Approved:

Date:

APOLLO GUIDANCE AND NAVIGATION PROGRAM

Approved:$&%&?&~'I'Y

-Date:* DIR

C OR (,

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INSTRUMENTATION LABORATORY
To be published in the IEEE Transactions

on Electronic Computers

E-1880

A CASE HISTORY OF

THE AGC INTEGRATED LOGIC CIRCUITS

Eldon C. Hall December 1965

COPY #

'33

0 '

ACKNOWLEDGEMENT

This report was prepared under DSR P r o j e c t 55- 238, sponsored bythe Manned Spacecraft Center of the National Aeronautics and Space Administration through Contract NAS 9-4065.

The publication of this repqrt does not constitute approval by the National Aeronautics and Space Administration of the findings or the conclusions contained therein. It is published only for the exchange and stimulation of ideas.

ii

E-1880
A CASE HISTORY OF THE AGC INTEGRATED LOGIC C I R C U I T

ABSTRACT
A case h i s t o r y o f t h e i n t e g r a t e d c i r c u i t u s e d f o r t h e

l o g i c i n t h e Apollo Guidance C i r c u i t i s g i v e n .

Achieving t h e

r e q u i r e d g o a l s of low w e i g h t , volume, and power c o u p l e d w i t h extreme high r e l i a b i l i t y n e c e s s i t a t e d t h e u s e of one s i n g l e , simple i n t e g r a t e d c i r c u i t f o r a l l l o g i c f u n c t i o n s .

A brief

d e s c r i p t i o n of t h e e v o l u t i o n o f t h e computer d e s i g n i s g i v e n a l o n g w i t h a g e n e r a l d i s c u s s i o n o f some o f the e n g i n e e r i n g and d e s i g n problems which arise w i t h t h e u s e of a s t a n d a r d i z e d semiconductor m o n o l i t h i c i n t e g r a t e d c i r c u i t .

The f l i g h t q u a l i f i c a t i o n p r o c e d u r e i s d e s c r i b e d .
A f t e r t h e q u a l i f i e d s u p p l i e r s l i s t h a s been formed, e a c h l o t s h i p p e d from any q u a l i f i e d s u p p l i e r i s exposed t o a s c r e e n and b u r n - i n p r o c e d u r e f o l l o w e d b y f a i l u r e a n a l y s i s o f generated f a i l u r e s .

The l o t i s a c c e p t e d or r e j e c t e d on t h e

b a s i s o f the number of f a i l u r e s g e n e r a t e d and t h e t y p e s o f f a i l u r e modes g e n e r a t e d .

The r e l i a b i l i t y h i s t o r y o f t h e NOR

Gate i s g i v e n showing d i f f e r e n c e s among v e n d o r s , showing d i f f e r e n c e s among l o t s s h i p p e d from a s i n g l e vendor , and updated f i e l d f a i l u r e r a t e s .

by Eldon C. H a l l December 1965

1.

TABLE OF CONTENTS

Section
I I1
INTRODUCTION ENGINEERING ASPECTS O F THE APOLLO COMPUTER RELIABILITY R E L I A B I L I T Y HISTQRY & DATA SUMMARY

Paqe

3
7

I11
IV V

20
28

32

2.

SECTION I INTRODUCTION

M i l i t a r y and s p a c e o b j e c t i v e s r e q u i r e t h e v e r y l a t e s t i n t e c h n o l o g i c a l development coupled w i t h r e l i a b i l i t y g o a l s t h a t require successful operation for several years. nology and h i g h r e l i a b i l i t y o b j e c t i v e s .
A

compromise m u s t o f t e n be made between t h e u s e o f new t e c h With j u d i c i o u s p l a n n i n g t h i s compromise c a n be i n s t i t u t e d e f f e c t i v e l y .

For example,

i n t e g r a t e d c i r c u i t s u s i n g p l a n a r t e c h n o l o g y have made new o b j e c t i v e s p o s s i b l e by r e d u c i n g t h e s i z e and w e i g h t o f a system w h i l e i n t r o d u c i n g an i m p o r t a n t f u t u r e r e l i a b i l i t y g a i n . The i n h e r e n t r e l i a b i l i t y g a i n s must be implemented i n t h e d e s i g n s t a g e s o f t h e computer. Guidance Computer. Hence t h e d e c i s i o n t o u s e one s i m p l e s i n g l e l o g i c element f o r t h e l o g i c i n t h e Apollo This r e s u l t e d i n h i g h volume procurement o f t h e i n t e g r a t e d c i r c u i t from m u l t i p l e s o u r c e s , so t h a t t h e needed h i g h r e l i a b i l i t y c o u l d be developed and proven w i t h i n a s h o r t p e r i o d of t i m e . The s t a n d a r d i z a t i o n approach, which i s p a r t i c u l a r l y a d a p t a b l e t o d i g i t a l computers, h a s been d e m o n s t r a t e d w i t h t h e P o l a r i s f l i g h t computer and extended w i t h i n t e g r a t e d c i r c u i t s t o t h e Apollo Guidance Computer. Both computers were d e s i g n e d t o u s e a t h r e e i n p u t NOR Gate a s t h e o n l y l o g i c e l e m e n t .
A l l l o g i c f u n c t i o n s a r e generated by i n t e r c o n n e c t i n g the t h r e e

i n p u t NOR Gate w i t h no a d d i t i o n a l l o g i c b l o c k s , r e s i s t o r s , or

it a p p e a r s t h a t u s i n g o n l y one t y p e o f l o g i c b l o c k g r e a t l y i n c r e a s e s t h e number of b l o c k s recapacitors.

A t f i r s t glance,

q u i r e d f o r ' t h e computer.

But, by j u d i c i o u s l y s e l e c t i n g and

o r g a n i z i n g t h e l o g i c f u n c t i o n s it i s q u i c k l y a p p a r e n t t h a t few a d d i t i o n a l blocks a r e necessary.

The few a d d i t i o n a l u n i t s

r e q u i r e d a r e g r e a t l y c o u n t e r b a l a n c e d by t h e i n c r e a s e d r e l i a b i l i t y g a i n d u r i n g b o t h t h e m a n u f a c t u r i n g o f components and f a b r i c a t i o n o f t h e components i n t o modules.

3.

The l o g i c element u t i l i z e d i n t h e A p o l l o Guidance

'

Computer i s t h e t h r e e i n p u t NOR Gate a s shown i n F i g . 1.

At

t h e t i m e t h a t t h e d e c i s i o n was made t o u s e i n t e g r a t e d c i r c u i t s , t h e NOR Gate, a s shown, was t h e o n l y d e v i c e a v a i l a b l e i n l a r g e quantities. The s i m p l i c i t y of t h e c i r c u i t allowed s e v e r a l manuBecause o f r e c e n t p r o c e s s development f a c t u r e r s t o p r o d u c e i n t e r c h a n g e a b l e d e v i c e s so t h a t r e a s o n a b l e c o m p e t i t i o n was a s s u r e d . i n i n t e g r a t e d c i r c u i t s , t h e NOR Gate h a s been a b l e t o remain c o m p e t i t i v e on t h s b a s i s of s p e e d , power and n o i s e immunity. T h i s c i r c u i t i s used a t 3 V and 15mw, b u t i s r a t e d a t 8 V and

1OOmw.
process.

Unpowered t e m p e r a t u r e r a t i n g i s 150C.

The b a s i c

s i m p l i c i t y o f t h e t h r e e i n p u t g a t e a i d s an e f f e c t i v e s c r e e n i n g
A l l t r a n s i s t o r s and r e s i s t o r s c a n be t e s t e d t o i n s u r e

product uniformity.

The s i m p l i c i t y o f t h e c i r c u i t a l s o a i d s i n

t h e q u i c k d e t e c t i o n and d i a g n o s i n g of i n s i d i o u s f a i l u r e s w i t h o u t e x t e n s i v e p r o b i n g a s r e q u i r e d w i t h more c o m p l i c a t e d c i r c u i t s . One a d d i t i o n a l i n t e g r a t e d c i r c u i t u s e d i n t h e A p o l l o Guidance Computer i s t h e memory s e n s e a m p l i f i e r . Fig.

2,

A s seen i n

t h e c i r c u i t i s c o n s i d e r a b l y more complex t h a n t h e The e x p e r i e n c e w i t h t h i s more c o m p l i c a t e d c i r c u i t However, s i n c e it

NOR Gate.

h a s b e e n comparable w i t h t h e l o g i c g a t e .

i s a l o w u s a g e i t e m t h e r e i s a v a i l a b l e less i n f o r m a t i o n of
h i s t o r i c i n t e r e s t , t h a t i s , r e l i a b i l i t y information such a s f a i l u r e rates and modes of f a i l u r e s . r e l a t e s t o h i s t o r y of t h e l o g i c g a t e . The b a l a n c e of t h i s r e p o r t

'\

4.

r
I 1
I

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I-

I I I I 1 I I
I

I I I I

f 0

1 I

I I I I I 1

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+ m-

I I

I I

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I

I I I

I I I

I I II

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A """ "

5.

SENSE AMPLIFIER C I R C U I T
+ 14 VOLTS

SENSE LINE INPUT

I I

II
REFERENCE VOLTAGE Vz

I I

I h I
I

OUTPUT

I
I

I
1

INTEGRATED CIRCUIT

SECTION I1
E N G I N E E R I N G ASPECTS O F THE APOLLO COMPUTER

F i g u r e 3 p i c t u r e s t h e Block I1 A p o l l o Guidance Computer. T h i s v e r s i o n d i f f e r s from t h e Block I Computer i n t h a t t h e memory, i n s t r u c t i o n and i n p u t o u t p u t was i n c r e a s e d .

t h e s i n g l e g a t e i n a TO-47 used i n Block I .

The Block I1

Computer a l s o u s e s a d u a l g a t e i n a f l a t package r a t h e r t h a n F i g u r e s 4 and 5 i l l u s t r a t e t h e packaging t e c h n i q u e s used i n t h e Block I1 computer. The Block I1 l o g i c s t i c k s a r e made u s i n g t h e f l a t package welded t o m u l t i l a y e r i n t e r c o n n e c t i o n b o a r d s . machine w i r e wrap t e c h n i q u e a s shown i n F i g . 6 . i n t e r f a c e w i t h t h e computer.

The

modules a r e i n t e r c o n n e c t e d u s i n g a t r a y which i s w i r e d by

T o identical w

D i s p l a y and keyboards a s shown i n F i g . 7 p r o v i d e t h e man machine T a b l e I i s a g e n e r a l summary o f

t h e Block I1 computer c h a r a c t e r i s t i c s .

S i n c e t h e l o g i c d e s i g n o f t h e computer was r e s t r i c t e d t o a s i n g l e t y p e o f g a t e , a method t o p r o v i d e f a n - i n and f a n - o u t expansion w a s p r o v i d e d a s shown i n F i g . 8 . A l s o , methods t h a t

w e r e used t o p r o v i d e i n t e r c o n n e c t i o n s between l o g i c and memory

c i r c u i t s and c o n n e c t i o n s t o o u t s i d e world a r e shown i n F i g . 9.
A l l h i g h f r e q u e n c y i n f o r m a t i o n t r a n s f e r between t h e computer

and p e r i f e r a l equipment i s accomplished w i t h t r a n s f o r m e r coupled c i r c u i t s a s shown i n t h e t o p view.

DC l e v e l t y p e s i g n a l s .

The second row i s t h e t y p e

o f c i r c u i t used i n t h e memory i n t e r f a c e s and f o r l o w f r e q u e n c y

The r e c e i v e r i s shown on t h e r i g h t .

The bottom r o w p r o v i d e s l o w f r e q u e n c y DC l e v e l i n p u t s .

I n t e r e s t i n g and s u b t l e problems a r i s e w i t h t h e u s e o f integrated circuits. To i l l u s t r a t e , F i g . 10 ( a ) d e p i c t s a v e r y d e s i r a b l e c i r c u i t t h a t can be used t o d r i v e l o n g cables f o r ground t e s t equipment while r e q u i r i n g no power d r a i n from t h e a i r b o r n e equipment. F i g u r e 1 0 (b) shows t h e same c i r c u i t When p o i n t ( x ) r i s e s above b u t i n c l u d e s some o f t h e p a r a s i t i c d i o d e s n o t u s u a l l y represented i n t h e integrated c i r c u i t .
2 v o l t s , d i o d e c a p a c i t o r coupling o c c u r s t h r o u g h t h e r e s i s t o r s u b s t r a t e which a c t i v a t e s t h e unused t r a n s i s t o r s . T h i s c o u p l i n g 7.

Figure 3

MODULE MOUNTING FRAME AND MULTILAYER BOARD WITH MICROLOGIC ASSEMBLED f PRIOR TO FINAL WELDING 1

Figure 4

10

1 1

Figure 7

12

AGC CHARACTER I ST1CS

Word Length Number System Memory Cycle Time Fixed Memory Registers Erasable Memory Register Number of Normal Instructions ( I nterrupt, I ncrement, etc. 1 Interrupt Options Addition Time Multiplication Time Double Precision Addition Time Double Precision Multiplication Subroutine Ti me increment Time Number of Counters Power Consumption Weight
Size

15 Bits + 1 Parity One's Complement 11.7 4 sec

36,864 Words 2,048 Words

10 10 23.4 ,dec 46.8 b s e c 35.1 p s e c 575 p s e c

11.7 p sec 29

100 Watts (AGC + DSKY's) 58 Pounds (Computer Only) 1.0 Cubic Foot (Computer Only)

Table I.

LOGIC DESIGN

SYMBOL FOP POWER NOT CONNECTED

0 0
0

>
0

OUTPUT

0 0

H I G H FAN OUT GATE

H I G H FAN I N GATE
Figure 8

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d-

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I3

c =>

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v v
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QL

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V
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QL

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16.

i s a feedback p a t h which slows up t h e p u l s e r i s e times.

The

r i s e time w i l l be a f u n c t i o n o f t h e g a i n o f t h e unused t r a n s i s t o r
and a l s o a f u n c t i o n o f r e p e t i t i o n r a t e o f t h e d r i v e which t e n d s t o t u r n t h e t r a n s i s t o r s o f f a t high r e p e t i t i o n rates. t h e feedback t h u s s p e e d i n g up t h e p u l s e r e s p o n s e . logic c i r c u i t s using integrated c i r c u i t s . Connecting a l l unused i n p u t s t o t h e emitter (OV) w i l l p r e v e n t o r minimize Another i n t e r e s t i n g and much d i s c u s s e d problem i s t h a t o f n o i s e i n
I t i s w e l l known

t h a t a l l d i g i t a l computers h a v e n o i s e problems and t h e r e a r e

w e l l known d e s i g n t e c h n i q u e s which when p r o p e r l y a p p l i e d w i l l

minimize these problems. I n t h e e l e c t r i c a l design a s w e l l a s t h e mechanical d e s i g n there a r e t r a d e o f f s t h a t must be made

i n o r d e r t o meet a l l o f t h e ground r u l e s p l a c e d on t h e computer d e s i g n e r . Noise i s one of t h e major c o n s t r a i n t s t h a t must be

considered during the design. One m u s t c o n s i d e r b o t h s e l f Although t h e c a u s e i s induced and e x t e r n a l l y induced n o i s e . can be i l l u s t r a t e d by F i g . 11.

d i f f e r e n t f o r b o t h t y p e s , t h e e f f e c t i s u s u a l l y t h e same and From t h i s f i g u r e i t i s s e e n

h o w s w i t c h i n g c u r r e n t s i n t h e c i r c u i t ground p l a n e can c a u s e
v o l t a g e t r a n s i e n t s t h a t w i l l e r r o n e o u s l y switch t h e t r a n s i s t o r s shown. o u t s i d e e i t h e r b y conducted o r r a d i a t e d i n t e r f e r e n c e .

These ground c u r r e n t s c a n a l s o be induced from t h e To 1.

S e l e c t c i r c u i t s t h a t h a v e maximum immunity: t h e r e i s a b o u t a f a c t o r of 2 r e a l i z a b l e between
t h e w o r s t and best i n t e g r a t e d c i r c u i t s .

maximize t h e immunity o f t h e computer t h e d e s i g n e r s h o u l d ,

2.
3.

P r o v i d e good ground p l a n e s and s i g n a l p a t h s . P r o v i d e proper s h i e l d i n g , grounding and f i l t e r i n g o f t h e computer, and a l l i n t e r f a c e wires.

Obviously one must compromise here a l s o , o t h e r w i s e t h e p r o t e c t i o n a s w e l l as t h e magnitude of t h e n o i s e would c o n t i n u e

to esculate.
availability.

I n t h e c h o i c e o f t h e NOR Gate, t h e Apollo Computer T e s t i n g o f t h e f i n i s h e d computer h a s shown t h a t

may h a v e s a c r i f i c e d some n o i s e immunity f o r s i m p l i c i t y and

i t s s u s c e p t i b i l i t y i s much lower t h a n t h e limits s p e c i f i e d i n

MIL-1-26600 which is t h e s p e c i f i c a t i o n f o r e l e c t r o m a g n e t i c compatibility. I n f a c t , i n o r d e r t o l o c a t e a r e a s o f weakness,

17.

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\ \

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18

s p a r k d i s c h a r g e s h a v e been used d u r i n g t e s t i n g . enough t o induce computer f a i l u r e .

The normal

r a d i a t i o n s u s c e p t i b i l i t y t e s t s do n o t g e n e r a t e l e v e l s h i g h I n f a c t , MIL-1-26600
For

i s weak i n o t h e r a r e a s when a p p l i e d t o d i g i t a l computers.

example, a power t r a n s i e n t between a power i n p u t l i n e and case

i s n o t o r i o u s f o r i n d u c i n g t r o u b l e s and l o c a t i n g areas of weakn e s s , a l t h o u g h t h i s t e s t i s n o t a r e q u i r e m e n t of t h e MIL s p e c .

The Apollo computer h a s been s u b j e c t e d t o and p a s s e d t h e s e

more s t r i n g e n t t e s t s .

19.

SECTION I11

RELIABILITY

Because o f t h e h i g h r e l i a b i l i t y a p p l i c a t i o n o f t h e A p o l l o Guidance Computer, t h e r e l i a b i l i t y a s s u r a n c e of t h e i n t e g r a t e d c i r c u i t s w i l l be d i s c u s s e d . been p r e v i o u s l y r e p o r t e d i n detail, here.

I t became immediately o b v i o u s t h a t small- sample

The p r o c e d u r e s have

b u t w i l l be summarized

stress t e s t i n g c o u l d n o t g u a r a n t e e t h a t e a c h p u r c h a s e d l o t

would meet t h e A p o l l o i n t e g r a t e d c i r c u i t f a i l u r e r a t e r e q u i r e ments. The MIL-S-19500D s t a t i s t i c a l sampling p r o c e d u r e was b o t h F u r t h e r m o r e , a s l o n g as a l l n o t a p p l i c a b l e nor p r a c t i c a l .

f a i l u r e modes w e r e n o t c o m p l e t e l y s c r e e n a b l e , one- hundred p e r c e n t s c r e e n i n g a l o n e was n o t s u f f i c i e n t t o a t t a i n t h e required high r e l i a b i l i t y goals.

A s t u d y of

t h e various

f a i l u r e modes o f i n t e g r a t e d c i r c u i t s c r e a t e d t h e dilemma whereby some of t h e f a i l u r e modes were e a s i l y s c r e e n e d by s t a n d a r d s c r e e n i n g t e c h n i q u e s and o t h e r s o n l y o c c a s i o n a l l y detected.

N o a s s u r a n c e c o u l d be made w i t h any r e a s o n a b l e
T o overcome t h i s problem,

confidence t h a t t h e d e v i c e s w i t h t h e s e troublesome d e f e c t s had been removed from t h e l o t . l o t a c c e p t a n c e c r i t e r i a w e r e e s t a b l i s h e d which would i d e n t i f y w i t h h i g h c o n f i d e n c e t h o s e l o t s i n which i n s i d i o u s

f a i l u r e modes were n o t p r e v a l e n t and s c r e e n i n g had been

adequate. P r o v i d i n g a n e f f e c t i v e f a i l u r e mode d e t e c t i o n s y s t e m , t h e p r o c e d u r e f o r l o t a c c e p t a n c e i s b a s e d o n onehundred p e r c e n t n o n d e s t r u c t i v e t e s t s and sample d e s t r u c t i v e testing.
A l l t h e f a i l u r e s g e n e r a t e d from t h e t e s t i n g are

completely analyzed.

The f a i l u r e s a r e t h e n c l a s s i f i e d by
It must

g r o u p s and compared t o t h e a c c e p t a n c e c r i t e r i a .

be emphasized t h a t t h e l o t i s a c c e p t e d o r r e j e c t e d n o t

o n l y b e c a u s e o f t h e number o f f a i l u r e s b u t a l s o on whether

t h e f a i l u r e modes g e n e r a t e d were n o n s c r e e n a b l e o r i n s i d i o u s
and l o n g t i m e d e p e n d e n t .

20.

FI
i

The Apollo Guidance and N a v i g a t i o n S p e c i f i c a t i o n ,

ND 1002248, i s t h e c e n t r a l document on which e a c h p r o c u r e d

l o t q u a l i f i c a t i o n is based. qualified parts. d e t a i l s of:

1.

T h i s document s p e c i f i e s t h e

procedures required f o r l o t acceptance r e s u l t i n g i n f l i g h t

I n p a r t i c u l a r , ND 1002248, s p e c i f i e s t h e

The o p e r a t i o n a l and e n v i r o n m e n t a l s t r e s s t e s t p r o c e d u r e s and sequence commonly r e f e r r e d t o a s t h e s c r e e n and b u r n - i n p r o c e d u r e .

The s c r e e n

and burn- in p r o c e d u r e was d e s i g n e d t o d e t e c t f a i l u r e modes which c o u l d o c c u r d u r i n g t h e normal

stress and e n v i r o n m e n t a l a p p l i c a t i o n o f t h e
device.
2.

The e l e c t r i c a l p a r a m e t e r t e s t s t o be performed d u r i n g t h e screen and b u r n - i n p r o c e d u r e . e n g i n e e r i n g e v a l u a t i o n and were chosen t o d e t e c t f a i l u r e s and a s s u r e p r o p e r computer operation.

The

t e s t s a s d e f i n e d were determined d u r i n g t h e

3.

D e f i n i t i o n s of f a i l u r e s .

F a i l u r e s have been

d e f i n e d a s c a t a s t r o p h i c , s e v e r a l c a t e g o r i e s of n o n - c a t a s t r o p h i c , induced, and i n s p e c t i o n f a i l u r e s . 4. A l l o c a t i o n of f a i l u r e s . The c o n d i t i o n s a r e d e f i n e d f o r removal from t h e screen and b u r n - i n p r o c e d u r e of f a i l u r e s which a r e t o be forwarded t o f a i l u r e analysis.
5. Classes o f f a i l u r e modes.

F a i l u r e modes a r e

c l a s s i f i e d a c c o r d i n g t o s c r e e n a b i l i t y and detectability.
6.

Maximum a c c e p t a b l e number of f a i l u r e s p e r c l a s s o f f a i l u r e mode f o r a l l 100% e l e c t r i c a l parameter

test s t a t i o n s .
7.

Maximum a c c e p t a b l e number o f f a i l u r e s f o r none l e c t r i c a l t e s t s and a l l sample e l e c t r i c a l para-

meter t e s t s .

21.

8.

The r e p o r t r e q u i r e d f o r each f l i g h t q u a l i f i e d l o t . The r e p o r t m u s t c o n t a i n t h e complete h i s t o r y of t h e l o t w i t h t h e s p e c i f i c d a t a and a n a l y s i s r e q u i r e d or f l i g h t qualification.

9.

Data and f a i l e d p a r t s s t o r a g e .

In order t o assure

t r a c e a b i l i t y and f u t u r e a n a l y s i s s h o u l d f i e l d f a i l u r e s o c c u r , t h e c o n d i t i o n s o f d a t a and f a i l e d p a r t s storage a r e given. 10. C o n t r a c t u a l r e q u i r e m e n t s t o implement l o t q u a l i f ication.

To a s s i s t t h e u n d e r s t a n d i n g o f t h e l o t a c c e p t a n c e pro-

c e d u r e s , a g e n e r a l d i s c u s s i o n of t h e semiconductor p a r t vendor s e l e c t i o n and f l i g h t q u a l i f i c a t i o n p r o c e d u r e s w i l l b e g i v e n a s performed f o r t h e A p o l l o Guidance and N a v i g a t i o n Computer. The p r o c e s s b e g i n s w i t h an a s s e s s m e n t o f t h e v e n d o r ' s a b i l i t y t o s u p p l y d e v i c e s , t h e i n s t i t u t i o n of component s t a n d a r d i z a t i o n i n d e s i g n s , and t h e p r e l i m i n a r y s t u d y o f
device f a i l u r e m c d e s .
A b l o c k diagram of t h i s p r e l i m i n a r y

e v a l u a t i o n which p r e c l u d e s any p r o d u c t i o n procurement is given i n Fig. 1 2 .

The q u a l i f i c a t i o n p r o c u r e m e n t s which

s u p p l y p a r t s f o r t h e q u a l i f i c a t i o n t e s t i n g and e n g i n e e r i n g evaluations established t h e manufacturer's device processing. One of t h e i n d i r e c t r e s u l t s of t h e i n i t i a l procurements i s t h e e a r l y d e t e c t i o n o f new f a i l u r e modes. who i n t u r n a t t e m p t s c o r r e c t i v e a c t i o n . The c o n c l u s i o n s This c y c l i c procedure of t h e f a i l u r e a n a l y s e s a r e t h e n f e d back t o t h e m a n u f a c t u r e r
i s c o n t i n u e d u n t i l t h e most o b v i o u s problems have been e l i m i n a t e d

A d d i t i o n a l l y , t h e e a r l y d e t e c t e d f a i l u r e modes coupled w i t h p a s t e x p e r i e n c e a r e u t i l i z e d t o d e s i g n the q u a l i f i c a t i o n t e s t i n g . The f o r m a l i z e d q u a l i f i c a t i o n t e s t i n g b e g i n s when t h e v e n d o r s h a v e s u p p l i e d d e v i c e s r e p r e s e n t a t i v e of t h e i r f i n a l i z e d manufacturing process.

It is extremely important t h a t a l l

q u a l i f i c a t i o n and e n g i n e e r i n g t e s t i n g be performed on d e v i c e s f a b r i c a t e d from t h e i d e n t i c a l p r o c e s s used t o s u p p l y computer production devices. The q u a l i f i c a t i o n t e s t s s u b j e c t t h e

22.

23.

d e v i c e s from v a r i o u s v e n d o r s t o t h e extremes of and, t o a l i m i t e d e x t e n t , beyond usage c o n d i t i o n s i n an a t t e m p t t o d e t e c t f a i l u r e modes which c o u l d occur i n normal a p p l i c a t i o n s .

The e n g i n e e r i n g e v a l u a t i o n s a r e performed s i m u l t a n e o u s l y
w i t h t h e q u a l i f i c a t i o n procedures t o determine d e v i c e speed,
f a n o u t c a p a b i l i t y , n o i s e immunity, and o p e r a t i n g t e m p e r a t u r e range. From t h i s e v a l u a t i o n , t h e optimum computer d e s i g n i s
I t i s a t t h i s t i m e t h a t t e s t s a r e conducted t o

developed.

d e t e r m i n e t h e e l e c t r i c a l p a r a m e t e r s which w i l l i n s u r e p r o p e r d e v i c e o p e r a t i o n i n e v e r y u s a g e mode and t o e s t a b l i s h t h e l o g i c a l d e s i g n r u l e s f o r t h e computer. The q u a l i f i c a t i o n and e n g i n e e r i n g e v a l u a t i o n s d e t e r m i n e t h o s e v e n d o r s who a r e c a p a b l e o f s u p p l y i n g t h e semiconductor p a r t and who do n o t e x h i b i t any g r o s s r e l i a b i l i t y problems. The q u a l i f i c a t i o n t e s t s a l o n e a r e i n s u f f i c i e n t t o d e t e r m i n e t h e a b i l i t y o f a vendor t o c o n t r o l h i s p r o c e s s , b u t l a r g e volume p r o d u c t i o n . p r o c u r e m e n t d a t a f e d b a c k from s c r e e n and b u r n - i n s u p p l i e s e x t e n s i v e vendor h i s t o r y . U t i l i z i n g the data generated during the engineering e v a l u a t i o n s and q u a l i f i c a t i o n t e s t s , t h e s p e c i f i c a t i o n c o n t r o l document (SCD) i s p r e p a r e d . production p a r t s are bought.

The SCD i s t h e document t o which

Based on t h e q u a l i f i c a t i o n by

v e n d o r s , t h e q u a l i f i e d s u p p l i e r s l i s t (QSL) i s formed which s p e c i f i e s t h e v e n d o r s from whom t h e p r o d u c t i o n p a r t s s h a l l

be p r o c u r e d .

Once t h e SCD and QSL h a v e b e e n released, p r o d u c t i o n procurement may b e g i n . Figure 1 3 p i c t u r e s the g e n e r a l flow
The

o f p a r t s and d a t a a s r e q u i r e d f o r f l i g h t q u a l i f i c a t i o n .

d e v i c e s p r o c u r e d by l o t s p r o c e e d t h r o u g h t h e screen and burn-

i n (S&BI) t e s t sequence.
Upon c m p l e t i o n o f s c r e e n and b u r n - i n , t h e l o t i s s t o r e d

u n t i l f a i l u r e a n a l y s i s i s completed.

A l l f a i l e d u n i t s are

c a t a l o g u e d , a n a l y z e d , and c l a s s i f i e d t o c o m p l e t e the l o t

assessment, f o l l o w e d by a w r i t t e n r e p o r t . I f t h e l o t p a s s e d , a l l t h e d e v i c e s t h a t p a s s e d a l l t e s t s c a n be i d e n t i f i e d a s a f l i g h t q u a l i f i e d p a r t w i t h a new p a r t number and

24.

[":

25

s e n t f o r production usage.

Only t h e semiconductor p a r t w i t h From f a i l u r e a n a l y s i s , r e j e c t e d I n the event t h a t t h e l o t

t h e f l i g h t q u a l i f i c a t i o n p a r t number c a n be used i n f l i g h t q u a l i f i e d computer a s s e m b l i e s . f o r future study i f required. p a r t s proceed t o r e j e c t s t o r a g e where t h e y w i l l be a v a i l a b l e f a i l e d b e c a u s e of c i r c u m s t a n c e s n o t c o m p l e t e l y d e f i n e d t h r o u g h f a i l u r e c l a s s i f i c a t i o n , t h e l o t c a n be f l i g h t q u a l i f i e d by waiver.

The w a i v e r must be a u t h o r i z e d by NASA and w i l l

accompany t h e computer.

I n c e r t a i n l i m i t e d c a s e s , p a r t s from

a f a i l e d l o t may be r e s u b m i t t e d f o r r e s c r e e n i n g .
The accumulated d a t a from t h e s c r e e n and b u r n - i n proc e d u r e ( F i g . 1 4 ) and f a i l u r e a n a l y s i s a r e u t i l i z e d t o f u r t h e r e v a l u a t e t h e vendor p r o d u c t i o n c a p a b i l i t y and h i s d e v i c e q u a l i t y and r e l i a b i l i t y .
T h i s i n turn a f f e c t s a vendor's

c o n t i n u e d s t a t u s as a q u a l i f i e d s u p p l i e r .

26.

S & 81 SEQUENCE
Failures Removed failures to Analysis

Visual I nsQection ( 1001)

i
1

{
I
I

lStElectrical Test

1
1
I

(Sample1
L

Thermal Cycle

Centrifuge Failures to Analysis

m

Znd Electrical Test

1
I

r w r a t i n q Life 168 hrs Failures to Analysis

jrd Electrical

Test

f
Figure 1 4

T Lot Storage o

SECTION I V
RELIABILITY HISTORY AND DATA

The r e l i a b i l i t y h i s t o r y of t h e NOR Gate w i l l e x e m p l i f y

some of t h e d i f f i c u l t i e s e n c o u n t e r e d and s u c c e s s e s a c h i e v e d i n
b u i l d i n g a d i g i t a l computer u t i l i z i n g i n t e g r a t e d c i r c u i t s . T a b l e I1 i s a summary of t h e r e l i a b i l i t y d a t a f o r t h e
NOR Gate accumulated up t o October 1964. 2

This d a t a h a s b e e n The e l e c t r i c a l

previously discussed i n d e t a i l

b u t i s p r e s e n t e d h e r e t o show

t h e extreme d i f f e r e n c e s among m a n u f a c t u r e r s .

f a i l u r e d e f i n i t i o n s d u r i n g s c r e e n and b u r n - i n were any ino p e r a b l e d e v i c e s or any d e v i c e e x c e e d i n g t h e e l e c t r i c a l specifications. The p e r c e n t a g e s i n c l u d e a p p r o x i m a t e l y 0.05 t o 0.1% combined induced f a i l u r e s and t e s t i n g e r r o r s . where t h e f a i l u r e d e f i n i t i o n was a n i n o p e r a b l e d e v i c e .

The

i n i t i a l q u a l i f i c a t i o n r e s u l t s a r e a l s o i n c l u d e d i n Table I1

The extreme d i f f e r e n c e s among t h e m a n u f a c t u r e r s i s a l s o r e f l e c t e d i n t h e f a i l u r e modes g e n e r a t e d d u r i n g b o t h t h e i n i t i a l q u a l i f i c a t i o n and s c r e e n and b u r n - i n . For t h e d a t a i n T a b l e I1 M a n u f a c t u r e r A r a r e l y e x h i b i t e d t h e n o n s c r e e n a b l e , and/or long- time dependent f a i l u r e modes while both M a n u f a c t u r e r s B and C c o n s i s t e n t l y d i d . The i n o p e r a b l e f a i l u r e s g e n e r a t e d
a t computer u s e c o n d i t i o n s f o r M a n u f a c t u r e r s B and C were o f t h e n o n s c r e e n a b l e , long- time dependent f a i l u r e modes.
I t i s i n t e r e s t i n g t o n o t e t h a t t h e same d e v i c e s used t o

g e n e r a t e t h e d a t a of Vendor A of Table I1 h a v e s i n c e e x h i b i t e d a 3 f i e l d f a i l u r e r a t e o f 0.0015YdlO h o u r s a t 90% c o n f i d e n c e a s of

The same d e v i c e s o f Vendors B and C h a v e n o t improved t h e i r f a i l u r e

r a t e s because a d d i t i o n a l f a i l u r e s have occurred. The more s u b t l e d i f f e r e n c e s i n q u a l i t y and r e l i a b i l i t y may be o b s e r v e d i n v a r i a t i o n s of l o t s s h i p p e d from one manufacturer.

30 September 1965 w i t h one o p e r a t i o n a l f a i l u r e .

The d a t a of F i g . 1 5 i n d i c a t e s the n u m e r i c a l v a r i a t i o n s

28.

OCT 64 SCREEN & BURN-IN % FAILURES TOTAL FAILURE RATES AT USE CONDITIONS 90% CONFIDENCE 2nd & 3rd iLECTRlCA~

P R E QUALIFICATION dENDOR % FAILURES

5
26

1.8
3.8

0.3
1.7

0.005%/lo3 hrs (0 FAILURES)

B
C

0.3%/103 (2 FAILURES) hrs

1.8% lo3hrs (26 FAILURES) /

58

5.0

2.5

SEPT 65 : VENDOR A 0.O015%/lO3 (1 FAILURE) VENDOR 8 & C- N O IMPROVEMENT

Table 11.

*l
-3

(0

CD

cu
0

30

f o r t h e NOR Gate from o n e q u a l i f i e d m a n u f a c t u r e r . t e s t i n g e r r o r s have been e l i m i n a t e d from t h e d a t a . shown i n F i g . 1 4 . Each p o i n t i n F i g .

Here, o n l y These

t h e i n o p e r a b l e f a i l u r e s a r e p l o t t e d and induced f a i l u r e s and

NOR Gates were exposed t o t h e s c r e e n and b u r n - i n p r o c e d u r e a s

1 5 r e p r e s e n t s a shipment

l o t of 2000 t o 5000 NOR G a t e s .

F i g u r e 15 ( a ) shows t h e p e r -

c e n t c a t a s t r o p h i c f a i l u r e s a t t h e incoming e l e c t r i c a l t e s t s . F i g u r e 1 5 (b) shows t h e p e r c e n t c a t a s t r o p h i c f a i l u r e s which

were g e n e r a t e d a f t e r s t r e s s i n g w i t h incoming c a t a s t r o p h i c
f a i l u r e s removed. There a r e fewer p o i n t s p l o t t e d i n F i g . 1 5
There was
(b) t h a n i n F i g . 15 ( a ) , since some l o t s n o t used f o r f l i g h t

hardware w e r e n o t exposed t o s c r e e n and b u r n - i n .

no buying o f t h e t h r e e i n p u t NOR Gate between June and October 1964, so t h a t t h e l i n e p r o d u c i n g t h e i n t e g r a t e d c i r c u i t was temporarily discontinued.
A s a r e s u l t when t h e p r o d u c t i o n
A t t h a t time r a p i d feedback t o

l i n e was r e i n s t a t e d , s e v e r a l l o t s a f t e r October 1964 i n d i c a t e d a new r e g i o n of i n s t a b i l i t y . t h e m a n u f a c t u r e r from t h e c u s t o m e r s r e s u l t e d i n s u b s e q u e n t d e c r e a s e o f c a t a s t r o p h i c f a i l u r e s d u r i n g t h e s c r e e n and burni n procedure.

31.

SECTION V

SM AY U MR Controversy still e x i s t s w i t h r e s p e c t t o t h e d e c i s i o n made i n t h e d e s i g n o f t h e Apollo Guidance Computer. tages.

In particular

s t a n d a r d i z a t i o n of l o g i c g a t e s i s claimed t o have many d i s a d v a n But, a s a r e s u l t o f s t a n d a r d i z a t i o n t h e NOR G a t e s o f t h e Apollo Computer h a s b e e n a b l e t o e s t a b l i s h t h e r e l i a b i l i t y w i t h o p e r a t i n g f a i l u r e r a t e s lower t h a n e v e r b e f o r e r e a l i z e d .

To date,

f o u r t e e n Block I computers have been b u i l t

and a r e i n f i e l d u s e f o r f l i g h t s i m u l a t i o n , s p a c e c r a f t i n t e g r a t i o n

t e s t , and v a r i o u s q u a l i f i c a t i o n t e s t s .

These computers have

accumulated 38,442.0 h o u r s of o p e r a t i n g time a s of 30 September 1965. The f i r s t p r o t o t y p e computer was o p e r a t i n g i n J u l y 1963 w i t h t h e Raytheon b u i l t f l i g h t computer o p e r a t i n g i n J a n u a r y 1964.

32.

REFERENCES:
1.
J. P a r t r i d g e , E.C.

H a l l , L.D.

Hanley,

"The A p p l i c a t i o n

o f F a i l u r e A n a l y s i s i n P r o c u r i n g and S c r e e n i n g o f I n t e g r a t e d C i r c u i t s " , p r e s e n t e d a t t h e F o u r t h Annual Symposium of P h y s i c s o f F a i l u r e i n E l e c t r o n i c s , November 1 6 , 1965.

2.
I 1

J. P a r t r i d g e , L.D.

Hanley, E.C.

Hall,

"Progress

Report on A t t a i n a b l e R e l i a b i l i t y o f I n t e g r a t e d C i r c u i t s f o r Systems A p p l i c a t i o n " , M i c r o e l e c t r o n i c s and Large Systems, E d i t e d by Mathis, Wiley, S p a n d o r f e r 1965.

33.

E- 1880

DISTRIBUTION LIST Internal M. Adams (MIT/S&ID)

J . Arnow (Lincoln)

E. Hickey

M. R i c h t e r (MIT/MSC)

D. Hoag
F. Houston L. B. Johnson

J. Rhode
K. Samuelian
P. S a r m a n i a n

R. Battin
P. Bowditch / F. S i r a c o

A. Boyce R. Boyd

M. Johnston
B. Katz

G. Schmidt

W. Schmidt

R. B y e r s
G. C h e r r y

A. Koso
M. K r a m e r

R. Scholten E. Schwarm
J. Sciegienny

N. Cluett
E. Copps W. Coleman

W. Kupfer A. L a a t s
D. Ladd
J. L a r s e n

N. S e a r s J. Shillingford W. Shotwell (MIT/ACSP)

R. C r i s p G. Cushman

L. L a r s o n
J. Lawrence(MIT/GAEC)

T. Shuck
J. S i t o m e r

J. Dahlen J. DeLisle
E. Duggan

T. J. Lawton
T. M. Lawton(MIT/MSC)

W. S t a m e r i s J. Stone J. Suomala W. T a n n e r

J. R. J. P. S.

Dunbar Euvard

D. Lickly

R. Magee L. Martinage G. Mayo

J. McNeil

B. F e l d m a n Felleman
Felix

R. T h e r r i e n
W. Toth

M. T r a g e s e r

J. F l a n d e r s (MIT/KSC) J. F l e m i n g
L. Cediman

R. McKern
R. Millard J a m e s Miller John Miller

R. Weatherbee R, White L. Wilk

M. Wolff R. Woodbury

J. G i l m o r e

F. Grant D. Grief
Eldon Hall (100)
W. Heintz

R. Mudgett
J. Nevins J. Nugent
E. O l s s o n

W. W r i g l e y

D. Yankovich
Apollo L i b r a r y (2) M I T / I L L i b r a r y (6)

T. Hemker

W. P a t t e r s o n
M. P e t e r s e n

External
W. Rhine (NASA/MSC)

NASA /RASPO
I,.

Holdridge ( N A A / M I T )

T. Heuermann (GAEC/MIT) AC E l e c t r o n i c s Kollsman Raytheon M a j o r H. W h e e l e r (AFSC/MIT) MSC: National Aeronautics and Space Administration Manned Spacecraft Center Apollo Document Distribution Office ( P A 2 1 Houston, T e x a s 77058 LRC: National Aeronautics and Space Administration Langley R e s e a r c h C e n t e r Hampton, Virginia Attn: M r . A. T. Mattson GAEC: G r u m m a n A i r c r a f t Engineering Corporation Data Operations and S e r v i c e s , Plant 25 Bethpage, Long Island, New York Attn: M r . E. Stern
(3

(25 f 1R)

+ 1R)

NAA :
North A m e r i c a n Aviation, Inc. Space and Information S y s t e m s Division 1 2 2 1 4 Lakewood Boulevard Downey, California Attn: Apollo Data R e q u i r e m e n t s AE99 Dept. 41-096-704 (Bldg 6 )

(18 + 1R)

NAA RASPO: NASA Resident Apollo Spacecraft P r o g r a m Office North A m e r i c a n Aviation, Inc. Space and Information S y s t e m s Division Downey, California 90241
ACSP RASPO: National Aeronautics and Space Administration Resident Apollo Spacecraft P r o g r a m Officer Dept. 32-31 AC E l e c t r o n i c s Division of G e n e r a l Motors Milwaukee 1, Wisconsin Attn: M r . W. Swingle

E x t e r n a l (Cont'd) ACSP RASPO: Mr. 13. P e t e r s o n Bureau of Naval Weapons c 10 Raytheon Company Foundry Avenue Waltham, M a s s a c h u s e t t s

M r . S. Schwartz DOD, DCASD, Garden C i t y 60 5 S t e w a r t Avenue Garden City, L. I . , N. Y. Attn: Quality A s s u r a n c e

D. R. Kohls A F P R O (CMRKKA) A C E l e c t r o n i c s Division of G e n e r a l Motors Milwaukee 1, Wisconsin 53201