Abstract

This article aims to provide an update of the reliability aspects of research on power electronic components and hardware systems. It introduces the latest advances in the understanding of failure mechanisms, testing methods, accumulated damage modeling, and mission-profile-based reliability prediction. Component-level examples (e.g., Si IGBT modules, SiC MOSFETs, GaN devices, capacitors, and magnetic components) are used for illustration purposes in addition to system-level studies. The limitations and associated open questions are discussed to identify future research opportunities in power electronics reliability.

Highlights

  • E FFICIENCY and power density have been at the heart of the power electronics community over the course of the last five decades

  • In [4], the primary research activities in the power cycling tests of power modules between 1994 and 2015 are summarized, which shows the varieties in packaging technologies, control strategies, failure mechanisms

  • 1) Short-circuit and overstress failure of SiC MOSFETs: The reliability performance of SiC MOSFETs is of significant consideration in power electronic applications

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Summary

INTRODUCTION

E FFICIENCY and power density have been at the heart of the power electronics community over the course of the last five decades. The business model in industry has been transitioning from product suppliers to holistic service providers This demands life-cycle-cost reduction and operation optimization of power electronic converters through innovative design, in-depth understanding of failure mechanisms and mission profiles, and predictive maintenance. In 2013-2014, the authors reviewed the three aspects of research in power electronics reliability in [1, 2]. In [4], the primary research activities in the power cycling tests of power modules between 1994 and 2015 are summarized, which shows the varieties in packaging technologies, control strategies, failure mechanisms. This paper starts with a description of the relevance of component-level failure mechanisms in power electronic applications.

FAILURE IN POWER ELECTRONIC COMPONENTS AND SYSTEMS
Examples of field experiences
Selected failure mechanisms
DEGRADATION AND LIFETIME OF POWER ELECTRONIC COMPONENTS
Limitations of existing lifetime models
Implications on component-level accelerated testing
MISSION-PROFILE-BASED RELIABILITY PREDICTION
Simplified electro-thermal modeling
Limitations of existing mission-profile-based reliability prediction methods
OUTLOOK FOR POWER ELECTRONICS RELIABILITY RESEARCH
Physics-of-degradation and condition monitoring
Accumulated damage modeling
High resolution and fast temperature measurement
Reduction of reliability testing time
Findings
CONCLUSIONS
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