Thermal design aspects of an avionic module including fully populated PCBs housed in a sealed enclosure have been studied by means of computational fluid dynamics. Effect of power distribution between the sides of a double-sided PCB on the case temperature of surface-mounted components has been investigated within a proposed simulation strategy. Simulation-based guidelines have been developed for thermal design of avionic modules, regarding preferable power configuration on a double-sided PCB, representing an alternative approach to thermal management, as compared to introducing additional cooling devices.

A flexible experimental setup enabling power control of a fully populated double-sided PCB has been realized, and is described in detail. A CFD model of a double-sided PCB housed in a sealed enclosure has been validated in a 19/spl deg/C environment by means of temperature and flow measurement. The difference between simulated and measured component temperatures has been within 10%. Potential errors both in the model and in the experiments have been discussed and their impact on temperatures has been numerically evaluated.

Anexperimental procedure for investigating the effect of power distribution onthe cooling of a double-sided PCB is implemented. A numberof computational fluid dynamics (CFD) models are validated by laboratoryexperiments performed in 19.5°C temperature environment. Case temperatures of surface-mountedcomponents fully populating the PCB sides are measured and monitoredin simulations. Different combinations of power distribution with other coolingmethods, such as a heatsink tooled on a sealed oropen enclosure, at natural or forced convection, are studied. Thermallyefficient uniform and non-uniform power configurations are determined on adouble sided PCB. It is concluded that managing power distributionon a double-sided PCB can be considered as a measureto improve the thermal performance of electronic modules.

Results are presented on durability analysis of an electronic module subjected to thermal and power cycles, and vibration. A hierarchical analysis process for analyzing the durability of the module is described. The initial step is a transient thermal analysis of the unit in which the module is located. The three operating modes of the unit are modeled and analyzed using acommercially available computational fluid dynamics (CFD) tool. The tool generates a time history of the temperature at all points within the unit and module. The second step comprises exporting temperatures from the transient temperature analysis to a durability prediction tool. The temperatures calculated by the global analysis are mapped to the printed wiring assembly (PWA) mounted within the box, yielding the temperature distribution of the PWA as functions of time. The durability tool utilizes a modified Coffin Manson formula together with the transient temperature profile to estimate the durability of each lead and solder joint included in the module. Thermomechanical fatigue level of leads and solder joints within the unit are reported as a cumulative damage index (CDI). The CDI is the ratio of the number of cycles required for the test item to endure under a life time to the number of cycles the item is predicted to sustain before failure. Durability analysis of solder joint due to vibration is performed separately. The environment is specified according to the location where the unit is mounted. CDI due to vibration is added to form an overall CDI based on Miner's rule.

Purpose – The purpose of this paper is to introduce a novel computational method to evaluate damage accumulation in a solder joint of an electronic package, when exposed to operating temperature environment. A procedure to implement the method is suggested, and a discussion of the method and its possible applications is provided in the paper.

Design/methodology/approach – Methodologically, interpolated response surfaces based on specially designed finite element (FE) simulation runs, are employed to compute a damage metric at regular time intervals of an operating temperature profile. The developed method has been evaluated on a finite-element model of a lead-free PBGA256 package, and accumulated creep strain energy density has been chosen as damage metric.

Findings – The method has proven to be two orders of magnitude more computationally efficient compared to FE simulation. A general agreement within 3 percent has been found between the results predicted with the new method, and FE simulations when tested on a number of temperature profiles from an avionic application. The solder joint temperature ranges between +25 and +75°C.

Practical implications – The method can be implemented as part of reliability assessment of electronic packages in the design phase.

Originality/value – The method enables increased accuracy in thermal fatigue life prediction of solder joints. Combined with other failure mechanisms, it may contribute to the accuracy of reliability assessment of electronic packages.

Thermal cycling tests have been performed for a range of electronic components intended for avionic applications, assembled with SAC305, SN100C and SnPbAg solder alloys. Two temperature profiles have been used, the first ranging between −20 °C and +80 °C (TC1), and the second between −55 °C and +125 °C (TC2). High level of detail is provided for the solder alloy composition and the component package dimensions, and statistical analysis, partially supported by FE modeling, is reported. The test results confirm the feasibility of SAC305 as a replacement for SnPbAg under relatively benign thermomechanical loads. Furthermore, the test results serve as a starting point for estimation of damage accumulation in a critical solder joint in field conditions, with increased accuracy by avoiding data reduction. A computationally efficient method that was earlier introduced by the authors and tested on relatively mild temperature environments has been significantly improved to become applicable on extended temperature range, and it has been applied to a PBGA256 component with SAC305 solder in TC1 conditions. The method, which utilizes interpolated response surfaces generated by finite element modeling, extends the range of techniques that can be employed in the design phase to predict thermal fatigue of solder joints under field temperature conditions.

A practical method has been suggested for solder joint thermal fatigue prognostics, which enables real-time fatigue calculations based on uncompressed temperature data embedded in a host system that performs safety-critical operations. The accuracy of the prognosticated remaining useful life depends on the level of details captured in the model, and the level of confidence from validation efforts.

This paper elaborates the 3T-approach to life consumption monitoring of solder joints in operating temperature environment without requiring simplification of operating loads. An overview of the 3T-approach is provided including assumptions made for a proposed realization in an avionic application. Associated implementation routines are highlighted and exemplified for a lead-free PBGA256 package with creep strain energy density (SEDcr) as damage metric. Factors that affect the prediction accuracy are investigated. A data resolution has been determined that delivers response surfaces that provide results comparable to 3-D finite-element (FE) simulations, while bearing two orders of magnitude higher computational efficiency. A stress-free temperature modification routine is proposed and proves to further mitigate accuracy problems.