Drive Frame Weld Stability

Energie & Umwelt

Development of an accelerated test method to evaluate the long-term reliability of ultrasonically welded load current connections of high-performance semiconductor modules under cyclic mechanical loads as a fast alternative to thermal shock tests.

Acronym

Project running time

01/02/2022 - 05/01/2023

Projectbudget in EUR

Contract research

The project will develop a fast method to evaluate the long-term reliability of ultrasonically welded load current connections of high power IGBT modules. The approach for this feasibility study is an accelerated mechanical load test by coupling an electromagnetic shaker. The type of uniaxially induced load is based on thermal expansion values from climatic chamber experiments and environmental conditions in the field. The focal points of the accelerated test method include

Generation of a weld delamination
Evaluation of the service life through cycles Evaluation at specific load amplitudes
Comparison of the degree of delamination with Thermal Shock Test (AQG 324) after 1000 cycles
Possibility of a variable load direction
Determination of local differential deflection loads in all three spatial directions
Vibration load at higher frequencies <100 Hz
Visual crack detection and crack propagation using in-situ microscopy
Mechanical FEM simulations for the load test
Evaluation of the FEM stress profile to assess the fracture modes