IGBT modules robustness during turn-off commutation

The behaviour in terms of robustness during turn-off of power IGBT modules is presented. The experimental characterisation is aimed to identify the main limits during turn-off in power IGBT modules in typical hard switching applications. In this paper an experimental characterization of high power IGBT modules at output currents beyond RBSOA, at high junction temperatures and under different driving conditions is presented. Several devices of different generations, current and voltage ratings have been considered. The experimental characterisation has been performed by means of a non-destructive experimental set-up where IGBT modules are switched in presence of a protection circuit that is able to prevent device failure at the occurrence of any possible instable behaviour. The experimental analysis confirms the very good robustness of high power IGBT modules which can withstand large current overstress well beyond the declared RBSOA limits even at temperatures larger than those one declared by manufacturers. A comparison between IGBT device generation is also presented.     

The high frequency behaviour of high voltage and current IGBT modules

Sharp voltage gradients act as a stimulus for high power IGBT modules, which can exhibit a potentially instable high frequency behaviour. In fact, they can act as a radio frequency amplifier and, in particular operating conditions, the interaction between the device and the control or the external circuit can cause self-sustaining oscillations or the enhancement of the unevenness in current distribution inside a power module thus having a significant impact on the reliability of the power converter. Moreover, this RF amplification worsen the generated EMI (Electro Magnetic Interference). This paper presents an extensive experimental investigation about the high frequency behaviour of IGBT high power modules. The measurements were performed by means of an original experimental set-up that was specifically conceived and constructed. The data are analysed with the help of a theoretical small signal model which is able to describe RF behaviour of high power IGBT modules.     

Some observation dealing with the failures of IGBT transistors in high power converters

The explosion strength of high power IGBT modules is one of the important parameters that may decide on converter equipment reliability in extreme circumstances. The explosion strength of a device is represented by the peak value of the collector current (so called “peak case nonrupture current”) that cannot be exceeded. Some main IGBT failure mechanisms under service conditions are discussed. Test methods and experimental results on device case explosion strength are presented. Experiences concerning starting, tests and service of high IGBT converters are given. Preliminary load tests with rapidly changing current values are useful for newly fabricated IGBT converters.     

Assessment of the Trench IGBT reliability: low temperature experimental characterization

The purpose of this study is an assessment of the Trench IGBT reliability at low temperature under static and dynamic operations by the aim of intensive measurements. The analysis of the Trench IGBT behaviour in these conditions is dedicated to the HEV applications. One question can be raised in case of the use of HEV in countries where during winter the temperature drops down −50 °C or less: are Trench IGBT strongly affected by the low temperature environment? In this paper, we present experimental results under various test conditions (temperature, gate resistance, voltage and current) to give an understanding of the device behaviour by focusing on the device current and voltage waveforms and the power losses.     

Statistical analysis of characteristic of ageing precursor of IGBT based on synthetic effect of multi-physical fields

The IGBT power modules are widely used in photovoltaic power generation, high-voltage direct current transmission and other fields. Due to the need for high reliability in the application fields, the industry is very concerned about the reliability of IGBT power modules. Based on the two different working conditions of the three-level NPC photovoltaic inverter, this paper has monitored the health status of bonding wires of the IGBT modules inside the inverter. In addition, for the experimental results of monitoring, theoretical analysis and experimental demonstration from the perspective of multi-physics (temperature field, electromagnetic field, etc.) are innovatively introduced, which provides a new perspective for the research of power module reliability.     

Boundary element analysis of thermal fatigue effects on high power IGBT modules

The technology of high power IGBT modules has been significantly improved these last years against thermal fatigue. The most frequently observed failure modes, due to thermal fatigue, are the solder cracks between the copper base plate and the direct copper bonding (DCB) substrate and bond wire lift-off. Specific simulation tools are needed to carry out reliability researches and to develop device lifetime models. In other respects, accurate temperature and flux distributions are essential when computing thermo-mechanical stresses in order to assess the lifetime of high power modules in real operating conditions. This study presents an analysis method based on the boundary element method (BEM) to investigate thermal behavior of high power semiconductor packages subjected to power cycling loads. The paper describes the boundary integral equation which has been solved using the BEM and applied to the case of a high power IGBT module package (3.3 kV–1.2 kA). A validation of the numerical tool is presented by comparison with experimental measurements. Finally, the paper points out the effect on the thermal stress of the IGBT chips position on the DCB substrate. In particular, a light shifting of the silicon chips may be sufficient to delay significantly the initiation and the propagation of the cracks, allowing a higher device lifetime of the studied module.     

Fast power cycling protocols implemented in an automated test bench dedicated to IGBT module ageing

This paper presents fast test protocols for ageing IGBT modules in power cycling conditions, and a monitoring device that tracks the on-state voltage V_CE and junction temperature T_J of IGBTs during ageing test operations. This device is implemented in an ageing test bench described in previous papers, but which has since been modified to perform fast power cycling tests.The fast test protocols described here use the thermal variations imposed on IGBT modules by a test bench operating under Pulse Width Modulation conditions. This test bench reaches the maximal values of power cycling frequencies attainable with a given module packaging in order to optimize test duration.The measurement device monitors V_CE throughout the ageing test that is needed to detect possible degradations of wire bonds and/or emitter metallization. This requires identifying small V_CE variations (a few dozen mV). In addition, the thermal swing amplitude of power cycling must be adjusted to achieve a given ageing protocol. This requires measuring junction temperature evolution on a power cycle, which is carried out by means of V_CE measurement at a low current level (100 mA).Experimental results demonstrate the flexibility of this test bench with respect to various power cycling conditions, as well as the feasibility of the proposed on-line monitoring methods.     

Compact modelling and analysis of power-sharing unbalances in IGBT-modules used in traction applications

IGBT modules are critical components for the reliability of power converters used in traction applications. A thorough analysis of all stressful operating conditions is a complex task, which requires versatile simulation capability. In this paper a comprehensive electro-thermal model of an IGBT-module is developed. Then, circuit simulation is used to investigate the power sharing between parallel chips during transient operation. Unbalances are observed, their causes identified and their influence on device degradation pointed out and discussed.     

Power cycling test and failure analysis of molded Intelligent Power IGBT Module under different temperature swing durations

Molded IGBT modules are widely used in low power motor drive applications due to their advantage like compactness, low cost, and high reliability. Thermo-mechanical stress is generally the main cause of degradation of IGBT modules and thus much research has been performed to investigate the effect of temperature stresses on IGBT modules such as temperature swing and steady-state temperature. The temperature swing duration is also an important factor from a real application point of view, but there is a still lack of quantitative study. In this paper, the impact of temperature swing duration on the lifetime of 600 V, 30 A, 3-phase molded Intelligent Power Modules (IPM) and their failure mechanisms are investigated. The study is based on the accelerated power cycling test results of 36 samples under 6 different conditions and tests are performed under realistic electrical conditions by an advanced power cycling test setup. The results show that the temperature swing duration has a significant effect on the lifetime of IGBT modules. Longer temperature swing duration leads to the smaller number of cycles to failure. Further, it also shows that the bond-wire crack is the main failure mechanism of the tested IGBT modules.     

功率MOS和IGBT器件在无嵌位电感开关条件下的动态雪崩特性研究

The ability of high-voltage power MOSFETs and IGBTs to withstand avalanche events under unclamped inductive switching(UIS) conditions is measured.This measurement is to investigate and compare the dynamic avalanche failure behavior of the power MOSFETs and the IGBT,which occur at different current conditions.The UIS measurement results at different current conditions show that the main failure reason of the power MOSFETs is related to the parasitic bipolar transistor,which leads to the deterioration of the avalanche reliability of power MOSFETs.However,the results of the IGBT show two different failure behaviors.At high current mode,the failure behavior is similar to the power MOSFETs situation.But at low current mode,the main failure mechanism is related to the parasitic thyristor activity during the occurrence of the avalanche process and which is in good agreement with the experiment result.     

Electrothermal simulations in punchthrough and nonpunchthroughIGBT's

The performance of 1200 V punchthrough (PT) and nonpunchthrough (NPT) insulated gate bipolar transistors (IGBT's) is studied in detail under unclamped inductive switching (UIS) and short circuit (SC) conditions. The need for a good physics based simulator to carry out a reliability study is pointed out in the paper. Using such a finite element-based device and circuit simulator it is shown that NPT-IGBT's show a much better performance than PT-IGBTs under UIS condition. It is also shown that an NPT device has a better short circuit withstanding capability than a PT device due to the structural differences between the two devices. As there is a huge power loss within the device during these operating conditions, device self-heating is expected to have a significant impact on device characteristics. Electrothermal simulations are used to study device self-heating and it is shown that it significantly influences device performance under SC operation whereas self-heating influences the UIS performance of only the PT device with little effect on the NPT device. The study is validated by an experimental study of short circuit failure of PT IGBTs     

Effects of current density and chip temperature distribution on lifetime of high power IGBT modules in traction working conditions

This paper deals with ageing parameters of high power IGBT modules in traction applications. Using the results of a great number of power cycling tests on 400A modules, it shows that, in addition to the junction temperature excursion, other parameters like the maximal chip temperature and the current density are involved in thermal fatigue failures. Besides, contact temperature measurements achieved on IGBT chip surface in cycling conditions to localise the maximal thermomechanical stress are presented and correlated with modules failure analysis. The role of the current density in the ageing process is finally shown by determining its influence on the temperature gradient on chip surface.     

TLM method for thermal investigation of IGBT modules in PWM mode

The insulated gate bipolar transistor (IGBT) is popularly used in high power, high frequency power-electronic applications such as motor control and inverters. These applications require well designed thermal management system to ensure the protection of IGBTs. Choice simulation tools for accurate prediction of device power dissipation and junction temperature become important in achieving optimised designs.In this paper, thermal analysis of a 1200 A, 3.3 kV IGBT module was investigated and analysed using the three-dimensional transmission line matrix (3D-TLM) method. The results show a three-dimensional visualisation of self-heating phenomena in the device. Since the comparison TLM results with the analytical solutions do not exist for this IGBT module, we use the MSC.NASTRAN tool to find the similar range of the temperatures. Results are compared.Typically, IGBT is used in a three-phase inverter leg where the control signals are generated via PWM scheme so, the prediction of the temperature rise is important in the pulse operation conditions for the IGBT device. A view of the dynamic thermal temperature rise is obtained with 100 W-step pulse dissipation applied at IGBT chips. The temperature rises are calculated using TLM method during the PWM load cycles. Simulations give clear indications of the importance of the spreader material and are helpful in selecting the proper one.TLM has been successful in modelling heat diffusion problems and has proven to be efficient in terms of stability and complex geometry. The three-dimensional results show that method has a considerable potential in power devices thermal analysis and design.     

Tiny-scale “stealth” current sensor to probe power semiconductor device failure

“Stealth” electric current probing technique for power electronics circuits, power device modules and chips makes it possible to measure electric current without any change or disassembling the circuit and the chip connection for the measurement. The technique consists of a tiny-scale magnetic-field coil, a high speed analog amplifier and a digitizer with numerical data processing. This technique can be applied to a single bonding wire current measurement inside IGBT modules, chip scale current redistribution measurement and current measurement for surface mount devices. The “stealth” current measurement can be utilized in the failure mechanism understanding of power devices including IGBT short circuit destruction.     

Thermal characterization of IGBT power modules

In this paper we report on experimental techniques for the thermal characterization of IGBT power modules. Three different systems have been used: the first one performs “in-time” characterization in order to control the most significant device parameters during normal operation or stress tests; the second one is for a complete and dynamic thermal characterization; finally, infrared optical analysis has been performed to validate the results.     

Transient temperature measurements and modeling of IGBT's undershort circuit

This paper discusses the estimation of possible device destruction inside power converters in order to predict failures by means of simulation. The study of insulated gate bipolar transistor (IGBT) thermal destruction under short circuits is investigated. An easy experimental method is presented to estimate the temperature decay in the device from the saturation current response at low gate-to-source voltage during the cooling phase. A comparison with other classical experimental methods is given. Three one-dimensional thermal models are also studied: the first is a thermal equivalent circuit represented by series of resistance-capacitance cells; the second treats the discretized heat-diffusion equation; and the third is an analytical model developed by building an internal approximation of the heat-diffusion problem. It is shown that the critical temperature of the device just before destruction is larger than the intrinsic temperature, which is the temperature at which the semiconductor becomes intrinsic. The estimated critical temperature is above 1050 K, so it is much higher than the intrinsic temperature (~550 K). The latter value is underestimated when multidimensional phenomena are not taken into account. The study is completed by results showing the threshold voltage and the saturation current degradation when the IGBT is submitted to a stress (repetitive short circuit)     

3-D electrothermal simulation of active cycling on smart power MOSFETs during short-circuit and UIS conditions

Active cycling of power devices operated in harsh conditions causes high power dissipation, resulting in critical electrothermal and thermo-mechanical effects that may lead to catastrophic failures. This paper analyzes the ageing-induced degradation of the chip metallization of a power MOSFET and its impact on the device robustness during short-circuit and unclamped inductive switching tests. A 3-D electrothermal simulator relying on a full circuit representation of the whole device is used to predict the influence of various ageing levels. It is found that ageing can jeopardize the robustness of the transistor when subject to short-circuit conditions due to the exacerbated de-biasing effect on the gate-source voltage distribution; conversely, this mechanism does not arise under unclamped inductive switching conditions. This allows explaining the difference in time-to-failure experimentally observed for the transistors subject to these tests and dissipating the same energy.     

Field failure mechanism and improvement of EOS failure of integrated IGBT inverter modules

In this paper, we have proved that the soft damage from human body ESD can actually cause EOS damage, while integrated IGBT inverter modules (or intelligent power modules) are operating. Failure mechanism was defined as a latchup phenomenon by ESD damage leakage. Failure modes of each failed IGBT inside two integrated IGBT inverter modules were soft and hard burnout, respectively. To determine the failure mechanism, we have done fault tree analysis. From this analysis, we could conclude the main factor as the ESD event between device ESD immunity and PCB assembly line. In addition, from the PCB assembly line, we have identified damage samples due to an ESD event. Based on this result, we have implied ESD on IGBT and intentionally caused a leakage, then applied the device to the system. After an aging test, we could reproduce soft burnout and hard burnout.     

Enhanced power cycling performance of IGBT modules with a reinforced emitter contact

A typical emitter contact of an IGBT consists of a front metallization and bond wires. In this study, the power cycling performance of a special emitter contact design is experimentally verified. The emitter contact includes a metal plate, which is Ag-sintered to the metallization and wire bonded on the top surface. Either Cu or Al bond wires were implemented. Power cycling tests were performed to investigate the performance of such IGBT modules. The results were very promising and a cycling lifetime was achieved, which is about 20 times higher than the lifetime of typical IGBT modules. For a better understanding of the experimental results, the electrical and thermal response of the IGBT modules were simulated by FEM. The results of this study, provide a key for high-reliability designs of the emitter contact of IGBT modules with superior power cycling capability.