Destructive Physical Analysis, abbreviated as DPA, is a series of tests and analyses performed on component samples from production batches to verify whether the design, structure, materials, and manufacturing quality of the components meet the specified requirements and relevant specifications. DPA is not only applicable to military electronic components but also to civilian electronic components, such as procurement inspections, incoming inspections, and quality monitoring during the production process.

Purpose of DPA:

The purpose of DPA is to analyze qualified products using techniques similar to failure analysis, evaluate whether components with good characteristics have any defects that may affect reliability, and assess the batch quality. Conducting DPA analysis on qualified products in the final production process allows for the early detection of abnormal conditions in the manufacturing process, which is beneficial for process improvement and product quality enhancement. User-controlled DPA techniques can verify and evaluate the quality of components, detect abnormal conditions that may affect performance and reliability, and ensure the quality of installed components.

DPA is a preventive measure developed with the aim of preventing failures, ensuring the reliability of component usage, and has gained widespread attention from component users. Many departments and engineering units have established corresponding DPA standards and specifications.

Significance of DPA:

The design work for reliability must adhere to the principle of “prevention-oriented, early involvement,” with a focus on preventing, detecting, and correcting defects in reliability design, components, materials, and process methods. Mature design and effective reliability analysis and testing techniques should be employed to ensure and improve the inherent reliability of weapons and equipment. Early investment can achieve significant results and reduce the overall life-cycle cost (life-cycle cost = development cost + production cost + maintenance cost).

DPA adheres to the principle of “prevention-oriented, early involvement” and performs DPA on important components before they are put into use. Sample components from production batches are subjected to DPA to eliminate substandard or defective batches, ensuring the use of components that meet quality requirements, thus guaranteeing system reliability.

Based on the results of DPA, batches with obvious or potential defects in production can be rejected, appropriate measures can be taken for abnormal batches, and improvement measures can be proposed for components in terms of design, materials, or processes. It effectively prevents the use of components with obvious or potential defects and ensures the installation of components that meet quality requirements, thereby reducing the probability of failures caused by inherent component defects during system testing and field use.

The primary significance of conducting destructive physical analysis is as follows:

(1)Identifying deviations and process defects in design and manufacturing and proposing improvement measures.

(2)Inspecting and verifying the quality of components supplied by the supplier.

(3)Preventing the use of components with obvious or potential defects.

Scope of Application for DPA

Under what circumstances should components conduct a DPA? When should DPA be conducted?

DPA is conducted in various situations, which are typically specified in the DPA specification documents for the particular type. DPA should be conducted in the following cases:

(1)Components used in high-reliability fields such as aerospace, aviation, and military.

(2)Components designated as critical or important in electronic products or devices, where their failure may lead to product malfunctions or impact mission completion.

(3)Components with quality levels lower than the specified requirements.

(4)Components that have exceeded the specified storage time.

(5)Quality reinspection of components already installed.

The timing for conducting DPA mainly includes the following situations:

(1)During product quality identification, including identification by authorized national institutions and by the end-user.

(2)During product acceptance, if DPA is specified in the purchase contract, the end-user can supervise the production process on-site to conduct DPA, or a qualified third-party laboratory can perform DPA before the manufacturer supplies the products, and the qualified products can be delivered only after passing the inspection.

(3)DPA can be conducted on components after they arrive but before installation, combined with secondary (supplemental) screening, to serve as a good quality reinspection.

(4)DPA should be conducted on components that have exceeded the specified storage period according to international/domestic standards and requirements.