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Several research studies have investigated the degradation of BaTiO3-based dielectric capacitor materials, focusing on the impact of composition, defect chemistry, and microstructural design to limit the electromigration of oxygen vacancies under electric fields at finite temperatures. Electromigration can be a dominant mechanism that controls failure rates in the individual multilayer ceramic capacitor (MLCC) components in testing the reliability of failures with highly accelerated lifetime testing (HALT) to determine the mean time to failure of MLCCs surface mounted onto printed circuit boards (PCBs). Conventional assumptions often consider these failures as independent, with no interaction between components on the PCB. However, this study employs a Physics of Failure (PoF) approach to closely examine transient degradation and its impact on MLCC reliability, emphasizing thermal crosstalk and its influence on dependent and independent failure rates. Finite element analysis thermal modeling and infrared thermography were used to assess the impact of circuit layout and component spacing on heat dissipation and thermal crosstalk under various electrical stress conditions. The study distinguishes between dependent and independent failures under a HALT, quantified through a β′ factor reflecting common cause failures due to thermal crosstalk. Through a series of experimental and statistical analyses, the β′ factor is evaluated with respect to temperature, voltage, and component spacing. These insights highlight the importance of understanding the nature of the data in reliability testing of MLCCs and optimizing the layout design of high-density circuits to mitigate dependent failures, improving overall reliability and informing better design and packaging strategies. 

Base metal electrode (BME) multilayer ceramic capacitors (MLCCs) are widely used in aerospace, medical, military, and communication applications, emphasizing the need for high reliability. The ongoing advancements in BaTiO3-based MLCC technology have facilitated further miniaturization and improved capacitive volumetric density for both low and high voltage devices. However, concerns persist regarding infant mortality failures and long-term reliability under higher fields and temperatures. To address these concerns, a comprehensive understanding of the mechanisms underlying insulation resistance degradation is crucial. Furthermore, there is a need to develop effective screening procedures during MLCC production and improve the accuracy of mean time to failure (MTTF) predictions. This article reviews our findings on the effect of the burn-in test, a common quality control process, on the dynamics of oxygen vacancies within BME MLCCs. These findings reveal the burn-in test has a negative impact on the lifetime and reliability of BME MLCCS. Moreover, the limitations of existing lifetime prediction models for BME MLCCs are discussed, emphasizing the need for improved MTTF predictions by employing a physics-based machine learning model to overcome the existing models’ limitations. The article also discusses the new physical-based machine learning model that has been developed. While data limitations remain a challenge, the physics-based machine learning approach offers promising results for MTTF prediction in MLCCs, contributing to improved lifetime predictions. Furthermore, the article acknowledges the limitations of relying solely on MTTF to predict MLCCs’ lifetime and emphasizes the importance of developing comprehensive prediction models that predict the entire distribution of failures. 

Abstract This paper reviews the synthesis of BaTiO₃-based ceramic and composites through the cold sintering process. Cold sintering is a densification process that works with a low-temperature mechanism known as pressure solution creep. This provides several opportunities to fabricate BaTiO₃into new composite structures that could provide important advanced dielectric properties. Here we revisit the challenges of densifying a material such as BaTiO₃that has incongruent dissolution. We consider the issues of surface chemistry, selection of transient flux, core–shell designs in BaTiO₃, co-sintering with polymers in the grain boundaries and the technical challenges associated with incorporating all these ideas into tape casting steps for future fabrication of multilayer device structures. 

Adding excessive metal oxide doping to a powder batch is a known way to compensate for the loss of volatile cation species during high temperature sintering. An important case in the piezoelectric ceramics is the bismuth oxide in the lead-free ferroelectric ceramic bismuth sodium titanate (BNT). Building from the earlier knowledge about excessive bismuth oxide's influences on the properties of BNT, we further note that varying the sintering temperature can both control the distribution of excessive Bi3+ and impact the relaxor/normal ferroelectric behaviors and corresponding phase transition. In addition to the nature of polarization, the sintering temperature also significantly manipulates the electrical conductivity. A hypothetical mechanism for the resistive grain boundary is proposed, based on inferences from electrical—microstructure—processing relations in 85% Bi0.5Na0.5TiO3-15% BaTiO3 with batched Bi2O3 excess and acceptor Mg2+ in a co-doped strategy.