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COURSE DETAILS

This class uses extensive real life examples to teach the practical “How To” of the most efficient accelerated test methods available today. Accelerated test methods for mechanical and electrical devices will be explained and practiced in class following an explanation of the sciences that support their use. Class time is organized by failure mechanism. The physics of each failure mechanism is explained, both at a science level and at a practical level. The major Stress-Life models that apply to each of the failure mechanisms will be explained through example in class. The majority of the class time will be spent learning exactly how to apply the accelerated test methods and their associated Stress-Life models to common test requirements. Class exercises along with video of product testing will reinforce all concepts taught. Methods for converting from “reliability on test” to “expected reliability in the field” will be explained by example. Explanation of the underlying concept of Stress-Strength-Interference will form the foundation for tying it all together.
Statistical methods that take advantage of accelerated testing will be explained and practiced in class. Accelerated testing reduces test time so drastically that a decrease in sample size can be achieved with the WeiBayes method. This method will be explained and contrasted to the various alternatives. The CALT method, which uses a process of extrapolation to normal stress from the outcome of increased stress tests, represents one of the most versatile and efficient accelerated test methodologies available. This method will be shown and explained through numerous examples. Degradation Analysis for wear will be explained and shown through a video example.
HALT will receive special attention. Videos of actual HALT tests will be shown, covering a wide range of mechanical and electronic products. Failure modes will be viewed and discussed along with a thorough explanation of fixturing, test profiles, and supplier involvement. This portion of the class should complete your working knowledge in using HALT. Demonstrating reliability with HALT will be discussed and correlation calculations explained.

Practical use of HAST, an accelerated humidity test, will be explained and shown in video. The use of the Arrhenius-Peck model to calibrate HAST to normal use will be explained through examples.

Developing a Reliability Program Plan and the related Test Planning will be discussed in detail. Examples of test plans that make the best use of sequencing failure mechanisms will be shown and explained. All of the methodologies explained above will be placed in the context of a reliability program plan for fast and efficient product development.

WHO SHOULD ATTEND

This class/workshop is designed for the manager or working engineer who is challenged with the task of designing and executing highly efficient reliability program plans.
The class maintains a focus on validating the reliability requirements of highly reliable products as quickly as possible, and with the fewest resources. This is not a management overview, but rather provides detailed and complete working knowledge in the use of accelerated testing.

BENEFITS

Companies wishing to operate on the leading edge of “Best Practices” in the world of reliability will find this course comprehensive and very practical. Accelerated Test methods for mechanical and electrical devices will be covered thoroughly. The benefits of applying these methods will result in significant time and cost reductions during development and validation. The explanation of the advantages of each method is balanced with full explanation of the risks. While the risks are minimum, this balanced approach will allow the engineer or manager to choose the optimum method for any set of conditions. The techniques that will be taught are used daily by the instructor, and have a documented track record resulting in 10 to 100 times reduction in test time over traditional methods.

OBJECTIVES

This class will provide the student with all of the skills necessary to demonstrate reliability requirements using accelerated test methods. The class will focus on accelerated test design that employs increased stress levels. This approach has tremendous advantage in reducing test time, sample size, and test facility resources. The methodologies taught are applicable to all types of stresses spanning the electrical and mechanical worlds.

COURSE OUTLINE

• Stress-Strength Interference as the basic concept for addressing reliability requirements
• Explanation of the physics of failure for each of the major failure mechanisms, electrical and mechanical
• Life-Stress models most suitable for each of the failure mechanisms
  o Inverse Power Model for fatigue and voltage effects
  o Arrhenius Diffusion Model for elevated temperature testing
  o Coffin-Manson Model for thermal cycling based thermal fatigue
  o Norris-Landzberg Model for high ramp rate thermal cycling
  o Arrhenius-Peck Model for accelerated humidity testing
• Filling in the missing parameters for the Life-Stress models
  o The Calibrated Accelerated Life Test methodology using accelerated test extrapolation (CALT)
  o Using established parameters developed by others
• Degradation Analysis using accelerated test methods for quantifying failure through degrading parametric measurements (without failure)
  o Especially suited to wear as a failure mechanism
• Applying reliability statistical methodologies to the life-stress models to demonstrate reliability requirements
  o CALT
  o Success-Run
  o Over-Cycling Testing (WeiBayes)
  o Weibull Analysis
  o Stepped Stress Methods
• Converting reliability on test to expected reliability in the field
• Developing the overall Reliability Program Plan through integration of all methods taught
• Where and how HALT fits into the Reliability Program plan
• HAST – the humidity corollary to HALT
  o How to use, where to use, and how to calibrate to normal usage
• Sequential test planning examples
  o Cumulative damage strategies and the use of pre-treating
  o Example test plans will be provided for electrical and mechanical systems

This class will be a mixture of lecture and workshop to insure that each student develops competent use of the methods being taught.
The student who completes this class should be able to quickly develop a well-balanced reliability plan that will be optimally efficient for any type of product or time constraint. The student will gain insightful knowledge in all forms of accelerated testing in order to demonstrate reliability requirements faster and more efficiently than ever before.

This class is also designed to be fun, as that is the catalyst that increases retention of what is taught.

PLEASE BRING A CALCULATOR TO CLASS