LED Research Group


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Physics of Failure (PoF)

The failure mechanisms of LEDs are divided into three categories: the semiconductors, interconnects and the package. Semiconductor-related failure mechanisms include defect and dislocation generation and movement, die cracking, dopant diffusion and electromigration. Interconnect-related failure mechanisms are electrical overstress-induced bond wire fracture and wire ball bond fatigue, electrical contact metallurgical interdiffusion and electrostatic discharge. Package-related failure mechanisms include carbonization of the encapsulant, delamination, encapsulant yellowing, lens cracking, phosphor thermal quenching and solder joint fatigue. This section discusses the various failure mechanisms of LEDs.


Bases on research performed by CALCE, we lay the foundation for such an understanding. Following tables summarize the relationships between various failure sites and the associated causes, effects on devices, failure modes and failure mechanisms. However new research and field experience with LEDs is necessary to develop improved understanding to further update the inter-relationships.


Failure Site
Failure Cause
Effect on Device
Failure Mode
Failure Mechanism

 

 

 

 

 

 

 

 

 

 

Semiconductor (Die)

High Current - Induced Joule Heating
Thermomechanical Stress
Lumen Degradation, Increase in Reverse Leakage Current, increase in Parasitic Series Resistance
Defect and Dislocation Generation and Movement
High Current - Induced Joule Heating

 

 

 

Thermomechanical Stress

 

 

 

Lumen Degradation

 

 

 

Die Cracking

Ambient High Temperature
Poor Sawing and Grinding Process
Poor Fabrication of p-n Junction

 

 

 

Thermal Stress

 

 

 

Lumen Degradation, Increase in Series Resistance and/or Forward Current

 

 

 

Dopant Diffusion

High Current Induced Joule Heating

High Ambient Temperature

 

High Drive Current or High Current Density
Electrical Overstress
No Light, Short Circuit
Electromigration
Failure Site
Failure Cause
Effect on Device
Failure Mode
Failure Mechanism

 

 

 

 

 

 

 

 

 

 

 

 

Interconnects
(Bond Wire, Ball, and Attachment)

High Drive Current/
High Peak Transient Current

Electrical Overstress

No Light,
Open Circuit

Electrical Overstress-Induced Bond Wire Fracture

Thermal Cycling Induced Deformation

 

 

 

Thermomechanical Stress

 

 

 

 

No Light, Open Circuit

 

 

 

 

Wire Ball Bond Fatigue

 

Mismatch in Material Properties (e.g., CTEs, Young's Modulus)

Moisture Ingress

Hygro-mechanical Stress

High Drive Current or
High Pulsed / Transient Current

Electrical Overstress

 

 

Lumen Degradation,
Increase in Parasitic Series Resistance, Short Circuit

 

Electrical Contact Metallurgical Interdiffusion

High Temperature

Thermal Stress

Poor Material Properties (e.g., poor Thermal Conductivity of Substrate)

Thermal Resistance Increase

 

 

 

No Light, Open Circuit

 

 

 

Electrostatic Discharge

High Voltage (Reverse Biased Pulse)

Electrical Overstress

Failure Site
Failure Cause
Effect on Device
Failure Mode
Failure Mechanism

 

 

 

 

 

Package (Encapsulant, Lens, Lead Frame, and Case)

High Current - Induced Joule Heating

 

 

Electrical Overstress

 

Lumen Degradation

 

Carbonization of Encapsulant

High Ambient Temperature
Mismatch in Material Properties (CTEs and CMEs)

 

 

Thermomechanical Stress

 

 

 

Lumen Degradation

 

 

 

Delamination

Interface Contamination
Moisture Ingress
Hygro-Mechanical Stress

Prolonged Exposure to UV

Photodegradation
Lumen Degradation
Encapsulant Yellowing