FAILURE ANALYSIS COMPONENTS ACCIDENT INVESTIGATIONS

1 WRDC-TR-90-4075. FAILURE ANALYSIS TECHNIQUES FOR THE EVALUATION OF. ELECTRICAL AND ELECTRONIC COMPONENTS IN AIRCRAFTM. ACCIDENT INVESTIGATIONS . Donald Galler Donald E. Allison David W. Mercaldi FAILURE ANALYSIS Associates 00 115 Flanders Road Westborough, MA 01581 DT. August 1990. Final Report for Period September 1989 - April 1990. Approved for Public Release; Distribution is Unlimited MATERIALS LABORATORY. WRIGHT RESEARCH AND DEVELOPMENT CENTER. AIR FORCE SYSTEMS COMMAND. WRIGHT-PATTERSON AIR FORCE BASE, OHIO 45433-6533. NOTICE. WHEN GOVERNMENT DRAWINGS, SPECIFICATIONS, OR OTHER DATA ARE USED FOR ANY. PURPOSE OTHER THAN IN CONNECTION WITH A DEFINITELY GOVERNMENT-RELATED. PROCUREMENT, THE UNITED STATES GOVERNMENT INCURS NO RESPONSIBILITY OR ANY. OBUGATION WHATSOEVER. THE FACT THAT THE GOVERNMENT MAY HAVE FORMULATED OR IN. ANY WAY SUPPUED THE SAID DRAWINGS, SPECIFICATIONS, OR OTHER DATA, IS NOT TO.

2 BE REGARDED BY IMPUCATION, OR OTHERWISE IN ANY MANNER CONSTRUED, AS UCENSING. THE HOLDER, OR ANY OTHER PERSON OR CORPORATION; OR AS CONVEYING ANY RIGHTS OR. PERMISSION TO MANUFACTURE, USE, OR SELL ANY PATENTED INVENTION THAT MAY IN ANY. WAY BE RELATED THERETO. THIS REPORT HAS BEEN REVIEWED BY THE OFFICE OF PUBLIC AFFAIRS (ASOIPA). AND IS RELEASABLE TO THE NATIONAL TECHNICAL INFORMATION SERVICE (NTIS). AT. NTIS IT WILL BE AVAILABLE TO THE GENERAL PUBUC INCLUDING FOREIGN NATIONS. THIS TECHNICAL REPORT HAS BEEN REVIEWED AND IS APPROVED FOR PUBLICATION. GEORGE A. SLENSKI THOMAS D. COOPER, Chia Materials Integrity Branch Materials Integrity Branch Systems Support Division Systems Support Division Materials Laboratory Materials Laboratory FOR THE COMMANDER. Syste upport Division Materials Laboratory IF YOUR ADDRESS HAS CHANGED, IF YOU WISH TO BE REMOVED FROM OUR MAIUNG.

3 LIST, OR IF THE ADDRESSEE IS NO LONGER EMPLOYED BY YOUR ORGANIZATION PLEASE. NOTIFY W, WRIGHT-PATTERSON AFB, OH 45433-6sq. TO HELP MAINTAIN. A CURRENT MAILING LIST. COPIES OF THIS REPORT SHOULD NOT BE RETURNED UNLESS RETURN IS REUIRED BY. SECURITY CONSIDERATIONS, CONTRACTUAL OBLIGATIONS, OR NOTICE ON A SPECIFIC. DOCUMENT. UNC[LAS S I F [ ED. SECURITY CLASSIFICATION OF THIS PAGE. REPORT DOCUMENTATION PAGE IForm Approved OFBNo. 0704-01a8. la. REPORT SECURITY CLASSIFICATION lb. RESTRICTIVE MARKINGS. Unclassified 2a. SECURITY CLASSIFICATION AUTHORITY 3. DISTRIBUTION /AVAILABILITY OF REPORT. N/A Approved for Public Release; Distribution is 2b. DECLASSIFICATION / DOWNGRADING SCHEDULE Unlimited N/A. 4. PERFORMING ORGANIZATION REPORT NUMBER(S) S. MONITORING ORGANIZATION REPORT NUMBER(S). FaAA-BN-R-90-3-1 WRDC-TR-90-4075. 6a. NAME OF PERFORMING ORGANIZATION 6b.]]

4 OFFICE SYMBOL 7a. NAME OF MONITORING ORGANIZATION. * (If applicable) AF Wright Research & Development Center FAILURE ANALYSIS Associates Materials Laboratory (WRDC/MLSA). 6c. ADDRESS (City, State, and ZIP Code) 7b. ADDRESS (City, State, and ZIP Code). 115 Flanders Road Wright-Patterson Air Force Base, Ohio Westborough, MA 01581 45433-6533. 8a. NAME OF FUNDING/SPONSORING J8b. OFFICE SYMBOL 9. PROCUREMENT INSTRUMENT IDENTIFICATION NUMBER. ORGANIZATION I (If applicable). Aeronautical System Div. ASD/PMRRB F33615-89-C-5647. 8c. ADDRESS (City, State, and ZIP Code) 10. SOURCE OF FUNDING NUMBERS. Ai Frc BsePROGRAM. WrihtPateso PROJECT TASK I-WORK UNIT. WrighC-Patterson Air Force Base ELEMENT NO. NO. NO ACCESSION NO. Ohio 45433-6503 65502F 3005 52 63. II TITLE (Include Security Classification). FAILURE ANALYSIS Techniques for the Evaluation of Electrical and Electronic COMPONENTS in Aircraft ACCIDENT INVESTIGATIONS 12.

5 PERSONAL AUTHOR(S). Caller, Donald Allison, Donald, E. Mercaldi, David, W. 13a. TYPE OF REPORT j13b. TIME COVERED 14. DATE OF REPORT (Year,MonthODy) 15. PAGE COUNT. Final J FROMa/2D/8( TOJ =90 1990 August 150. 16. SUPPLEMENTARY NOTATION. 17. COSATI CODES 18. SUBJECT TERMS (Continue on reverse if necessary and identify by block number). FIELD GROUP SUB-GROUP - ' FAILURE ANALYSIS , Aircraft ACCIDENT investigation , 01 0103 Lamps, Wiring, Connectors, Switches, Magnets, Printed 09 090- Wiring Boards, Microelectronic; Electronics, Electrical 19. ABSTRACT (Continue on reverse if necessary and identify by block number). FAILURE componentsanalysis techniques for: are summarized for lamps, the evaluatior, of electrical and electronic wiring, connectors, switches, magnetic materials, printed wiring boards and microelectronic devices. Techniques using optical and scanning electron microscopy (SEM) for the ANALYSIS of these COMPONENTS are descrioed.)

6 Energy Dispersive X-ray ANALYSIS (EDAJU) of elemental constituents, X-ray radiography, and specialized electrical measurements are also described. The potential for the techniques to distinguish pre- ACCIDENT conditions from post-impact damage was assessed. Data on the FAILURE rates of aircraft electrical COMPONENTS was reviewed. Data from the Air Force Mishap database indicates that 36 percent of electrical failures on aircraft are caused by interconnections: wiring and connectors. Corrosion is identified as a major cause of connector problems. 20. OISTRIBUTION/AVAILABILITY OF ABSTRACT 21. ABSTRACT SECURITY CLASSIFICATION. E3 UNCLASSIFIED/UNLIMITED 0 SAME AS RPT. C3 OTIC USERS UNCLASSIFIED. 22a NAME OF RESPONSIBLE INDIVIDUAL 22b. TELEPHONE (Include Area Code) 22c. OFFICE SYMBOL. (eorac (513) 2-36r23 1 WRI) DO Form 1473, JUN 86 Previous editions are obsolete.

7 SECURITY CLASSIFICATION OF THIS PAGE. UNCLASSTFIED. TABLE OF CONTENTS. EXECUTIVE SUMMARY .. 1. CHAPTER I. INTRODUCTION .. 2. INTRODUCTION .. 3. PURPOSE OF THIS PHASE I TASKS .. 4. REPORT ORGANIZATION .. 5. CHAPTER II. FAILURE STATISTICS OF ELECTRICAL EQUIPMENT ON AIRCRAFT .. 6. INTRODUCTION .. 7. AIR FORCE MISHAP DATABASE .. 7. AVIONICS INTEGRITY PROGRAM DATA .. 8. HUGHES AIRCRAF. FACTORY DATA .. 16. SUMMARY .. 16. REFERENCES .. 16. CHAPTER III. FAILURE ANALYSIS TECHNIQUES FOR AIRCRAFT ACCIDENT investigation 19. INTRODUCTION .. 20. INCANDESCENT LAMPS .. 21. W IRING .. 36. CONNECTORS .. 49. SWITCHES .. 66. PERMANENT MAGNET MATERIALS .. 76. PRINTED WIRING BOARDS .. 88. MICROELECTRONICS .. 113. CHAPTER IV. SUM MARY .. 138. SUMMARY .. 139. RECOMMENDATIONS FOR FURTHER WORK .. 144. APPENDIX A. GLOSSARY OF FAILURE ANALYSIS TERMINOLOGY .. 145. ii~i EXECUTIVE SUMMARY.

8 FAILURE ANALYSIS techniques for the evaluation of electrical and electronic COMPONENTS during aircraft ACCIDENT investigation have been identified and examined. FAILURE ANALYSIS techniques are summarized for: lamps, wiring, connectors, switches, magnetic materials, printed wiring boards and microelectronic devices. Optical and scanning electron microscopy (SEM) are fundamental tools for the ANALYSIS of these COMPONENTS . Energy Dispersive X-ray ANALYSIS (EDAX) of elemental constituents, X-ray radiography, and specialized electrical measurements are also described. The potential for the techniques to distinguish pre- ACCIDENT conditions from post- impact damage was assessed. To establish priorities for further development of FAILURE ANALYSIS techniques, data on the failures of aircraft electrical COMPONENTS was reviewed. A review of data from the Air Force Mishap database indicates that 36 percent of electrical failures on aircraft are caused by interconnections: wiring and connectors.

9 Corrosion is identified as a major cause of connector problems. The priority for the further development of FAILURE ANALYSIS techniques was assessed by considering the component failures, the ability of the FAILURE ANALYSIS techniques to distinguish pre- ACCIDENT conditions from post-impact damage and the existing documentation on the techniques. Additional testing is recommended to provide documentation to support FAILURE ANALYSIS of microelectronic devices, switches, wiring, connectors and printed wiring boards. The development of computer- assisted methods for improving the reliability of analyzed data and for physical modeling of COMPONENTS to support FAILURE ANALYSIS are also recommended. This report summarizes the efforts of a Phase I SBIR contract The intended Phase II work will result in a handbook of FAILURE ANALYSIS techniques for use in aircraft ACCIDENT investigation .

10 DiOC TAb3 -. (~' t t,- c'. o'. I A I), idIor DSistiuf CHAPTER I. INTRODUCTION. INTRODUCTION. This report was prepared by FAILURE ANALYSIS Associates,, Inc. (FaAA) for the Air Force under contract number F33615-89-C-5647 for the Materials Laboratory, Wright Research and Development Center, Wright-Patterson Air Force Base. The purpose of the work was to collect information on FAILURE ANALYSIS techniques that can be used for the evaluation of electrical and electronic COMPONENTS during aircraft ACCIDENT INVESTIGATIONS . A further goal of the work was to identify potential ACCIDENT investigation techniques that might be developed from FAILURE ANALYSIS methods used in industrial applications or ongoing research. Fundamental material properties were also considered as sources of new ACCIDENT investigation methods. Particular attention was paid to those techniques which can distinguish pre- ACCIDENT conditions from post- impact damage.