Detection of Corrosion in Thick Film Resistors by X-Ray Imaging

Jonny M Ingman,Joni P A Jormanainen,Joonas A R Leppanen,Tommi J Karkkainen,Aleksi M Vulli,Samu K Jarvinen,Natalia I Kanko,Juuso Rautio,Janne Jappinen,Pertti Silventoinen

doi:10.1109/access.2021.3116282

Jonny M Ingman, Joni P A Jormanainen + Show 8 more

Open Access

https://doi.org/10.1109/access.2021.3116282

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Abstract

In this article, a non-destructive method is presented, using 2D X-ray imaging, to investigate corrosion defects in thick film resistors stressed by two different corrosion experiments, a single gas experiment and a flowers of sulphur experiment. In total, 370 devices under test (DUTs) were investigated, using the 2D X-ray imaging technique, of which 10 were imaged in a sequence of 2D X-ray images to evaluate the corrosion propagation. The observed underlying corrosion product was verified by using focused ion beam analysis combined with an energy dispersive X-ray spectroscopy. The presented 2D X-ray imaging technique enables a fast and non-destructive method for accurately identifying corrosion and corrosion progression in thick film resistors. The presented imaging method was found to be particularly suitable for supplier benchmarking purposes, as well as for the failure analysis of field returns as it allows for a proper corrosion evaluation of surface mount thick film resistors, while keeping the analysed assembly intact.

Highlights

F REQUENCY CONVERTERS are used in vastly different fields of industries and applications, such as solar, wind, pulp and paper production, rubber vulcanization and mining
This study demonstrates an effective non-destructive X-ray imaging method for analysing corrosion in thick film resistors
No failures were recorded in the electrical measurements for the single gas experiment, incipient corrosion in the silver electrode was still detected with 2D X-ray imaging

Summary

Introduction

F REQUENCY CONVERTERS are used in vastly different fields of industries and applications, such as solar, wind, pulp and paper production, rubber vulcanization and mining. Humidity plays a significant role on the drive’s reliability Other harsh environments, such that contains corrosive pollutants, can be found in pulp and paper production, as well as in rubber vulcanization and mining applications. In these industries, the amount of atmospheric sulphur in the environment has a big impact on the lifetime of the frequency converter. The amount of atmospheric sulphur in the environment has a big impact on the lifetime of the frequency converter Critical components, such as power modules [1], electrical contacts and thick film resistors are affected by corrosion due to the sulphur in the environment. Corrosion phenomena, such as electrochemical migration [13] and open connection [4,5], have been reported

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