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In pursuit of improved range, greater reliability, and faster charging, electric vehicles are driving the demand for high-voltage electronics. Other applications driving this demand include wind farms, data centers, and server farms, to name a few. As the interest for high-voltage electronics increases, the risks associated with their sudden failure must be considered.
Much of what causes high-voltage equipment to malfunction can be linked to the conditions of the climate in which it operates. Specifically, condensation on electronic surfaces caused by humidity can lead to corrosion, which can result in stray leak current and dendrite shorting during Electrochemical Migration (ECM).
Predicting, mitigating, and helping proactively design to account for corrosion is the focus of the Centre for Electronic Corrosion (CELCORR) research group at the Technical University of Denmark (DTU). The group’s researchers are working with industry partners to develop models and simulation apps that will help in building robust electronics designs. Their goal is to develop knowledge that can be used for manufacturing electronics to withstand humid operating conditions.
Electronic Failure: “It’s Not the Heat; It is the Humidity”
Automotive electrification and renewable energy systems rely on electronics at all stages of the energy chain. When these electronics, such as the example PCB in Figure 1, are exposed to the effects of moisture, they can become potential failure points.
“Anywhere you are producing, converting, transporting, and using energy, you need these high-power electronic systems that get affected by the humidity,” explained Dr. Rajan Ambat, DTU professor and manager of CELCORR. Ambient moisture can seep into the devices and machines that require these electronics and cause unexpected functional issues through corrosion. When these electronics are involved in particularly high-voltage applications (such as wind farms, data centers, electric vehicles, and server farms), failure due to humidity exposure can even lead to fire.
“There might be a situation where somebody installs a solar panel near the seashore or in an area with high humidity, and within a short period of time, a conducive condition forms inside the electronics that results in a failure,” Ambat said. “This is why we need to understand exactly how the conducive condition of condensation is created, when the condition is created, and how the system is failing.”
Figure 1. The electrolyte potential and current density distributions on a PCB surface (with pinholes). CELCORR/DTU
Identifying corrosion as the underlying cause of some electronic failures is still a challenge. “Fifty percent of failures in electronics are currently branded with an unidentified root cause,” Ambat explained. “When engineers open up the system, they do not realize that the failure was due to corrosion, because moisture disappears without leaving any sign of corrosion unless there is ECM dendrite formation.”
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