ML20236Q198

Littlefuse Type Flas-05 Fuses Predicted Svc Life

ML20236Q198
Person / Time
Site:	Sequoyah   (SME-MET-87-901)
Issue date:	09/28/1987
From:	TENNESSEE VALLEY AUTHORITY
To:
Shared Package
ML20236Q176	List: ML20236Q173 ML20236Q187 ML20236Q198 ML20236Q201
References
SME-MET-87-901, NUDOCS 8711190235
Download: ML20236Q198 (30)

Text

r TENNESSEE VALLEY AUTHORITY DIVISION OF NUCLEAR ENGINEERING NUCLEAR ENGINEERING BRANCH SINGLEION MATERIALS ENGINEERING LABORATORY Best Available Copy SEQUOYAH NUCLEAR PLANT LITTLEFUSE TYPE FLAS-05 FUSES PREDICIED SERVICE LIFE SME-MET-87-901 September 28, 1987 All work contained in this report'with the exception of data provided by Littlefune, Inc. was conducted under Singleton Materials Engineering Laboratory's QA program as described in the SME-QCP Manual.

-3 Prepared by Y. Mb5 i /

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Reviewed by O,C 6, [I ja vo Approved by Mad A27149 1 8711170235 B'/1117 DR ADOCK 050 7

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U MLE**UME ?YPE PLAT.Os; FUSE 9 PPC'MICTES ' SERVICE LTD'E Econa Best Available Copy The purpose of this investigation is to conduct a series of l

stress-rupture evaluations of Littlefuse type FLAS-05 fuses which will.

lead to a prediction of solder joint creep failure as a function of service temperature.

The principal te=perature range of. interest is 100 to 130 F.

A secondary objective of the evaluation is to conduct parallel tests of l

fuses rejected by a radiographic technique (fluoroscopy)'to determine the

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validity of this technique as a screening method.

i Inteduction Littlefuse FLAS-05 midget type indicating fuses, shown schematically in figure 1, are assembled with a spring to resistor solder joint designed to release following an open circuit in the shunt wire, 1

j Premature release of the solder joint without an open circuit (blown fuse) became an increasing problem with the initial assemb'ly involving a bismuth containing solder.

An evaluation by Littlefuse, Inc. suggested the solder l

joint was failing due to creep induced by the stress on the joint created by the spring force.

For improved joint inte6rity, the solder composition was changed from bismuth to a cadmium bearing solder (50 percent tin, S

1 32 percent lead, 18 gercent cadmium).

Asaneva[uationofthe'newsolder,f 3

Littlefuse conducted limited stress-rupture tests on the fuses at 78 F and 200 F to evaluate the creep life of the joint.

These tests, included in this report, indicate a significant temperature dependence of creep rate, as well na moderately uniform solder joints which will allow meaningful stress-rupture data to be obtained.- A continuation of this creep life or

-y t-

2 e

gest Available Copy stress-rupture evaluation was conducted at TVA's Singleton Materials Engineering Laboratory (SME) at te=peratures of 100, 120, and 143 F.

These data combined with results of Littlefuse, Inc. tests at 78 and 200 F, I

provide the predicted eervice life compiled in table 1 on the following page.

Average service life as given by this table is defined as the average i

tice to stress-rupture (creep failure) of a typical FLAS-05 spring-loaded 1

solder joint under a 1-lb epring load.

The minimu= service life predicted by this table is based on the earliest failure time of all FLAS-0$ fuse tests i

involved in this evaluation (83 separate tests).

The ternary cadmium-lead-tin alloy (50 percent tin, 32 percent lead, 18 percent cadmiu=) has a celting point of 145 5 0 (294 F), reported shear and tensile strengths of 9,600 pai and 14,900 pai, and a co= mon use in fusibility and safety devices.

Applications of this alloy under stressed conditions at te=peratures of 100 to 125 F should normally consider the time dependence of strain or creep.

This temperature range involves homologous temperatures, defined as the ratio of application

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te=perature to the celtira temperature en an absolute te=perature scale, of the range 0 74 to 0.78.

Such temperatures are considered high tc=peratures for any metal or alley.

Consequently, all metals and alloys including this alley would be expected to undergo a time-dependent increase in length (creep) under a constant load at eimilarly elevated temperatures.

As a rule, creep becomes %

t.

cf ' engineering significance at a homologous temperature

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greater than 0.5.

o.

Ernerirental 1

In order to make predictions on the service life of FLAS-05 fuses, stress-rupture tests were conducted at a series of temperatures of interest with the solder joint of the fuse stressed in a manner simulating

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LITTLEDUS? FLALoti TMBTCATING TUS?R PPentc?rn ErnvTcr LTeE Ben AvaHable Copy Service Average Pdn1 mum Temeeenture Servios Life #

Service Lire s e

• F mo mo 72 k21 131 l

74 379 118 76 341 106 78 307 95 80 276 B2 86 249 k

84 77 225

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86 70 203 BB 63 184 57 90 166 52 92 150

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96 42 1

123 38 f

98 112 100 35 102 i

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104 29 105 26 j

84 80 1

110 25 i

63 20 J

115 50 118 16 l

44 120 14 40 125 12 32 126 99 31 130 95 26 135 8.0 21 140 6.4 17 145 5.2 14 150 4.2 11 155 3.4 9.1 160 2.8 74 200 23 a

5,

17 05 1

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1. Values calculated from least aquares curve fit of f1 ure 9 6

, involving the equation in time (min) =

- 11 724.

• • Values calculated from lower bound curve given by:

In time (min) =

- 12.8939 A27271 2 l

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. spring loading.

Direct-loading through the spring at the higher stress levels necessary in conducting short term stress-rupture tests was not possible as the ultimate capacity of the spring is limited to just a few pounds.

In these tests, after the resistor and spring assembly had been removed from the body of the fuse, the fiber washer providing the reaction -

to the stretched spring was removed by saw cutting with a thin abrasive disc in a moto tool, and replaced by a slotted, hardened steel disc.

The slotted disc served to transfer the load suspended as a weight from the resistor to l

the spring at the resistor / spring solder joint.

A schematio of the loading technique is given in figure 1..

In this manner, loads up to the ultimate a

i capacity of the solder joint and/or resister could -be applied in order to obtain the range of stress-rupture data necessary for meaningful extrapolations.

The slotted dise was placed over a -hole in the arm of a load i

fra=e with the resistor, attaching chuck, and dead weight load suspended below. See figure 3 Multipleloadframesallowedaseriesofteststobe[

conducted simultaneously at temperatures of 100, 120, and 143*F.

Loads were selected to provide stress-rupture data approximately uniformly over over a minimum of three logarit!mio oyoles of time.

Constant temperatures were provided by laboratory evens and environmental chambers.

A more complete description of that test procedure is given in SME Procedure MET-11 3

.g Fuse Creep.

h Best Avail *N' W Renuits

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• Time to failure as a function of load placed on the solder joint is shown plotted in figures 4, 5, and 6 as typical log-log stress-rupture plots.

Figures 7 and 8 present data provided by Littlefuse, Inc. for similar tests conducted at 78 and 200 F prior to this evaluation.

At each b.

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5 temperature, the data is described by a linear relationship indicating no structural changes such as oxidation, recrystallization, grain Browth, etc. are taking place.

This is very important from the standpoint that such instabilities can create serious errors in extrapolation of the data to the stress-rupture time for the 1-lb spring force.

l Table 2 gives a summary of the resulting least squares linear curve fit for the five temperatures involved in the combined TVA and Littletuse, Inc tests.

These' data, involving principally slopes and 1

j intercepts, were obtained from graphs which were based upon the average I

logaritmic time at each load value.

This prevents multiple tests at a given load from excessively influencing the curve fit.

Consequently, table 2 foes I

not provide identical numbers as given by the plots given in figures 4 3

through 7.

Graphs and data based on the average time at each load are given in the appendix.

Linear in time versus in load relationships are described by the equation 1

in t = In ty + alope x in w Best Avaihble Copy or more aimply ta t w*

y 1

-2:

w

'g l

where t e

time for rupture at a given stress or7ead

=

ty time intercept at w a 1 load or weight on solder joint w a and x = slope of linear in t versus in W relationship.

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6 The extrapolated intercept t is the rupture time (creep failure) for a y

weight of 1-lb, i.e., the spring load in an assembled fuse, and consequently the predicted "servios life" of the fuse at each temperature investigated.

In order to incorporate ~the results of these extrapolations into a single expression, the logarithm of time to failure at a load of 1-lb was plotted. against the reciprocal of the absolute temperature.

It is empirically known, supported by various atomistic theories, that the temperature sensitivity or dependence of oreep can be expressed in this The resulting linear graph of figure 9 confir=s an Arrhenius rate canner.

relationship of the form Rate = 1/t = Ae-Q/RT where t = time to failure at a load of 1-lb Q s activation energy for orsep Best Av202ble Copy R = gas constant l

T = absolute temperature A a constant.

For the data involved in this investigation the predicted service life as a function of temperature for FLAS-05 ruses assembled with Sn-Pb-Cd solder can be expresged as

.T l

g Y.

l-In time (min) a A

7

- 11 724 p.

This equation was used to develop the average service life given in table 1.

t.

l

7 The predicted minimum service.lito of FLAS-05 fuses included in table 1 was determined from lower bound curves established for each constant temperature in t-versus in w plot.

A data point associated with the 143 F curve produced the greatest negative deviation from the lease squares curve fit, and thus provided the lower bound for all the tests conducted.- A line parallel to the linear curve describing the average service life was constructed to pass through the point defining the ' deviation.

j Hence all. data involved in this evaluation (83 tests) fall on or above this line.

The j

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equation of this lower bounding line is g

in time (min)

^

- 12.893 T

Stress-rupture tests conducted at 100 F on fuses rejected by fluoroscopy are shown as a composite plot in figure 10, which contains

" accept" as well as " reject" tests.

All the data given in this plot can be described by a single linear expression with a slope and intercept equivalent to that obtained for the " accepted" fuses only.

Compare figure 10 with figure 4.-

The two groups of fuses are not distin'guishable from each other on the basis of solder joint stress-rupture tests.

Mneussien It is recognized numerous factors such as solder joint length and

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1 quality, entrapped gas or voids in the solder jognt, and eccentricity of that resistor wire to the axis of the spring can affect the outcome of stress-rupture tests of the type described in the report.

LittlefuseJype FLAS-05 l

fuses are however assembled with the necessary uniformity to provide sufficiently consistent data required for constructing and interpreting stress-rupture plots.

1 8

Extrapolations over as many as 2-1/2 oyoles of time are involved in predicting fv ) creep failure times at the lower te=peratures involved in a

I this evaluation.

Consequently the slopes of'the log-log plots become very l

important and should be established over as great a range of load values as i

I time per=its.

Even though additional data may have some influence on each of the stress-rupture curves, the in t versus 1/T plot involving the combined data of TVA and Littlefuse shows an exceptionally good R-square correlation of 0 995 Further testing may serve to refine the data, but einical changes would be expected in the average servios life' values.

I A factor noted in the successful testing fuses by the method described involves supporting the spring at the solder joint uniformly on both sidee of the slotted washer to prevent bending.-

This was accomplished by orienting the slotted washer with the aid of a stereo:ioroscope.

When severe bendinE did occur, the data was rejected as nonrepresentative.

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e in tire vs in lond in tire correintion Tire Tire min min to 78 3 6663 16.5143 0 970 14.86 x 10 343 6

100 3.6479 15.1638 0 989 3 85 x 10 gg,3 6

120 2 7709 14.4434 0.999 1.87 x 10 a3,, g.

6 143 3 6212 13 1765 0 993 5 28 x 10 12.2 5

200 3.8524 11 3024 0 990 8.10 x 10 1.88 4

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SINGLETON MATERIALS ENGT'7EERING LABORATORY LTTTLEPUSE 1PLA%08; Tfm TCA?TNG FUEEE

'2//,6je Copy CREEP FATLUPE TP9T9 0F SPPIN0/DFMTRTOR SOL"ER JOTUT Fuse Lot / Batch / Type PLALou Tndicater Punes - Accented Test Temp 300 + ? F Oven / Environmental Chamber concrete enviren reer Balance 7hc2cc to a kr and b6?*66 above c kre Temperature Monitor.32652 start Test Start End Elapsed III Meicht No.

Veicht Weicht Date Time ETT ETI Tire com ents gm ib min 14 4A 1853 7 4.087 B-29-87 4:25 p 94,166 112,802 18,636

" pull out 15 4B 1845.6 4.069 B-29-87 4:25 p 92,726 108,196 15,470 pull out 3

5A 2572 7 5.678 9-5-87 2:50 p 00,000 7,534 7,534 pull out 4

SB 2597 3 5 726 9-5-87 2 51 p 00,000 97 7 h 5,862 pull out 2

BA 3594 7 923 9-7-87 7:23 p 00,000 6,491 6,491 pull out 15 BB 3B93 8 583 9-9-87 6:02 p 8,200 9,186 986 pull out 15 BB 3893 8.583 9-10-87 5:02 p 9,190 11,285 2,095 pull out 1

10A 4525 9.976 9-5-87 4:00 p 00,000 824 824 pull out i

10A 4525 9 976 9-7-87 11:32 a 1,300 2,382 1,082 pull out 1

12 5A 5683 12 53 9-B-B7 4:08 p 2,644 3,343 699 pull out i

12.5A 5683 12 53 9-9-87 3:56 p 3,607 3,927 320 pull out 1

15 5A 7070 15.59 9-9-87 B:23 a 3,344 3,452 specimen bending i

15.5A 7070 15 59 9-9-87 11:30 a 3.452 3,607 155 pull out 1

15.5A 7070 15 59 9-10-87 10:22 a 3,930 4,114 184 pull out i

19 8600 18.96 9-8-87 7:36 a 2,383 2,437 54 pull out i

19 8600 18 96 9-8-87 9:03 a 2,440 2,561 121 pull out 1

22 10,044 22.14 9-10-87 5:03 p 4,114 4,147 33 pull out 1

22 10,044 22.94-9-11-87 12:52 p 4.147 4,182 35 pull out Testsd by OM d

f.

Reviewed by Cw A. #-.

Aw/m

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A27271 3

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4 SINoteTON McTeovAte Egora,'erRTNG LAPORATOPY LT"TterUSE PLAS-Oc ??micATING FUSPA g

0FFrP FATtURE *ESTS Oe SPRING / PPSTATOP SOLSFR JOTUT i/

1. 0/e cO Py Fuse Lot / Batch / Type Puses Radected by Piueresnony Test Te=p

• 00 + ? F Oven / Environmental Chamber cenerete enviren reer Balance phooce te c ke end D62c6f ebeve c ke Te=perature Monitor E08652 Start Test Start End Elapsed C Veicht Mo, Weicht_ Waicht _Date Tire TTT ETI Tiro cortents gm ib min 1

8 5A 3893 8.583 9-24-87 4:34 p 6,700 7,991 1,291

' pull out 2

8.5B 3890 8 576 9-24-87 4:36 p 7,570 9,040 1,470 pull out 14 10A 4524 9 974 9-24-87 4:40 p 12,891 13,645 754 pull out 14 10A 4524 9 974 9-24-87 7:32 a 13,646 14,755 1,109 pull out 3

12.5A 5680 12.52 9-24-87 4:42 p 8,765 9,494 729 pull out 3

12.5A 5680 12.52 9-25-87 7:34 a 9,495 10,003 508 pull out 15 15 5A 7010 15.45 9-26-87 8:00 a 11,285 11,393 specimen bending 15 15.5A 7010 15.45 9-26-87 9:50 a 11,394 11,538 144 pull out 15 15.5A 7010 15.45 9-26-87 12:20 p 11,539 11,696 157 pull out 14 19 8600 18 96 9-26-87 8:45 a 14,755 14,046 91 pull out 14 19 8600 18.96 9-26-87 10:30 a 14,846 15,042 196 pull out 14 22 10,044 22.14 9L26-87 1:15 p 15,042 15,074 32 pull out 14 22 10,044 22.14 9-26-87 2:00 p 15,074 15,101 27 specimen bendir4 14 22 10,044 22.14 9 87 3: 10 p 15,101 15,117 16 resister tracture 14 22 10,044 22.14 9-26-87 3:30 p 15.117 15,152 35 pull out Tested by Md O i/

Reviewedby2:bA/+

ube/w

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A27271.4

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a ETM0f??ON MA'ITRT AY M ENCTNFERTMG LAPORATORY LT**L? FUSE PLALOM TNDICf"INC FUFPR CRPFP FATf.TfRP TESTS OF SMRTNU/ RPMISTOR SDLDER JOTNT 4/lJbfe gU P'

Fuse Lot / Batch / Type PLALos Indicator Punan - Accented Test Temp _--120 - ? F Oven /Envirer. mental Chamber Diue M h68cc8 -

Balance 2be?cc to a ke and h6?c66 above c ke Temperature P.onitor b?2100 Stant Test Start End Elapsed C Weirbt No.

Wafcht Weicht Dnte Time ETI ETT Time Oct-ents gm lb cin 12 3C

'1543 2 3.402 6-29-87 4:30 p 0',000 Fracture of re'aistor body.

13 3D 1543 6 3 403 8-29-87 4:30 p 94,172 105,B74 11,702 pull out-9 30 1543 2 3 402 9-9-87 6:08 p 1,917 25,898 23,981

. pull out 9

4 5A 2026.6 4.468 9-5-87 3:52 p 00,000 4,229 4,229 pull out 10 4.5B 2264.6 4 993 9-6-87 3: 52 p 00,000 1,012. Resistor wire break.

10 4.53 2264.6 4 993 9-9-87 6:06 p 1,207 13,846-12,639 pull out 1

7A 3189 7 031 9-13-87 9:23 a 4,184-5,445 1,261 pull out 2

TB 3183 7 017 9-13-87 9:23 a 6,492 7,710 1,218 pull out 3

10A 4562 9 978 9-13 87 3: 12 P 7,801 7,989 188 pull out 3

10A 4562 9 978 9-14-87 7:41 a 7,969 8,280 311 pull out 10 10A 4562 9 978 9-26-87 8:35 a 13,846 14,090 244 pull out 10 12 5B 5669 12 50 9-8-87. 2: 45 p 1,042 1,207 165 pull out 10 12 5A 5681 12 52 9-13-87 11: 30 a 7,599 7,699 100 pull out 3

12.5A 5681 12.52 9-13-87 1:00 p 7,682 7, 812 130 pull out 14 19A 8600 18 96 9-13-87 12:40 p 12,802 12,837 35 pull out 14 19A 8600 18 96 9-13-87 1:29 p 12,837 12,863 26 pull out 14 19A 8600 18.96 9-13-87 1:58 p 12,863 12,B91 28 pull out a

Tested by m) d >

0/b l

___ Reviewed by A M.

-l

/

A27271 5

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b

.I I

??MotNTOM MATERIALM ENrlTNrrPING LADOPATORY LITTLEensr rtance TMbici?TMc Ftists CREEP FAfttfRP TPRTS DF SPRTNU/ MESTSTOR 50tBEM JOINT dp.

gj C*py i

Fuse Lot / Batch / Type __FLA Log indienter Punes. Accented Test Temp itt + 2

• Oven / Environmental Chamber **010' i

Balance Pue?"* to c ke and M2M4 above c ke Temperature Monitor c222$4-

'.I stant Test Start End-Elapsed m vedeht No.

We4cht Weicht Bate Tha ETI

_ ETT-Time cements gm ib min 5

2.5B 1177 9 2 597 9-5-87 3:00 p 00,000 2,861

' severe bending 6

2.5A 1165.8 2.570 9-5-87 3:00 p 00,000 12,911 12,911 pull out.

8 2 5B 1177 9 2.597 9-9-87 5:55 p 26.1 h 478.1 h 27,120 pull out 7

3A 1508.2 3 325 9-5-87 3:00 p 00000.1 63 7'h 3,822 pull out 8

3B 1518.5 3 348 9-5-B7 3:00 p 00000.1 26.1 h severe bending 5

3A 1508.2 3 325 9-9-87 5:55 p 2.862 9,716 6,854 pull out 6

3B 1519 3 349 9-18-87 10:23 p 14,636 25,168 10,532 pull out 5

3A 1508 3 325 9-18-87 10:21 p 10,831 21,445 10,614 pull out 5

5A 2254 4 969 9-14-87 ~5:55 p 9,716 10,830 1,114 pull out 6

5B 2253 4 967 9-14-87 5:57 p 12,898 13,496 598 pull out 6

5B 2245 4.949 9-15-87 B:38 a 13,496 1_4,635 1,139 pull out 8

1 7A 3189 7 031 9-14-87 5:43 p 5,296 5,681 385. pull out 13 78 3183 7.017 9-14-87 5:46 5,365 Time failed to turn orr.

13 7A 3169 7 031 9-15-87 8:55 a 6,193 7,018 825 pull out i

7B 3183 7 017 9-15-87 8:55 a 5,681 6,195 514 pull out l

3 10A 4525 9 976 9-15-87 6:20 p 8,279 8,402 123 pull out 3

10A 4525 9 976 9-16-87 7:38 a 8,402 8,515 113 pull out 3

10A 4525 9 986 9-16-87 10:31 a 8.517-8,645 128 pull out 3

12 5A 5678 1

12.

3 12 5A 5678 12.p2 9-16-87,12:48 p 8,6 45 8,699 54 pull ont 52 -

9-16-87 2:03 p 8,700 8,765 65 pull out o

Tasted by d

l[

Reviewed by

/ >N 8, fu _

/

A27271.6 i

ST'tGLE*0N MArrPTArn rnmnfryNO LAPORA*01:Y LT*Tf'etfSM etAR 09 T@TCA?!NG Ft?Srs CF? FATLURE TESTS OF S2f!NG/ Prs"S?0F SOBEF J0TM-*

'st Waf Tuse Lot /Datch/ Type FLAS-09 Indientor Puses - Littlefuse. Inc. Data Cop f

y Test Temp _

"B ?

Oven / Environ:: ental Chacter Balance -

Temperature Monitor start Test.

Start End Elapsed M Wedeht No.

Feicht Woleht Date Time

???

ETT Tiro ce mm e n t.m gm lb ein 67 16.560 6.7 23,040 90 8,202 9.0 1,602 90 2.946 14.0 790 14.0 1,191 16.9 410 16 9 232 20 7 241 20 7 242 23 3 242 23 3 155 hb

.?

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A27271 7

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D STNOf MON MGTERTALS ENGTNEEPTNG LA90PRT g i

LTT?tP#t1SM PLALO9 TMMIOfTING PtfSES CPE" 'ATLt?RP ??S?S OF SPPTN0/ PESTSTOR 900ER JOTNT N

Csr

\\

Fuse Lot /Satch/ Type FfA L om Tmifentor Funen - Littletuse. Inc..rnta

1. 0/c p8 Test Temp 200 ?

Oven / Environmental Chamber

/9-Balance Temperature Honitor i

l l

_ _ _. Start Test Start End Elapsed E Weicht No_._ Weicht Weirbt Bate Tire E"T ETI _

Tire Oor~ents gm lb cin 3 19 842 3 19 1,290 l

4.19 l

4.19 306 l

333 6.0 6.0 54

{

75 1

l 95 l

18 9.5 95 13

\\

95 19 15 1

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A27271.8

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