Reliability Screening Test for Metal Foil Resistors

A. Cyganowski[1], H. Leidecker[2], J. Brusse[2], L. Panashchenko[2], and T.E. Schmidt[3]
[1]Rensselaer Polytechnic Institute, Troy, NY, USA
[2]NASA Goddard Space Flight Center, Greenbelt, MD, USA
[3]St. Mary's College of Maryland, St. Mary's City, MD, USA

Metal foil resistors are often chosen for NASA space flight applications due to their high precision and stability. COMSOL Multiphysics is used to develop a test that screens out metal foil resistors containing gridline defects. The resistors will be subjected to repeated short duration electrical pulses that induce localized heating and fatigue only in areas with constrained gridlines. The pulse “on” time must be long enough to heat the defected region, yet short enough to protect the unaffected areas from stress. Meanwhile, the pulse “off” time must be long enough for the defected region to cool to near original temperature, so that the area experiences true cycling. COMSOL is used to determine the time required for adequate heating and cooling of the gridlines. COMSOL calculations will be compared with experimental data for model validation.