Component Engineering Training Course

1. Component Engineering Training Course This Training Course has been compiled and is presented by Spur Electron Ltd.

2. WHAT IS COMPONENT ENGINEERING? • It is an individual or group which provides the project team with a broad knowledge and experience of EEE components, including: • Electronic and semiconductor theory and principals • Materials, construction and manufacture • Space component procurement systems • Quality and screening requirements

3. HIGH RELIABILITY COMPONENTS • DEFINITION : A component is defined as :- • The smallest sub-division of a system which cannot be further sub- divided without destroying its function. • EEE stands for :- • E Electrical, e.g. Resistors, Capacitors, Connectors • E Electromechanical, e.g. Relays, Switches, Actuators • E Electronic, e.g. Integrated Circuits, Transistors, Diodes

4. HIGH RELIABILITY COMPONENTS (CONT.) • Europeans tend to use the word “Component”, whereas the Americans use the term “Part”. Both terms will be found within this presentation, and should be considered as synonymous. • Europeans use the term “High Reliability Components, Americans often use the term “Hi-Rel Part”. Again the terms are synonymous. • High Reliability components are those in which a very high degree of confidence can be placed that they have stable characteristics and a working life in excess of the mission requirements. • This definition is flawed, in that the components are manufactured to a standard set of requirements, whilst mission duration's vary considerably.

5. HIGH RELIABILITY COMPONENTS (CONT.) • A decade ago mission duration's were typically 3 to 5 years. Today mission duration's of up to 15 to 20 years are required. • The US Military market has led the field in specifying reliability standards. • In the mid 1960’s, various government agencies identified that defects, able to be screened out, were resulting in an equipment failure rate of about 1% per thousand hours. • In-depth failure analysis identified the predominant failure mechanisms.

6. HIGH RELIABILITY COMPONENTS (CONT.) • The Solid State Applications Branch of the RADC was assigned the task of developing a screening procedure to remove the infant mortality failures, which led to the high failure rates previously encountered. • In 1968 the RADC staff developed MIL-STD-883.

7. THE BATHTUB CURVE

8. OPERATING ENVIRONMENT FOR SPACE COMPONENTS • Environmental Extremes: • Temperature • Radiation • Mechanical Stresses • Vacuum

9. THE EUROPEAN APPROACH TO SPACE COMPONENTS

10. ORIGINS OF THE ESA/SCC SYSTEM • Need for Pan-European Specification System for EEE Components realized by ESRO, prior to the formation of ESA. • Until this need was recognized and acted upon a range of differing specification systems were being used

11. ORIGINS OF THE ESA/SCC SYSTEM (CONT.) • This resulted in: • - No standardization. • - Wide variations in test and inspection philosophies. • - Huge variances in manufacturers quoted price and delivery. • - Extreme difficulty in assessing comparative quality and reliability of delivered components.

12. ORIGINS OF THE ESA/SCC SYSTEM (CONT.) • In 1971 ESRO through its Joint Programmes and Policy Committee (JPPC) set up the Space Components Coordination Group (SCCG) on an interim basis as an advisory group. • Over 30 years later, this interim group is still operating. • In 1973 the JPPC approved the SCCG Terms of Reference. • The SCCG now set about the generation of a series of basic policy documents.

13. ORIGINS OF THE ESA/SCC SYSTEM (CONT.) • These documents were approved by the SCCG at its plenary meeting in November 1973 and submitted to the JPPC for its approval. • Before approval by the JPPC, ESRO and ELDO were merged into the present day ESA. • ESA then abolished the JPPC, and the SCCG was placed under the direct authority of the Director General.

14. ORIGINS OF THE ESA/SCC SYSTEM (CONT.) • This new status entailed new terms of reference and redefinition of responsibilities for both the SCCG and the Director General. • The placement of the SCCG under the Director General's control was finally approved in 1976. • This ESA policy has been superseded by ESCC and SCAHC

15. OBJECTIVES OF THE ESA/SCC SYSTEM • The basic objectives of the ESA/SCC System as defined by ESA/SCC Document No. 00000 “Object and Basic Rules of the ESA/SCC System” are: • - Political. The promotion of a European System of • Specifications for Space Components. • - Technical. The System capable of being integrated • with other international systems. • - Commercial. Promotion of the production in Europe of Components suitable for Space Application.

16. OBJECTIVES OF THE ESA/SCC SYSTEM • Standardisation • Interchangability • Improvement cost/schedule planning

17. SCCG ACHIEVEMENTS • By the early 1980s the SCCG had achieved a very complete ESA/SCC System comprising over 1000 specifications and had assisted in the qualification of some 350 components manufactured by a total of 40 European manufacturers. • In spite of this success the European user community were very concerned that ESA/SCC components were significantly more expensive than space qualified components from the US. • There was also a major concern that the SCCG was overly bureaucratic and the ESA/SCC System over specified technical requirements. • In 1993 ESA published a technical paper recommending some major areas of review and modification. • This lead to the formation of SCAHC.

18. SCAHC • What was SCAHC? • The Space Components Ad Hoc Committee (SCAHC) was established by ESA in October 1994 • It comprised of experts from all the main space sectors within Europe. i.e. ESA, National Space Agencies, Commercial Space Organisations, Space Industry and Space Component Manufacturers. In addition the European Commission was also represented. • The SCAHC task was to formulate a long term programme for space components that would enhance European competitiveness in the world market.

19. SCAHC RECOMMENDATIONS • In a final report released in 1995 the SCAHC made ten recommendations: • R1 – Maintain the ESA/SCC System of specifications including related qualification programmes and quality assurance approach in order to meet users needs and market trends. • R2 – Standards and specifications for components shall reflect a higher degree of delegation from suppliers with reduced customers controls. • R3 – Wherever possible, European component specifications and standards should be based on international standards and should be promoted to obtain international recognition.

20. SCAHC RECOMMENDATIONS (CONT.) • R4 – Implement a stringent system for the reduction of diversity of components for use in space, based on the usage of a European Preferred Parts List, giving preference to European components. • R5 – Establish a reliability system for European space Components • R6 – Establish an information Exchange system on component data with access for all European users. • R7 – Enable the mutual recognition of industrial performance in the various component disciplines, including component engineering, radiation hardness assurance, auditing and inspection (with formal certification of the latter), through provision of the relevant and regular training opportunities.

21. SCAHC RECOMMENDATIONS (CONT.) • R8 – Improve the availability of strategically important components, giving preference to European sources (Microprocessors, MMICs etc). • R9 – Implement, in full partnership with the users, manufacturers, commercial customers and agencies, a European Space Component Research and Technology Programme assuring coherence with other market sectors, and cost effectiveness. • R10 – Establish a permanent Component Steering Board (CSB) representing the interests of all the European space partners, to monitor market trends, to provide financing and to overview the technology programmes and its synergies, and advise on necessary policy changes.

22. SCSB ACHEIVEMENTS TO DATE • In the 7 years since the SCAHC recommendations were made progress has been slow but reasonably successful. • Using the recommendations as a guide we can demonstrate the following achievements. • R1 Maintain but improve the ESA/SCC system. • Two major contracts awarded. One to review the structure and organisation, relatively successful, the SCSB now responsible for the policy and the Executive responsible for the day to day operation. • Second contract to carry out in depth review. Results very controversial. However general agreement appears to have been reached, some changes already incorporated, some still to be made.

23. ACHEIVEMENTS TO DATE (CONT.) • R2 Reduce Customer Controls. • Partially achieved by the reduction of deliverable documentation, now incorporated into the system. • R3 Gain international recognition for the system • NASA now accept ESA/SCC Level B as equivalent to US MIL Level S • R4 Establish a European PPL • Now available on ESCIES (see later) • R5 Establish a European reliability system • Problem found to be an international concern. NASA and NASDA are currently involved in seeking solutions. • R6 Establish Information Exchange Database • Now Established (see ESCIES).

24. ACHEIVEMENTS TO DATE (CONT.) • R7 Enable mutual recognition. • Set of training programmes envisioned. Still not fully initiated. • R8 Improve availability of strategically important components. • Incorporate into CTB activities, see R9 below. • R9 Establish a Component Technology Board. • The CTB is well established and has developed it’s own five year plan. However funding availability is a major concern. • R10 Establish a Space Components Steering Board (SCSB). • SCSB Charter was formally signed on 8th October 2002

25. MR. RODOTẦ SIGNS THE CHARTER

26. ESA/SCC STILL THE STANDARD • Even though the ESCC is intended to replace the ESA/SCC System, it hasn’t yet happened and is unlikely to be complete for a number of years. In the meantime the ESA/SCC System continues to be the preferred standard.

27. RELATIONSHIP TO THE ECSS SYSTEM • The ESA/SCC specification system is a self contained subset of the ECSS System in that ECSS-Q-00 identifies that components shall be procured by means of the ESA/SCC specification system, thus making it a part of the ECSS system. • ECSS-Q-60 is the Level II document applicable for EEE components. This document clearly identifies the requirement for maximum use and preference towards the ESA/SCC Specification System.

28. ESA/SCC DOCUMENT REF/001 • This identifies the existence and status of all documents and specifications issued on behalf of the Director General of ESA. • It is regularly updated and issued to all registered users of the ESA/SCC System. • At this time, this document comprises a total of >1000 documents and specifications, including:- • Percentage of Total Documents • Level 0 Series - Object and Basic Rules 0.5% • Level 1 Series - Organization, Procedures and Implementation 1.0% • Level 2 Series - Basic Specifications 10.5% • Level 3 Series - Generic Specifications 3.0% • Level 4 Series - Detail Specifications 86%

29. SCC DOCUMENTARY SYSTEM

30. LEVEL 2 DOCUMENTS BASIC SPECIFICATIONS • These specifications define the basic requirements for a process, document or test method. • There is no standard table of contents owing to the wide range of topics addressed. • Employs either a 5 or 7 digit code, • i.e. either • 20400 Internal Visual Inspection • 2049000 Internal Visual Inspection of Integrated Circuits

31. BASIC SPECIFICATIONS (EXAMPLES) • TEST METHODS • 22900 Total Dose Steady-State Irradiation Test Method • 23800 Electrostatic Discharge Sensitivity Test Method • 24800 Resistance to Solvents of Marking Materials and Finishes

32. BASIC SPECIFICATIONS (EXAMPLES) (CONT.) • INSPECTION METHODS • 2049000 Internal Visual Inspection of Integrated Circuits • 20500 External Visual Inspection • 21400 Scanning Electron Microscope Inspection

33. BASIC SPECIFICATIONS (EXAMPLES) (CONT.) • SYSTEM REQUIREMENTS • 20100 Requirements for Qualification of Standard Electronic Components for Space Application • 21500 Calibration System Requirements • 2263502 Evaluation Test Programme for Surface Acoustic Wave (SAW) Devices • 22800 ESA/SCC Non-Conformance System • 24600 Minimum Quality System Requirements

34. LEVEL 3 DOCUMENTS GENERIC SPECIFICATIONS • GENERIC SPECIFICATIONS: • - Generic meaning “CLOSELY RELATING TO ANY GROUP OR CLASS”. • - It defines the general Inspection, Test and Documentation requirements for a group of components. • - Employs a Four Digit Code, and may refer to a Family of components or a Sub-Family of components. • An example to illustrate its use:- • EXAMPLE • 4001 • 40 = Family Code (Resistor Family) • 01 = Sub-Family Code (Metal Film)

35. GENERIC SPECIFICATION CONTENTS • Defines the general requirements for a component family, including: • Qualification Approval • Capability Approval • Procurement • Lot Acceptance Testing • Delivery • Inspection & Test Schedules • Data Documentation

36. GENERIC SPECIFICATION • TABLE OF CONTENTS • 1. Introduction • 2. Applicable Documents • 3. Terms, Definitions, Abbreviations, Symbols and Units • 4. Requirements • 5. Production Control for Qualification and Capability Approval • 6. Final Production Tests • 7. Burn-in and Electrical Measurements • 8. Qualification Approval, Capability Approval and Lot Acceptance • Tests • 9. Test Methods and Procedures • 10. Data Documentation • 11. Delivery • 12. Packaging and Despatch • -- Test Flows -- • -- Sampling Plans --

37. GENERIC SPECIFICATIONS (EXAMPLES) (CONT.) • 3009 Capacitors, fixed, chips, ceramic dielectric types I and II • 4001 Resistors, fixed film • 5000 Discrete Semiconductor Components • 9000 Integrated Circuits, Monolithics.

38. LEVEL 4 DOCUMENTS DETAIL SPECIFICATIONS • Defines the detail requirements for a component type, including:- • Ratings • Physical and Electrical Characteristics • Test and Inspection Data • TABLE OF CONTENTS • 1. General • 2. Applicable Documents • 3. Terms, Definitions, Abbreviations, Symbols and Units • 4. Requirements • 5. Tables • 6. Figures • 7. Appendices

39. DETAILED SPECIFICATION EXAMPLES • 3009/004 Capacitors, fixed, chips, ceramic dielectric type I. • 4001/011 Resistors, fixed film, Non hermetically sealed. • 5000/005 Diodes, silicon, fast recovery, avalanche rectifiers, 400W. • 9000/001 Monolithic microwave integrated circuits (MMIC), GaAs, Travelling wave amplifier.

40. COMPONENT NUMBERING - RADIATION IDENTIFICATION

41. RADIATION IDENTIFICATION

42. OTHER PROCUREMENT SYSTEMS • CECC • NASA • US MILITARY

43. CECC • The Cenelec Electronic Components Committee (CECC) System for electronic components of assessed quality became operational in 1973. • Its object is to facilitate trade by the harmonization of specifications and quality assessment procedures for electronic components. • Components produced under CECC requirements carry a special mark and are accepted by all member states. • 15 countries participate in the CECC System:- • Austria, Denmark, France, Belgium, Finland, Germany, Ireland, Italy, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

44. CECC LOGO

45. CECC (Cont.) • There are a number of different types of approval available within CECC. • Manufacturers, specialist contractors, distributors and independent test houses, can each be approved for their particular capability. • Each approval carries its own award of a certificate.

46. CECC • Qualification Approval, CECC 00 114:part II • Enhanced Assessment of Quality, CECC 00 114:part IV • Capability Approval, CECC 00 114:part III • Technology Approval, CECC 00 114:part VI • Process Approval, CECC 00 114:part V • Distributor Approval, CECC 00 114:part 1 • Test Laboratory Approval, CECC 00 114:part 1

47. NASA • The National Aeronautics and Space Administration, NASA, was formerly established in 1958, to plan and execute the US civil space programme. It comprises about a dozen major facilities, employing around 25,000 civil servants.

48. MAIN NASA SITES • Goddard Space Flight Centre (GSFC) • Jet Propulsion Laboratory (JPL) • Kennedy Space Centre (KSC) • Marshall Space Flight Centre (MSFC)

49. NHB 5300.4 • NASA programmes are controlled through a top level handbook, NHB 5300.4 • This document is imposed on all contractors. • It details the requirements for the control, selection, procurement, testing and application of all flight and mission essential EEE components. • The hand book is divided into two major sections, Programme Management and Component Requirements.

50. NHB 5300.4 (Cont.) • The Programme Management Section also identifies the requirements to provide data to NASA in electronic form. • The Component Requirements Section addresses the detailed topics directly related to components including, selection and specification, screening, parts lists, critical parts, derating, GIDEP, traceability, handling, packaging and storage, qualification and quality conformance tests, receiving inspection and manufacturer surveillance.