Performing HALT in a nutshell (Highly Accelerated Life Test)

What is HALT - Highly Accelerated Life Test?

Highly accelerated life tests are proven methods developed by ESPEC to find design defects and weaknesses in electronic and electromechanical assemblies so that a more reliable product can be released to market in rapid order.

Specially engineered systems deliver temperature stresses, rapid thermal cycling, and random, tri-axial vibrations which rapidly reveal design weaknesses and product problems.

Stresses are delivered in an ordered sequence:

1. Thermal Step Stress
2. Cold Step Stress
3. Hot Step Stress
4. Rapid Thermal Transition Cycling
5. Vibration Step Stress
6. Combined Environment
7. Rapid Thermal Transition Cycling and Vibration Step Stress

At each level of applied stress, functional testing is performed on the product sample to evaluate its operation. When a failure occurs, the failure mode and stress level is recorded, the failure location is isolated, and the root cause of the failure is determined. A temporary fix is implemented and HALT testing is continued to uncover additional failures. As the failure modes are found and eliminated, limits are pushed further and further out, maximizing margins and increasing the product’s life and reliability.