**Introduction**
Silicon Carbide (SiC) power devices have emerged as strong alternatives to traditional silicon (Si) power devices in high-efficiency, high-voltage, and high-frequency power conversion systems. Thanks to their superior material properties, SiC-based power devices have enabled high-performance systems that meet the highest efficiency standards without compromising reliability. Wolfspeed’s (formerly Cree, Inc.) SiC diodes have been deployed in numerous applications for over a decade, accumulating more than 2 million operational hours in major industrial (indoor) settings with an average failure rate of less than 1 in a billion hours. In recent years, outdoor applications such as renewable energy and transportation have further highlighted the need for SiC power devices to optimize system size, weight, efficiency, and cost. Although SiC devices have met cost-performance expectations, they face unique challenges when operating in high-humidity environments.
**Humidity Problem**
The impact of humidity on electronic components under bias has long been a concern across the industry. Conventional Si power devices, which expose their chip surfaces to higher voltages, are particularly vulnerable to degradation due to increased humidity. This can lead to electrochemical migration and corrosion, ultimately resulting in loss of high-voltage blocking capability. The presence of large electric fields exacerbates these issues, especially in SiC devices, accelerating failure mechanisms. To address this, Wolfspeed engineers have invested significant effort into researching and mitigating these failure modes, leading to the development of new processes and designs for their W-Series power modules.
**New Certification Test Standard**
Traditionally, the JEDEC standard for industrial module certification has relied on the High Humidity, High Temperature Reverse Bias (H3TRB) test, which subjects devices to 85% relative humidity and 85°C ambient temperature for 1000 hours at 100 V bias. While most samples pass this test with minimal parameter drift, it is not sufficient for outdoor applications where voltage levels are much higher. To better reflect real-world conditions, researchers developed the High-Voltage H3TRB (HV-H3TRB) test, also known as THB-80. This test applies 80% of the rated blocking voltage, significantly increasing the stress on the device. For example, a 1200 V device is tested at 960 V instead of just 100 V. The Wolfspeed WAS300M12BM2 module successfully passed the 1000-hour HV-H3TRB test and continued to function beyond 2000 hours, demonstrating its reliability in harsh conditions.
**Full SiC Power Module for Harsh Environments**
The WAS300M12BM2 module features Wolfspeed’s latest MOSFET (CPM2-1200-0025A) and fifth-generation Schottky diodes, both designed to withstand extreme environmental conditions. During testing, 25 randomly selected samples from three different production batches passed the HV-H3TRB test, confirming consistent performance and reproducibility. The module matches the electrical performance of existing industrial-grade modules, offering low on-resistance (as low as 4.2 mΩ) and switching losses that are less than 20% of those found in comparable IGBT modules. Its construction includes a thermally conductive aluminum nitride substrate and optimized assembly techniques, ensuring compliance with industrial thermal and power cycling requirements.
Six modules were tested under HV-H3TRB conditions, with electrical stability monitored after every 500 hours. One module failed at 500 hours and another at 1000 hours, but visual inspections revealed no signs of oxidation or electrochemical migration. All other modules continued testing for over 2000 hours without failure. Additionally, leakage current (IDSS) was closely monitored, and all samples maintained stable IDSS waveforms throughout the test, with voltage and leakage current drifts well within JEDEC limits.
**Conclusion**
Wolfspeed’s WAS300M12BM2 power module has proven its reliability under high-humidity conditions, passing the HV-H3TRB test with no detectable defects. These results open the door for the W Series SiC power modules to be used in demanding outdoor applications such as renewable energy and transportation. With its advanced design and rigorous testing, the WAS300M12BM2 represents a significant step forward in the development of reliable, high-performance SiC power solutions for harsh environments.
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