Failure Analysis And Reliability Modeling For Electrical Connectors Under The Action Of Combined Environment Stresses

This dissertation analyzed the Y11X Series of Electrical Connectors' failure mode and mechanism under temperature and vibration stresses, then made Physics Models of Failure and Statistic.Firstly, summarize the history of Reliability Engineering, and introduce the Method of Reliability Test and Physics of Failure, then review Electrical Connectors' current reliability research and impending problems.Secondly, been generalized the failure data of Electrical Connectors from working and testing environment, electric contact failure, insulation failure, mechanical connection failure and other failure are four mainly failure modes of Connectors, moreover, built the Faulty-Tree to analyze their reliability level. However, contact fault failure was the most prevalent mode of electrical connectors. Under natural working and reserving conditions, the contact stress decreasing, fretting and surface film growing are mainly reasons to make electrical connector failure. While the main factor that affected them were environmental vibration and temperature. These could make foundation for failure mechanism analyzing.Thirdly, under temperature stress the connectors' failure mechanism is oxide film thickening, while through analyzing the structure and dynamic character of electrical connectors, the failure mechanism of electrical connectors is fretting under vibration stress. Combined these two stresses, their failure mechanism are fretting either, but the velocity of degeneration are accelerating, because temperature stress create more oxide production let connectors failure more easily. In a following part of dissertation we could make reliability model according to these analyzing.Fourthly, based on analyzing the failure mechanism of Electric Connectors, made the contact resistance model which indicate the relationship between the suffice oxide film and contact resistance, then built the Physics of Failure Models and Statistic Models. All of these models could help for planning accelerated life test and stat. failure data.Eventually, gave a conclusion to research content of entire dissertation, and proposed the research content of the reliability test and analysis of electrical connectors, and theresearch direction of this Foundation project.