Degradation behavior of 600 V–200 A IGBT modules under power cycling and high temperature environment conditions

One challenge for automotive hybrid traction application is the use of high power IGBT modules that can withstand high ambient temperatures, from 90 °C to 120 °C, for reliability purpose. The paper presents ageing tests of 600 V–200 A IGBT modules subjected to power cycling with 60 °C junction temperature swings at 90 °C ambient temperature. Failure modes are described and obtained results on the module characteristics are detailed. Especially, physical degradations are described not only at the package level, like solder attach delaminations, but also at the chip level, with a shift on electrical characteristics such as threshold voltage. Finally, numerical investigations are performed in order to assess the thermal and thermo-mechanical constraints on silicon dies during power cycling and also to estimate the effect of ambient temperature on the mechanical stresses.     

一种新型IGBT结温计算模型

为进一步研究IGBT电热参数与结温的关系,提出了一种用于计算IGBT结温的改进电热耦合模型。通过温度循环加速老化试验模拟IGBT的老化过程,记录不同老化程度下IGBT的电热参数,直到IGBT失效。根据电模型和热模型建立电热耦合模型,将不同老化程度下的电热参数及模型相结合,得到改进的电热耦合模型。采用单一参数法,研究了不同老化程度下电热参数对结温的影响。利用IGBT的稳态结温数据,得到电热参数对结温的影响度。     

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.     

Experimental study on the influence of junction temperature on the relationship between IGBT switching energy loss and device current

Accurate determination of power losses in semiconductor devices is important for optimal design and reliable operation of a power converter. The switching loss is an important component of the total device loss in an insulated-gate bipolar transistor (IGBT) in a voltage source inverter. The objective here is to study experimentally the influence of junction temperature on the turn-on switching energy loss E_on and turn-off switching energy loss E_off. More specifically E_on and E_off are both related to device current I_c; the influence of junction temperature on the relationship between E_on and I_c and that between E_off and I_c is studied. As the operating environmental conditions and load conditions of power converter vary widely, a wide range of junction temperatures between − 35 °C and + 125 °C is considered here. The experimental data enable precise determination of the switching loss in each device in a high-power converter at any practical operating condition. This leads to precise estimation of total device loss and optimal thermal design of the converter. This further helps off-line and/or on-line estimation of device junction temperatures required for study of thermal cycles and reliability.     

The effect of electro-thermal parameters on IGBT junction temperature with the aging of module

This paper presents the effect of the change of electro-thermal parameters on IGBT junction temperature with module aging. Five IGBT modules are subjected to advance power thermal cycling, and IGBT I–V characterization, switching loss, and transient thermal impedance curve are measured every 1000 power thermal cycles. Then, electro-thermal models of IGBT module under power thermal cycles were built by change electro-thermal parameters, and the influence of various parameters of the electro-thermal model on the junction temperature was researched respectively. Experimental results demonstrate that IGBT collector-emitter voltage, switching loss and thermal resistance increase more quickly with the aging process of module. Simulation results indicate that the variations of electro-thermal parameters have crucial influences on the IGBT junction temperature. After 6000 power thermal cycles, the IGBT steady state junction temperature mean and variation are increased 1.97 K and 0.1656 K over its initial value, respectively. The relative temperature rise is 38.10% and relative temperature variation is 15.08% after 6000 power thermal cycles. The rise in switching loss increases both the steady state junction temperature mean and variation. The change of thermal impedance has great influence on the steady state junction temperature mean, but has little effect on steady state junction temperature variation.     

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.     

A study on IGBT junction temperature (Tj) online estimation using gate-emitter voltage (Vge) at turn-off

A novel method is presented for online estimation of the junction temperature (Tj) of semiconductor chips in IGBT modules, based on evaluating the gate-emitter voltage (Vge) during the IGBT switch off process. It is shown that the Miller plateau width (in the Vge waveform) depend linearly on the junction temperature of the IGBT chips. Hence, a method can be proposed for estimating the junction temperature even during converter operation – without the need of additional thermal sensors or complex Rth network models. A measurement circuit was implemented at gate level to measure the involved time duration and its functionality was demonstrated for different types of IGBT modules. A model has been proposed to extract Tj from Vge measurements. Finally, an IGBT module with semiconductor chips at two different temperatures has been measured using Vge method and this method was found to provide the average junction temperature of all the semiconductor chips.     

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.     

Thermal stability of IGBT high-frequency operation

Thermal stability of high-frequency insulated gate bipolar transistor (IGBT) operation is studied in this paper. The nonpunch-through IGBT is found to be stable when operated within its rated temperature. Thermal runaway occurs with punch-through IGBTs at temperatures below the maximum junction temperature when operated at high frequency at well below rated current, with snubber or soft-switching circuits     

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.     

Performance and reliability testing of modern IGBT devices under typical operating conditions of aeronautic applications

As for railway traction applications, aeronautical power electronics implies high power density handling. Moreover typical aeronautical applications impose a harsh thermal environment. SiC technology has recently emerged for high power and high temperature application, but is not yet mature enough. Consequently it is still important to push the silicon devices temperature limits in order to increase the amount of switched power. Device ageing is accelerated and there exists the risk of catastrophic failure by thermal runaway. In order to design correctly high temperature power systems, knowing the IGBT characteristics at extended temperature ranges becomes essential. This paper describes an experimental setup and test procedure conceived to experiment with different available IGBT technologies at temperatures beyond the limits rated by manufacturers (?55 °C, +175 °C). The aim is to characterize the devices for a better understanding and optimized safe application. This will ease prototyping for future development of IGBT modules in aircraft.     

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.     

On the avalanche ruggedness of optimized termination structure for 600 V punch-through IGBTs

In this paper, the current paths in avalanche conditions of a Floating Field Ring (FFR) termination for a Punch-Through (PT) Insulated Gate Bipolar Transistor (IGBT) are analyzed. The design of the termination region is achieved with two different optimization techniques, and both static and dynamic electrical behavior are analyzed by means of 2D TCAD simulations, up to high current density levels. A comprehensive analysis of the Unclamped Inductive Switching (UIS) operation of the proposed terminations is carried-out with electro-thermal simulations. Although the behavior of both structures at low current levels is different, results show the same current crowding effect at the main junction for high current levels, resulting in a reduced conduction area of the overall termination, hence, of the avalanche reliability. Finally, experimental confirmation of filamentary current conduction during UIS test are detected on 600 V commercial devices by means of transient infrared thermography.     

基于IGBT模块饱和压降温度特性的结温探测研究

实验室条件下,IGBT模块的结温探测是瞬态热阻抗测试的关键。首先分别在热稳态和热瞬态下证明了饱和压降温度特性只与芯片有关,然后建立了IGBT模块结温探测模型,利用饱和压降值和集电极电流值来计算结温值,并将用模型计算出的结温与光纤实测的结温相比较,吻合性良好,证明了模型计算法能够准确探测结温。该方法可以用于恒流加热过程中瞬态热阻抗的测量,比起热敏参数法中冷却过程测量瞬态热阻抗相比,更具有实际意义。     

Lifetime analysis of solder joints in high power IGBT modules for increasing the reliability for operation at 150 °C

The increased demand for higher operating junction temperatures in IGBT modules is a main challenge for future packaging technologies. Two critical design features regarding this aspect include the terminal solder joints and the large area solder joints. The main focus of this investigation is on the consequences of raising the maximum operating temperature of IGBT modules and the required design modifications of solder materials at a microstructure level for tackling the drawbacks of state-of-the-art technologies.     

一种利用有限元法模拟LED芯片结点温度的方法

提出了一种以有限元法估算发光二极管(LED)光源模块结点温度的方法,提出了较详细的计算步骤,最后以6只1 W大功率LED组成的光源模块为例,演示如何以实测为基础,实测与软件试算相结合来估算LED光源模块的芯片结点温度.结果证明该方法具有较好的预测性,可以用来研究LED光源模块的温度分布,从而为研究LED封装材料匹配性、系统可靠性提供一定的参照.     

Lifetime predictions of LED-based light bars by accelerated degradation test

The accelerated degradation of light bars was tested under different stresses called junction temperatures, which result from the combination of current and ambient temperature. Light bars are used as a light source in laptops. A general procedure for an accelerated degradation test was used to analyze the useful lifetime of light bars under operating conditions. The degradation behavior for each light bar was fitted by an exponential function. The impact of parameter variations and measurement errors were also considered. The failure criterion was defined as the 50% decrease of the emitted optical power, when compared with the initial level. The failure time is, accordingly, the time required to achieve that failure criterion. A response model based on an inverse power (exponential) law for the failure time under different stresses was then calculated to predict the lifetime under operating conditions. The results show that the failure time of a light bar under operating conditions is about 11,571 h.     

IGBT junction and coolant temperature estimation by thermal model

The capability of IGBT (Insulated Gate Bipolar Transistor) to handle heat is one of its main limitations of high power application. This paper aims to study an IGBT thermal model under flow cooling condition and estimate the IGBT module junction and coolant temperature. Firstly, this paper studies the IGBT module internal sandwich structure and calculates the thermal resistance and thermal capacitor for each layer using a 1D physical model. Then a Cauer electric model is built for the IGBT module to evaluate the thermal constant time of the model. The liquid cooling method is applied in this project for fast cooling and the thermal parameters are studied and measured since this cooling method involves both solid and liquid. In order to estimate the junction temperature, the sensing temperature from NTC (Negative temperature coefficient) resistor inside the module is used as reference temperature. The equivalent thermal models, also named Foster model, from both junction to NTC and NTC to coolant are built, respectively. With these thermal models, the junction and coolant temperature estimation methods are derived. For the purpose of making the estimation accurate, the thermal coupling effect is carefully studied. Finally, the thermal model is verified by inverter application with current steps sweeping; the estimated temperature is compared with thermal camera measurement result which demonstrates good accuracy of the thermal model. The estimated coolant temperature is also well matched with thermocouple measurement result.     

压力对换流阀用压接型IGBT器件功率损耗的影响

功率损耗一直是功率半导体器件应用时备受关注的问题.压接型绝缘栅双极型晶体管(IGBT)器件靠外部压力使内部各个组件保持电气和机械连接,因此压力直接或间接地影响着压接型IGBT器件的功率损耗.将压接型IGBT器件工作时产生的结温作为耦合变量引入,基于此建立了IGBT器件应用于调制脉宽(PWM)换流设备时的功率损耗计算模型,并详细分析了影响功率损耗的各种因素,包括机械压力、开关频率等.以换流阀用3 300 V/1 500 A压接型IGBT器件为例,采用有限元法研究了压力对压接型IGBT器件功率损耗的影响,重点探讨了器件内部各芯片功率损耗的变化情况.结果表明,增加压力一定程度上可以降低压接型IGBT器件的功率损耗,改善器件内部芯片结温分布不均的问题.