A Lifetime Consumption Model for Combined Creep and Fatigue Loading of Aluminum Bonding Wires

(1) Aluminum bonding wires are mostly used for electrical contact and transmission of electrical signals in power electronic modules. Combined cyclical mechanical and thermal loads acting on the wires can lead to premature failure of the whole module. For this purpose, based on extensive fatigue tests on a 300 µm Al-Pure wire, the authors developed, calibrated and applied a fatigue life model for a cycle range of R=0.1 to R=0.7 to other comparable aluminum wires in two previous publications. (2) Since the model is supposed to be used in an FEM post-processor for predicting the lifetime of wire bridges, the existing model was expanded in the following work. (3) Temperature dependence is included in the fatigue model, and it is made more robust in the whole possible R-range to be able to cope with the highly variable load cases in real components. In addition, a creep rupture model was developed and combined with the fatigue model by linear damage accumulation. (4) The applicability of the lifetime consumption model is demonstrated for several combined load cases. It is shown that it is necessary to consider both fatigue and creep in a combined model for a reliable lifetime prediction. Otherwise, the lifetime could be underestimated by several orders of magnitude, depending on the load case.