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Mission Statement
CAVE is dedicated to working with industry in developing and implementing new technologies for the packaging and manufacturing of electronics, with special emphasis on the cost, harsh environment, and reliability requirements of the automotive, aerospace, military, computing, portable and other industries.
Message from Director

These are tough economic times, and there is greater a need to balance short term needs with long term strategic goals of technology advancement in preparation for the next cycle of products. CAVE3 is a NSF Industry University Cooperative Research Center (I/UCRC). The center provides an ideal forum in which academia and industry work in partnership on identification of key road blocks relevant to electronics in harsh environments and development of innovative technologies for enabling cost-effective solutions.

        The center is focusing on pre-product space with a mix of higher-risk, high-return programs to complement the industry's internal research and devel- opment efforts. In this newsletter, I have highlighted some of the recent scientific advancements made by CAVE3 researchers.

        Prognostics has gained increased visibility with the efforts to transition from a schedule based maintenance to a condition based maintenance. Advancements in this area have the potential of providing significant cost savings simultaneously with assuring needs of high reliability in electronics systems functioning in harsh environments. CAVE3 researchers have been developing damage precursors based approaches for prognostication of electronics in harsh environments. A new approach has been developed for anomaly detection and fault mode classification of interconnect reliability in shock and vibration. Methods have also been developed for the interrogation of system state in electronic systems subjected to multiple thermal environments. The advancements are part of a larger prognostic health monitoring system in development at CAVE3. You will find more information on the above mentioned advancements presented in the newsletter in greaterdetail. I encourage you to contact the center researchers in each case for further information.

        On May 19, 2009, I attended the first Pb-Free Electronics Manhattan Project (PERM) meeting in Hunt Valley Maryland to present the reliability concerns related to leadfree packaging for defense applications. It was clear that significant gaps existed in knowledge related to harsh environment reliability of leadfree electronics. The component manufacturers have largely transitioned to or are completely transitioning to leadfree electronic parts. However, reliability in long-life electronic systems subjected to harsh environments and dormant storage is yet to be completely characterized. In the interim, there are several solutions and accompanying potential problems including but not limited to mixed alloys, re-balled leadfree parts and mixed assemblies. CAVE3 researchers have been investigating the constitutive and damage behavior in these assemblies. Experimental results show that thermal aging adversely effects reliability of several of the SnAgCu formulation alloys which have been widely adopted as the front runners for leadfree transition. An overview of our findings is available inside.

        I am also glad to welcome Vortant Technologies and Advanced Thermal Technologies to the CAVE3 Industrial Membership. Our next technical review is on September 9-10, 2009 and I hope to see you all at the review. A preliminary listing of projects is attached inside.

Pradeep Lall,
Thomas Walter Professor and Center Director

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Inside
CAVE3 Review and Meetings

  1. CAVE3 Consortium Fall Technical Review Meeting
  2. 7th Annual SMTA-CAVE3 AIMS Harsh Environment Electronics Symposium

Research Facility Enhancements

  1. CAVE3 Acquires Drop/Shock Test Capabilities
  2. CAVE3 Adds Semi-Automatic Assembly Line

Research Highlights

  1. Life Prediction of Leadfree Electronics in Shock-Impact
  2. Fault-Mode Classification for Health Monitoring of Electronics Subjected to Drop and Shock
  3. ARMA based Prognostics and Condition Monitoring of Electronics
  4. Prognostication of Latent Damage and Residual Life in Leadfree Electronics
  5. Resistance Spectroscopy-based Condition Monitoring for Prognostication Under Shock-Impact
  6. Isothermal Aging Induced Evolution of the Material Behavior of Underfill Encapsulants
  7. Analysis of Mixed Formulation Solder Joints
  8. The Effects of SAC Alloy Composition on Aging Resistance and Reliability
  9. A Study of Vibration-induced Fretting Corrosion
  10. Alternative Method for In-Situ Environmental Testing for Solder Joint Reliability
  11. Auger Electron Spectroscopic (AES) Measurements on High Aspect Ratio Tin Whiskers
  12. Thermal Performance Of Laminate-To-Aluminum Attachment Materials
  13. Impact Of Component Termination On Conductive Adhesive Reliability
  14. Module Overmolding

Announcements

  1. Lall, Suhling give Technical Keynotes at EuroSimE in Delft, Netherlands, April 27-29, 2009
  2. Dr. Pradeep Lall is Elected an ASME Fellow (American Society of Mechanical Engineers)
  3. Dr. Jeff Suhling is Elected an ASME Fellow (American Society of Mechanical Engineers)
  4. CAVE3 Researchers Win Best Paper Award - SMTAI
  5. Roy Knight receives Outstanding ME Faculty-Member Award
  6. CAVE3 Student selected for Hutchins Grant
  7. Dr. Jinchun Gao Joins CAVE3
  8. Advanced Thermal Technologies and Vortant Technologies have joined CAVE3

Selected Recent Publications

Contact NSF Center for Advanced Vehicle and Extreme Environment Electronics (CAVE3)