Materials-based failure analysis in design of electronic devices

1. A computer-implemented method for using a prediction of failure of an electronic device during design of the device, the method comprising:

receiving data associated with a metallic component in the device, the data including data indicative of a response of the component to a specific load on the component while the device is in operation; and

calculating a prediction indicative of a potential failure of the device using a probabilistic model of failure of the component, wherein the probabilistic model is based on at least the specific load, and a microstructure-based failure model and the data, and wherein the probabilistic model utilizes at least one of fast probability methods and simulation techniques, and wherein the microstructure-based failure model represents heterogeneous microstructures in the component, and includes one or more of a crack nucleation model and a short crack growth model.

2. The method of claim 1 wherein the probabilistic model is derived by a method comprising:

obtaining a Finite Element Model (FEM) of the component;

analyzing the FEM to obtain stresses at nodes of the FEM;

determining a Representative Volume Element (RVE) for at least one of the nodes;

building a microstructure-based failure model for at least one RVE and including the microstructure-based failure model in the RVE;

simulating a component life using at least one RVE microstructure-based failure model, the simulating producing a result related to the component life; and

performing the simulating a plurality of times to produce results related to component life, wherein the results are used to provide a prediction of failure for the component.

3. The method of claim 1 , wherein the probabilistic model utilizes a fast probability method selected from: a first order reliability method; a second order reliability method; an advanced mean value method, and a mean value method.

4. The method of claim 1 , wherein the probabilistic model utilizes a simulation technique selected from: a Monte Carlo method, an importance sampling method, a Latin Hypercube method, and a stratified sampling method.

5. The method of claim 2 , wherein the microstructure-based failure model further includes a long crack growth model.

6. The method of claim 2 , wherein one of the results related to the component life, is a minimum number of cycles or a time to failure for any RVE.

7. The method of claim 2 , wherein the simulating comprises:

establishing a density of potential nucleation sites within each RVE;

establishing a number of potential nucleation sites within each RVE;

determining the number of cycles to failure for each potential nucleation site; and

calculating the life of the RVE as the smallest number of cycles to failure for any of the potential nucleation sites.

8. A computer system, configured to use a prediction of failure of an electronic device during design of the device, the system comprising:

a processor; and

a memory, wherein the processor is configured to execute instructions for:

receiving data associated with a metallic component in the device, the data including data indicative of a response of the component to a specific load on the component while the device is in operation; and

calculating a prediction indicative of a potential failure of the device using a probabilistic model of failure of the component, wherein the probabilistic model is based on at least the specific load, and a microstructure-based failure model and the data, and wherein the probabilistic model utilizes at least one of fast probability methods and simulation techniques, and wherein the microstructure-based failure model represents heterogeneous microstructures in the component, and includes one or more of a crack nucleation model and a short crack growth model.

9. The system of claim 8 wherein the processor is further configured to execute instructions for deriving the probabilistic model, according to:

obtaining a Finite Element Model (FEM) of the component;

analyzing the FEM to obtain stresses at nodes of the FEM;

determining a Representative Volume Element (RVE) for at least one of the nodes;

building a microstructure-based failure model for at least one RVE and including the microstructure-based failure model in the RVE;

simulating a component life using at least one RVE microstructure-based failure model, the simulating producing a result related to the component life; and

performing the simulating a plurality of times to produce results related to component life, wherein the results are used to provide a prediction of failure for the component.

10. The system of claim 8 , wherein the probabilistic model utilizes a fast probability method selected from: a first order reliability method; a second order reliability method; an advanced mean value method, and a mean value method.

11. The system of claim 8 , wherein the probabilistic model utilizes a simulation technique selected from: a Monte Carlo method, an importance sampling method, a Latin Hypercube method, and a stratified sampling method.

12. The system of claim 9 , wherein the microstructure-based failure model further includes a long crack growth model.

13. The system of claim 9 , wherein one of the results related to the component life, is a minimum number of cycles or a time to failure for any RVE.

14. The system of claim 9 , wherein the simulating comprises:

establishing a density of potential nucleation sites within each RVE;

establishing a number of potential nucleation sites within each RVE;

determining the number of cycles to failure for each potential nucleation site; and

calculating the life of the RVE as the smallest number of cycles to failure for any of the potential nucleation sites.

15. A computer readable non-transitory medium, configured with instructions for using a prediction of failure of an electronic device during design of the device, the instructions comprising instructions for:

receiving data associated with a metallic component in the device, the data including data indicative of a response of the component to a specific load on the component while the device is in operation; and

calculating a prediction indicative of a potential failure of the device using a probabilistic model of failure of the component, wherein the probabilistic model is based on at least the specific load, and a microstructure-based failure model and the data, and wherein the probabilistic model utilizes at least one of fast probability methods and simulation techniques, and wherein the microstructure-based failure model represents heterogeneous microstructures in the component, and includes one or more of a crack nucleation model and a short crack growth model.

16. The medium of claim 15 , configured with further instructions for deriving the probabilistic model, the instructions comprising instructions for:

obtaining a Finite Element Model (FEM) of the component;

analyzing the FEM to obtain stresses at nodes of the FEM;

determining a Representative Volume Element (RVE) for at least one of the nodes;

building a microstructure-based failure model for at least one RVE and including the microstructure-based failure model in the RVE;

simulating a component life using at least one RVE microstructure-based failure model, the simulating producing a result related to the component life; and

performing the simulating a plurality of times to produce results related to component life, wherein the results are used to provide a prediction of failure for the component.

17. The medium of claim 15 , wherein the probabilistic model utilizes a fast probability method selected from: a first order reliability method; a second order reliability method; an advanced mean value method, and a mean value method.

18. The medium of claim 15 , wherein the probabilistic model utilizes a simulation technique selected from: a Monte Carlo method, an importance sampling method, a Latin Hypercube method, and a stratified sampling method.

19. The medium of claim 16 , wherein the microstructure-based failure model further includes a long crack growth model.

20. The medium of claim 16 , wherein one of the results related to the component life, is a minimum number of cycles or a time to failure for any RVE.

21. The medium of claim 16 , wherein the simulating comprises:

establishing a density of potential nucleation sites within each RVE;

establishing a number of potential nucleation sites within each RVE;

determining the number of cycles to failure for each potential nucleation site; and

calculating the life of the RVE as the smallest number of cycles to failure for any of the potential nucleation sites.