What Is Halt

HALT/HASS Presentation
TM
www.chartchambers.com
This presentation is an introduction to accelerated testing

techniques. These techniques will be referred to as HALT and
HASS during this presentation.
1
Ë DVT- Design Verification Testing
u Typical testing done before product release
Ë HALT- Highly Accelerated Life Test
u used in Design for Product Ruggedization
Ë HASS- Highly Accelerated Stress Screen
u used in Production for Process Monitoring

TM
Traditional testing/Design Verification Testing is typically done

after the product is designed and released to manufacturing. It
simulates what the product is going to see in its intended
environment.
As you can see HALT is used in the design phase to ruggedize the
product and remove design related weaknesses. HASS, is used to
identify process and vendor problems during the production process.
The origin of these techniques dates back to the early 80’s when
there was a growing dissatisfaction with the prevalent reliability
techniques. Let’s start by discussing HALT.
2
Objective
Ë HALT defined
Ë Comparison to Traditional Testing
Ë Benefits Gained
TM
This a brief agenda on what we are going to discuss.

Definition of what HALT is and is not
How does it differ from traditional testing and philosophies?
What can be gained from using this technique?
3
HALT - What Is It?
Ë HALT is used to find the weak links in the
design and fabrication processes of a product
during the design phase.
Ë The stresses are not meant to simulate the
field environments at all, but to find the weak
links in the design and processes using only a
few units. The stresses are stepped up to well
beyond the expected field environment until
the “fundamental limit of the technology” is
reached.
TM
Fundamental limit of the technology – Product tested beyond the

spec limit, but up to a point. For example, if you are testing a part
that has plastic, you test it only below the melting point of plastic,
which is the fundamental limit of the technology.
4
HALT - What Is It?
Ë Discovery Process
Ë Not a Pass - Fail Test
Ë Stress Product Well Outside Operating Spec
Ë Stimulate Failures vs. Simulate Environment
Ë Find Failures - Fix “On the Fly”
Ë Expand Operating Limits
TM
Probably the best way to look at HALT is to describe it as a

discovery process. You are trying to find the strengths and
weaknesses; basically understand more about your product
It is not a pass/fail test. You are going to push the product well
beyond its operating environment to find what breaks.
You are not simulating an environment.
As you find failures you fix them, band aid them or isolate them
from the stress so you can continue testing.
When do you stop HALT? When you have reached the
fundamental limit of the technology (e.g., plastic melts) or when
changes to resolve problems are not financially feasible.
5
Why do HALT?
Fatigue Failure S-N Curve
X
Halt
or
Hass
S
t Onset of Failure
r for One Particular
e Failure Mode
s
s
(S) ESS
Number of Cycles (N) ∞

Time or Cost
TM
This is a good graph that shows the usefulness of HALT.

With testing at lower stress levels, it takes you more time and more
money to detect failures. But with the high stresses associated with
HALT, you can detect failures a lot quicker.
6
Why do HALT?
Ë You need to beat your competitor to market,
but make sure that your product is going to
last.
Ë HALT accelerates the testing process.
(Companies can’t afford a 20 year test to see
if a light bulb is going to last 20 years)
Ë With HALT you are able to find out within a
matter of days what you might not have been
able to find out for years.
TM
7
Why Do HALT?
Finding design weaknesses as early in the product design cycle
As possible, can add substantially to the bottom line
Ë $40 Design Phase

Ë $200 Before Procurement
Ë $400 Before Production
Ë $16,000 Before Shipment
Ë $680,000 At Customer Site
TM
8
Margin Discovery Process…
HALT is very different from qualification testing in that it
is not a pass/fail test; it is a process of discovery and
optimization
Ë In HALT what you are looking for are the operating limits and
the destruct limits.
Ë These are the points where the system ceases to work as
specified but will return to operation if the stress is removed
(operating limit) and ceases to operate even if the stress is
removed (destruct limit).
Ë In HALT we are trying to maximize the operating and destruct
margins of the product, by increasing these margins we reduce
the possibility that variations in products will result in product
failures in the field.
TM
9
Things to Consider Before Testing
Ë Be thoroughly familiar with the product to be tested.
You should know as much as possible of the end
environment that it will be placed in, then test
accordingly.
Ë You need to constantly monitor the product, for
some failures are intermittent and would not get
caught if you just take a reading at the beginning and
at the end.
Ë Before the testing begins, What will be considered
as a failure; is it the first intermittent failure? Or is it
all way to a hard failure??
TM
10
HALT Testing
Ë There is no one right way to run HALT
Ë HALT is a series of tests
Ë The best way to start is by testing using single
environments, then run with combined
environments for comparison
Ë Typical tests:
u Cold only, Heat only, Vibration only, Heat with
Vibration and Cold with Vibration
TM
11
HALT Testing
Cold Step Test
30
Room Temperature
20
10
Temperature (C)
-10
-20 Lower Temperature 10C every

10 minutes until failure.
-30 Ramp rate as fast as possible
-40
-50
Time in Minutes
TM
This is an example of the cold step. You start at Ambient conditions

and lower the temperature in 10°c increments. The graph shows to
stay at every step for 10 mins, but this totally depends on the
product size and if that is enough time for the entire product to
stabilize at that temperature.
12
HALT Testing
Heat Step Test

90
Raise Temperature 10C
80
every 10 minutes until failure.
70 Ramp rate is as fast as possible.
60
Temperature (C)
50
40
30
20 Room
10 Temperature
0
Time in Minutes
TM
This is an example of the heat step, similar to the previous graph

but obviously we are increasing the temperature.
13
HALT Testing
Vibration Test
16
14
12
Add 2 g's every 10 minutes until failure.
Vibration Level (g's)
10
0
Time in Minutes
TM
This is an example of the vibration step, similar to the previous

graph but obviously we are increasing the vibration level.
14
HALT Testing
Heat with Vibration
90
80 Step up heat 10C every 10

minutes while applying
70 vibration 2 minutes out of
every 5.
60
Temperature (C)
Thermal
50
40
30
20
Room Temperature
10 Vibration
0
Time in Minutes
TM
This is an example of step heating with steady vibration.
15
HALT Testing
Thermal Swings
100
Temperature swings gradually
80
growing larger
until failure is found. Ramp
60 rate as fast as
possible.
Temperature (C)
40
20
Room
0 Temperature
-20
-40
-60
Time in Minutes
TM
Here you are seeing gradual temperature swings growing larger

until failure is found.
16
HALT Testing
Thermal Swings with Vibration
100
Thermal swing test adding 2
minutes of vibration for every 5
80 Thermal
minutes of test time.
60
Room
Temperature
Temperature (C)
40
20
0
Vibration
-20
-40
-60
Time in Minutes
TM
Here you are seeing step vibration and gradual temperature swings
growing larger until failure is found.
17
Summary Of Halt Results
Typical Failure Percentage by Stress Type
Combined
Environment
20% Cold Step
Stress
14%
Hot Step
Stress
17%
Vibration Step
Rapid Thermal
Stress
Transition
45%
TM
4% www.chartchambers.com
18
Summary Of Halt Results
Tackle All Failure Modes Identified Up

to the Fundamental Limit of the
Technology
Even if Found “Above Spec”
If you find it, it is probably important!

TM
Again, the reason it is important is because failures found by

exposing a product to high stress above its spec limit equates to
failures that the product would see during normal operation for an
extended period of time.
19
HALT Chamber Design
• High Thermal Ramp rates are achieved with open
Nichrome heater wire design for heating and
direct Nitrogen atomization in the plenum for
cooling
Spray
Nozzle Heater Assembly
with open
Nichrome Wire
Blower Heating Element
Wheel
TM
Chart Chambers produces high thermal stress levels required for

HALT.
20
HALT Chamber Design
High vibration stresses are achieved
with a six degrees of freedom vibration
table; Allows accelerations in six axes
(3 Linear & 3 Rotational)
TM
The Vibration Technology used for HALT is very unique versus

traditional testing. Traditional vibration testing uses a single axis
Electrodynamic shaker which accelerates/excites the product in one
direction. In HALT, once the product is mounted to the table, it is
exposed to vibration in six axes, which is called six degrees of
freedom. The pnuematically actuated hammers are positioned in
such a way that acceleration is generated in the x, y and z axis and
also rotation about those axis.
21
HALT vs. Traditional Testing
HALT Traditional Testing
Ë Stresses product beyond Ë Verifies that a product
specification meets specification
Ë Gathers information on Ë Simulates a “Lifetime” of use
Product Limitations
Ë Focus on Design Ë Focus on Finding Failures
Weakness & Failures Ë Single Axis Vibration
Ë 6 DoF Vibration Ë Moderate Thermal Rate of
Ë High Thermal Rate of Change
Change Ë Narrowly Defined - Rigidly
Ë Loosely Defined - Modified Followed
“On the Fly” Ë “Pass/Fail” Test
Ë Not a “Pass/Fail” Test
TM
These are some of the differences between HALT and traditional

testing.
22
HALT Benefits
Ë Faster Time to Market
Ë Increased Reliability >> More Robust
Products
Ë Greater Customer Satisfaction
Ë Lowered warranty cost through higher MTBF
Ë Minimized chance of product recalls
TM
23
HASS- Highly Accelerated Stress Screen
TM
24
HASS - What Is It?
HASS is a screening process that uses accelerated
techniques to uncover manufactured product
weakness and flaws. The process requires the use
of HALT results, and other product specific
information to design the initial profile, and then tune
it for optimal effectiveness.
TM
25
HASS - What Is It?
Ë Discovery Process used in production for
manufacturing process monitoring
Ë Screens are designed based on HALT findings
Ë (Combined Environment of Temperature and
Vibration)
Ë Screens Strong Enough to Detect Latent Defects
Ë Screens Do Not Take Significant Life Out Of the
Product
TM
26
HASS Development Process
Ë Review HALT Results
Ë Determine Production Needs
(consider length of functional test)
Ë Design and Qualify Fixture
Ë Develop Profile (Initial Screen)
Ë Run Proof of Screen
TM
Proof of screen- The process of showing that the screen does not
remove too much life from a product and that the product is still
suitable for shipment to customer
27
Profile Development
Ë Profile Development Starting Point
u Test Within Op Limits (Detection Screen)
Temp (Rule of Thumb - 80% of cumulative range of
UOL and LOL)
Vibe (Rule of Thumb 50% of Operational Limits)
TM
28
Profile Development
Ë Incorporate Precipitation Screen (designed to
precipitate flaws)
u Test Beyond Op Limits, but within Destruct
Temp (Rule of Thumb - 50% of difference between OL
& DL)
Vibe (Rule of Thumb 50% of Destruct Limits)
TM
29
Proof- of Screen (two steps)
Ë Determine Screen Effectiveness:
u Use production units and Execute the profile one
time
Ë Perform Product Life Valuation:

u Execute profile numerous times (30+ times) for
greater confidence
TM
30
Benefits Gained from HASS
Ë Quickly detect shifts in manufacturing

processes
Ë Increased Reliability - More Robust
Products
Ë Increased Out-of-Box Quality
Ë Faster Time to Market
TM
31

What Is Halt

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HALT/HASS Presentation

This presentation is an introduction to accelerated testing

u Typical testing done before product release

Ë HALT- Highly Accelerated Life Test

u used in Design for Product Ruggedization

Ë HASS- Highly Accelerated Stress Screen

u used in Production for Process Monitoring

Traditional testing/Design Verification Testing is typically done

Ë Comparison to Traditional Testing

This a brief agenda on what we are going to discuss.

Fundamental limit of the technology – Product tested beyond the

Probably the best way to look at HALT is to describe it as a

Number of Cycles (N) ∞

This is a good graph that shows the usefulness of HALT.

Ë $40 Design Phase

-20 Lower Temperature 10C every

This is an example of the cold step. You start at Ambient conditions

Heat Step Test

This is an example of the heat step, similar to the previous graph

This is an example of the vibration step, similar to the previous

80 Step up heat 10C every 10

This is an example of step heating with steady vibration.

Here you are seeing gradual temperature swings growing larger

Tackle All Failure Modes Identified Up

Even if Found “Above Spec”

If you find it, it is probably important!

Again, the reason it is important is because failures found by

Chart Chambers produces high thermal stress levels required for

The Vibration Technology used for HALT is very unique versus

These are some of the differences between HALT and traditional

techniques to uncover manufactured product

weakness and flaws. The process requires the use

of HALT results, and other product specific

information to design the initial profile, and then tune

it for optimal effectiveness.

Ë Perform Product Life Valuation:

Ë Quickly detect shifts in manufacturing

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