same plan. Supporting generic
or family data reports should be noted in the comment section and attached. When requesting use of generic
or family data, attach a separate page detailing similarities or differences between parts referencing the criteria
in Appendix 1. There must be valid and obvious links between the data and the subject of qualification.
The example below is provided to demonstrate how the Qualification Test Plan Form, found on the AEC
website, should be used. In this case, a bipolar discrete part was chosen as being representative of a typical
new part qualification requesting reduced component testing by including generic test data. The part comes
from a supplier who previously qualified the package, assembly site etc. This example is shown for illustration
purposes only and should not limit any requirements from Table 1 herein.
ItemTest Test Conditions Exceptions Est. Start Est. Comp. # Lots S. S. Remarks
1 TEST Electrical Characterization @ 25C 4/1/2019 4/5/2019 all all
2 Preconditioning per AEC-Q101 4/8/2019 4/10/2019 all all
3 External Visual per AEC-Q101 4/11/2019 4/12/2019 all all
Parametric
4 Characterization @ -55, 25, & 150C 4/15/2019 4/19/2019 3 30
Verification
5 HTRB Reverse biased @ 64V 4/22/2019 6/24/2019 3 77
6 HTGB N/A Bipolar device
Temperture generic data uses -65/150C
7 Use attached generic data forthis package related test.
Cycling (rather than -55C)
8 Autoclave Ta = 121C, P = 15PSIG, RH = 100% Use attached generic data forthis package related test.
9 H3TRB Reverse biased @ 64V 4/22/2019 6/24/2019 3 77
10 IOL T on/off = 2 minutes, 15,000 cycles 4/22/2019 6/24/2019 3 77 SDS internal standard
11 ESD per AEC-Q101 4/22/2019 6/24/2019 1 30
12 DPA per AEC-Q101 6/24/2019 6/24/2019 3 2 2 ea from H3TRB and TC only.
Comments:
1. Supplier requests 1 lot qualification of this device type in addition to attached rel reports to similar parts to total 3 lots.
Rel Report #23-602 (PZT3906, the PNP compliment of this part) and #23-665 (PZTA62 NPN Darlington with larger 35 MIL die)
2. In addition, the die is qualified in SOT-23 version of this device, the SOT-223 package is qualified with larger (35 MIL) bipolar die (N611002BFDAARA & N611007BFDBARA).
3. Attached quarterly reliability results for 2017 & 2018 on generic PZT3904.
4. These devices all share the same wafer and assembly processes.
5. Tests 14-23 covered by annual SOT-223 packaging qual last approved 11/18.
* Note: This plan is only an example and does not represent all the required tests in this document.
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The supplier is required to complete and submit an Environmental Test Summary and Parametric Verification
Summary with each Discrete Semiconductor PPAP submittal. Figure A4.1 is an example of a completed
Environmental Test Summary. Figure A4.2 is an example of a completed Parametric Verification Summary.
The format of both summaries shall be followed. Soft copies of the formats may be found on the AEC website
or is available upon request. Other equivalent formats are acceptable if approved by the user.
* Note: This listing of test results is only an example and does not represent all the tests in this document.
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For Table 1 Test E1 (Pre- & Post-Stress Electrical Test), the following electrical parameters shall be used (as
a minimum):
Transistors
Diodes
Varactors
IR, CT
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Appendix 6: Plastic Package Opening for Wire Bond Testing, and Inspection
A6.1 Purpose
The purpose of this Appendix is to define a guideline for opening plastic packaged devices so that
reliable wire pull or bond shear results will be obtained. This method is intended for use in opening
plastic packaged devices to perform wire pull testing after temperature cycle testing or for bond shear
testing.
A6.2.1 Etchants
Various chemical strippers and acids may be used to open the package dependent on your experience
with these materials in removing plastic molding compounds. Red Fuming Nitric Acid has demonstrated
that it can perform this function very well on novolac type epoxies, but other materials may be utilized
if they have shown a low probability for damaging the bond pad material.
For some part designs (i.e., green compound molded), etching by red fuming Nitric acid and sulfuric
acid will etch Al wire/Al pad in high temperature. The process will damage 5mil Al (including below
5mil).
Various suitable plasma stripping equipment can be utilized to remove the plastic package material.
a. Using a suitable end mill type tool or dental drill, create a small impression just a little larger
than the chip in the top of the plastic package. The depth of the impression should be as deep
as practical without damaging the loop in the bond wires.
b. Using a suitable chemical etchant or plasma etcher, remove the plastic material from the
surface of the die, exposing the die bond pad, the loop in the bond wire, and at least 75% of
the bond wire length.
Caution: Do not expose the wire bond at the leadframe. These bonds are frequently made to
a silver plated area and many chemical etchants will quickly degrade this bond making wire
pull testing impossible.
* Note: For some part designs, especially for small packages, mounting the part may be
required to ensure the structural integrity of the package during the package opening process
and wire pull testing.
c. Using suitable magnification, inspect the bond pad areas on the chip to determine if the
package removal process has significantly attacked the bond pad metallization. If a bond pad
shows areas of missing metallization, the pad has been degraded and shall not be used for
bond shear or wire pull testing. Bond pads that do not show attack can be used for wire bond
testing.
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A6.4 Plastic Package Opening Procedure for Wire Bond Inspection after Temperature Cycling
a. Using a suitable chemical etchant or plasma etcher, remove the plastic material from the
surface of the die, exposing the die bond pad, the loop in the bond wire, the bond wire length,
and the wire bond at the leadframe.
Caution: Care must be taken when exposing leadframe wire bonds. These bonds are
frequently made to a silver plated area and many chemical etchants will quickly degrade this
bond making wire pull testing impossible.
* Note: For some part designs, especially for small packages, mounting the part may be
required to ensure the structural integrity of the package during the package opening process
and wire pull testing.
b. Using suitable magnification, inspect the bonds for damage from Temp cycle delamination.
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Successful completion of the test requirements in Table 2 allows the claim to be made that the part is
AEC Q101 qualified. Additional testing may be agreed between Component Manufactures and Tier 1
Component Users depending on more demanding application environments. To address these more
stringent conditions, application based Mission Profiles may be used for a reliability capability
assessment.
A mission profile is the collection of relevant environmental and functional loads that a component will
be exposed to during its use lifetime.
A7.1.1 Purpose
This appendix provides information on an approach that can be used to assess the suitability of a
component for a given application and its mission profile for unique requirements. The benefit of
applying this approach is that, in the end, the reliability margin between the component (specification)
space and the application (condition) space may be shown.
• Section A7.2 demonstrates the relation between AEC-Q101 stress conditions / durations and
a typical example of a set of use life time and loading conditions.
• Section A7.3 describes the approach, supported by flow charts that can be used for a reliability
capability assessment starting from a mission profile description.
A7.1.2 References
The use lifetime assumptions drawn here are an example used for demonstration purpose only. Many
typical mission profiles will differ in one or more characteristics from what is shown below.
The mission profile itself is generated by adding information on thermal, electrical, mechanical and any
other forms of loading under use conditions, to the above lifetime characteristics. Examples of these
and how they relate to the test conditions in Table 2 are shown in Table A7.1.
The basic calculations in Table A7.1 for each of the major stress tests demonstrate how one can derive
suitable test conditions for lifetime characteristics based on reasonable assumptions for the loading.
Caution should always be taken on use of excessive test conditions beyond those in Table 2, because
they may induce unrealistic fail mechanisms and/ or acceleration.
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This section demonstrates how to perform a more detailed reliability capability assessment in cases
where the application differs significantly from existing and proven situations:
• Application has a demanding loading profile
• Application has an extended service lifetime requirement
• Application has a more stringent failure rate target over lifetime
These considerations may result in extended test durations. In addition, there may be components
manufactured in new technologies and/or containing new materials that are not yet qualified. In such
cases, unknown failure mechanisms may occur with different times-to-failure which may require
different test methods and/or conditions and/or durations.
For these cases, two flow charts are available to facilitate both Tier 1 and Component Manufacturing
in a reliability capability assessment:
• Flow Chart 1 in Figure A7.1, describes the process at Component Manufacturer to assess
whether a new component can be qualified by AEC-Q101.
• Flow Chart 2 in Figure A7.2, describes (1) the process at Tier 1 to assess whether a certain
electronic component fulfills the requirements of the mission profile of a new Electronic Control
Unit (ECU); and (2) the process at Component Manufacturer to assess whether an existing
component qualified according to AEC-Q101 can be used in a new application.
For details on how to apply this method, please refer to SAE J1879, SAE J1211 and/or ZVEI Handbook
for Robustness Validation of Semiconductor Devices in Automotive Applications.
In summary, the flow charts result in the following three clear possible conclusions:
In addition, not shown in the flow charts, the expected end of life failure rate may be an important
criterion. Regarding failure rates, the following points should be considered:
• No fails in 231 devices (77 devices from 3 lots) are applied as pass criteria for the major
environmental stress tests. This represents an LTPD (Lot Tolerance Percent Defective) = 1,
meaning a maximum of 1% failures at 90% confidence level.
• This sample size is sufficient to identify intrinsic design, construction and/or material issues
affecting performance.
• This sample size is NOT sufficient or intended for process control or PPM evaluation.
Manufacturing variation failures (low ppm issues) are achieved through proper process controls
and/or screens such as described in AEC-Q001 and -Q002.
• Three lots are used as a minimal assurance of some process variation between lots. A
monitoring process has to be installed to keep process variations under control.
• Sample sizes are limited by part and test facility costs, qualification test duration and limitations
in batch size per test.
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Figure A7.1: Flow Chart 1 – Reliability Test Criteria for New Component
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Table A7.1: Basic Calculations for AEC-Q101 Stress Test Conditions and Durations
Acceleration Model
Stress Calculated Test Q101 Test
Loading Mission Profile Input Stress Test (all temperatures in K, not in °C) Model Parameters
Conditions Duration Duration
(K = °C + 273)
Tu
Cycling alloys, actual values depend on cycles
change in test
∆Tu =70°C
nn
(TC) failure mechanisms and range
environment: u
(average thermal cycle from 1 for ductile to 9 for brittle t
-55 °C to 150°C)
temperature change in materials) Af
use environment)
Thermo-
mechanical
Coffin Manson
A T
m
nu = 54,750 cycles t nt =12,283 cycles
(number of engine f (number of cycles
Tu
m = 2.5
on/off cycles over 15 ∆Tt =100°C
(Coffin Manson exponent 4 is to in test)
years of use) Intermittent (thermal cycle
be used for cracks in hard metal
Operational temperature 5000
Also applicable for Power alloys, actual values depend on
∆Tu =55°C for solder die
nt nu
Life change in test cycles
Temperature Cycle (PTC) failure mechanisms and range
attach (IOL) environment:
from 1 for ductile to 9 for brittle
(average thermal cycle 25°C to 125 C)
Remark: The use of a Coffin- materials)
Af
temperature change in
Manson model may not be
use environment)
appropriate to reflect time
dependence of material behavior.
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Table A7.1: Basic Calculations for AEC-Q101 Stress Test Conditions and Durations (continued)
Acceleration Model
Calculated Test Q101 Test
Loading Mission Profile Input Stress Test Stress Conditions (all temperatures in K, not in °C) Model Parameters
Duration Duration
(K = °C + 273)
Engine Non-operating:
tu = 119,400 hours Hallberg-Peck
(average engine off p p=3
A Ea 1 1
RHt = 85% (relative RH t Tt = 413 h
time over 15 years) Reference Hallberg-Peck (1991)
humidity in test f • exp •
RH u k B Tu T t tu
Humidity
RHu = 75 % (average
H3TRB
environment)
Ea = 0.9 eV t
t 1000 hours
relative humidity in off
Tt = 85°C (ambient
Reference Hallberg-Peck (1991) Af
mode) Also applicable for Temperature
temperature in test
Humidity Bias (THB) and Unbiased kB = 8.61733 x 10-5 eV/K
environment)
Tu = 30 °C (average Humidity Stress Test (UHST). See (Boltzmann’s Constant)
junction temperature Notes.
in engine off mode)
Notes:
• Autoclave (121°C/100%RH) is a highly accelerated test using a saturated moisture condition that will tend to uncover failure mechanisms not seen in normal
use conditions. For this reason, autoclave is not a test whose test conditions can be derived through models and assumptions. The current test conditions
were selected decades ago and the test has been used as part of a standard qualification ever since.
• Most Pressure Pot testing is performed with an Al Pressure Pot. Air purging is done at 100°C boiling water, and with both steam and liquid escaping from the
vent. The chamber walls are not independently heated at all. Control of the chamber wall temperature; air purging procedure, during ramp-up; ramp-down
temperature and pressure and overall temperature and pressure are key. In addition, when the test is ended the heater is turned off and the vent is opened. It
takes about 3 minutes to fully vent the pot. A significant concern is that venting before the pot chamber drops to 100°C, can cause a pressure differential from
the >100°C residual hot device and cause any water trapped in device void to create a pop-corning type of delamination.
• Regarding HAST vs. UHAST: bias does have an effect on failure rate and may be used to accelerate if component allows higher bias (e.g., corrosion, mobile
ions).
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Revision History
A May 5, 1999 General Revision - Corrected errors, made clarifications, changed lot
requirements. Removed CDF and “Automotive Grade” designations
throughout.
B July 25, 2000 Update signature block on page 1; Removed "Parts must be mounted to
test boards." from "Additional Requirements" for Pre-conditioning in Table
1 page 8; Changed "IOL" to "PTC" in "Additional Requirements" for Power
and Temperature Cycle in Table 1 page 9; Removed revision from
"Reference" for Resistance to Solder Heat in Table 1 page 10 (i.e. B-106-
A becomes B-106); Added note U to "Legend for Tables 1 and 2" on page
11.
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D May 18, 2013 Complete Revision. Revised document title to reflect that the stress test
qualification requirements are failure mechanism based. Revised Sections
1.2., 1.2.3, 2.2, 2.3, 2.4.4, 2.5, 2.6, 2.7, 3.1, 3.2, 3.2.1 to 3.2.4, 4.3,
Appendix 1, Appendix 2, Appendix 4, Figure A4.1, and Tables 1 to 3.
Added Sections 1.2.5, 1.3, 1.3.1 to 1.3.3, 2.4.5, 4.5, Appendix 6, Appendix
7, Figures 1, A7.1, A7.2, and Tables 2A, 2B, A7.1. Deleted Sections 1.1.2,
1.1.3, and 2.1.
E Mar. 1, 2021 Complete Revision. Revised Sections 1.2.2, 1.2.3, 1.2.4, 1.3.1, 1.3.3, 2.2,
2.4 to 2.7, 3.2.3, 4.2, 4.3.2, 4.3.3, 4.3.3, 4.4, Appendix 7, Table 1, Table 2
(for structure and content), Legend for Table 2, Table 2A, Table 2B, Table
3 (for structure and content), and Table A7.1. Added Sections A7.2.2,
A7.3, and Figure 2. Deleted Sections A7.2, A7.3.2, and A7.3.3 to A7.4.
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