GMW3172-2014

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General Specification for Electrical/Electronic Components – Environmental/Durability

WORLDWIDE

ENGINEERING

STANDARDS

General Specification

GMW3172

General Specification for Electrical/Electronic Components –

Environmental/Durability

GM Confidential

October 2014

Page 1 of 116

Index

Index .................................................................................................................................................................. 1

1 Introduction ..................................................................................................................................................... 5

1.1 Purpose ....................................................................................................................................................... 5

1.2 Applicability .................................................................................................................................................. 5

1.3 Remarks ...................................................................................................................................................... 6

2 References ..................................................................................................................................................... 6

2.1 External Standards/Specifications ............................................................................................................... 6

2.2 GM Standards/Specifications ...................................................................................................................... 6

2.3 Additional References ................................................................................................................................. 6

3 Parametric Definitions .................................................................................................................................... 7

3.1 Temperature and Voltage Definitions .......................................................................................................... 7

3.2 Parameter Tolerances ................................................................................................................................. 7

3.3 Operating Types .......................................................................................................................................... 8

3.4 Functional Status Classification (FSC) ........................................................................................................ 9

4 Process ........................................................................................................................................................... 9

4.1 A/D/V Process for Electrical/Electronic Components .................................................................................. 9

4.2 A/D/V Process Flow ..................................................................................................................................... 9

4.2.1 Test Flows .............................................................................................................................................. 11

4.2.2 Environmental Hardware Design Review ............................................................................................... 21

4.2.3 Analytical Activities ................................................................................................................................. 22

4.2.4 Development Activities ........................................................................................................................... 22

4.2.5 Design Validation Activities .................................................................................................................... 22

4.2.6 Product Validation Activities ................................................................................................................... 22

4.3 Summary of A/D/V Activities...................................................................................................................... 23

5 Requirements ............................................................................................................................................... 27

5.1 Target Life.................................................................................................................................................. 27

5.2 Reliability ................................................................................................................................................... 27

5.3 Quoting Requirements ............................................................................................................................... 27

5.3.1 Code Letter for Electrical Loads ............................................................................................................. 28

5.3.2 Code Letter for Mechanical Loads ......................................................................................................... 29

GM WORLDWIDE ENGINEERING STANDARDS

GMW3172

GM Confidential

October 2014

Page 2 of 116

5.3.3 Code Letter for Temperature Loads ....................................................................................................... 30

5.3.4 Code Letter for Climatic Loads ............................................................................................................... 31

5.3.5 Code Letter for Chemical Loads ............................................................................................................. 31

5.3.6 Code Letter for International Protection by Enclosures .......................................................................... 32

5.3.7 Code Designation by Location in the Vehicle ......................................................................................... 34

6 Test Setup and Component Verification ....................................................................................................... 36

6.1 5-Point Functional/Parametric Check ........................................................................................................ 36

6.2 1-Point Functional/Parametric Check ........................................................................................................ 37

6.3 Continuous Monitoring ............................................................................................................................... 37

6.4 Functional Cycling ..................................................................................................................................... 38

6.5 Visual Inspection and Dissection – DRBTR .............................................................................................. 38

6.6 Cross Section and Inspection .................................................................................................................... 41

6.7 Dimensional Check .................................................................................................................................... 42

6.8 Vibration Transmissibility Demonstration .................................................................................................. 43

6.9 Thermal Cycle Profile Development .......................................................................................................... 46

7 Analysis ........................................................................................................................................................ 47

7.1 Analysis Mission ........................................................................................................................................ 47

7.2 Electrical .................................................................................................................................................... 47

7.2.1 Nominal and Worst Case Performance Analysis ................................................................................... 47

7.2.2 Short/Open Circuit Analysis.................................................................................................................... 47

7.3 Mechanical ................................................................................................................................................ 48

7.3.1 Resonant Frequency Analysis ................................................................................................................ 48

7.3.2 High Altitude Shipping Pressure Effect Analysis .................................................................................... 48

7.3.3 Plastic Snap Fit Fastener Analysis ......................................................................................................... 49

7.3.4 Crush Analysis ........................................................................................................................................ 49

7.4 Climatic ...................................................................................................................................................... 49

7.4.1 High Altitude Operation Overheating Analysis ....................................................................................... 49

7.4.2 Thermal Fatigue Analysis ....................................................................................................................... 50

7.5 Enclosure ................................................................................................................................................... 50

7.6 Material ...................................................................................................................................................... 50

7.6.1 Lead-Free Solder Analysis ..................................................................................................................... 50

8 Development ................................................................................................................................................ 51

8.1 Development Mission ................................................................................................................................ 51

8.2 Electrical .................................................................................................................................................... 51

8.2.1 Jump Start .............................................................................................................................................. 51

8.2.2 Reverse Polarity ..................................................................................................................................... 51

8.2.3 Over Voltage ........................................................................................................................................... 52

8.2.4 State Change Waveform Characterization ............................................................................................. 52

8.2.5 Ground Path Inductance Sensitivity ....................................................................................................... 53

GM WORLDWIDE ENGINEERING STANDARDS

GMW3172

GM Confidential

October 2014

Page 3 of 116

8.3 Mechanical ................................................................................................................................................ 53

8.3.1 Highly Accelerated Life Test (HALT) ...................................................................................................... 53

8.4 Climatic ...................................................................................................................................................... 53

8.4.1 Temperature Measurement .................................................................................................................... 53

8.4.2 Low Temperature Wakeup ..................................................................................................................... 54

8.4.3 Frost ........................................................................................................................................................ 55

8.4.4 Highly Accelerated Stress Test (HAST) ................................................................................................. 56

8.5 Enclosure ................................................................................................................................................... 56

8.6 Material ...................................................................................................................................................... 56

9 Design Validation (DV) ................................................................................................................................. 56

9.1 DV Mission................................................................................................................................................. 56

9.2 Electrical .................................................................................................................................................... 56

9.2.1 Parasitic Current ..................................................................................................................................... 56

9.2.2 Power Supply Interruptions .................................................................................................................... 57

9.2.3 Battery Voltage Dropout ......................................................................................................................... 58

9.2.4 Sinusoidal Superimposed Voltage ......................................................................................................... 59

9.2.5 Pulse Superimposed Voltage ................................................................................................................. 59

9.2.6 Intermittent Short Circuit to Battery and to Ground for Input/Output ...................................................... 61

9.2.7 Continuous Short Circuit to Battery and to Ground for Input/Output ...................................................... 62

9.2.8 Multiple Power and Multiple Ground Short Circuits Including Pass Through ......................................... 63

9.2.9 Open Circuit – Single Line Interruption .................................................................................................. 65

9.2.10 Open Circuit – Multiple Line Interruption .............................................................................................. 65

9.2.11 Ground Offset ....................................................................................................................................... 66

9.2.12 Power Offset ......................................................................................................................................... 66

9.2.13 Discrete Digital Input Threshold Voltage .............................................................................................. 67

9.2.14 Over Load – All Circuits ........................................................................................................................ 70

9.2.15 Over Load – Fuse Protected Circuits ................................................................................................... 70

9.2.16 Insulation Resistance ........................................................................................................................... 71

9.2.17 Crank Pulse Capability and Durability .................................................................................................. 71

9.2.18 Switched Battery Lines ......................................................................................................................... 73

9.3 Mechanical ................................................................................................................................................ 75

9.3.1 Vibration with Thermal Cycling ............................................................................................................... 75

9.3.1.1 Random Vibration – Mounting Location Engine or Transmission ....................................................... 76

9.3.1.2 Random Vibration – Mounting Location Sprung Masses .................................................................... 77

9.3.1.3 Random Vibration – Mounting Location Unsprung Masses ................................................................ 78

9.3.1.4 Thermal Cycle Profile Used During All Vibration Tests ....................................................................... 79

9.3.2 Mechanical Shock – Pothole .................................................................................................................. 80

9.3.3 Mechanical Shock – Collision ................................................................................................................. 80

9.3.4 Mechanical Shock – Closure Slam ......................................................................................................... 81

GM WORLDWIDE ENGINEERING STANDARDS

GMW3172

GM Confidential

October 2014

Page 4 of 116

9.3.5 Crush For Housing – Elbow Load .......................................................................................................... 82

9.3.6 Crush For Housing – Foot Load ............................................................................................................. 83

9.3.7 GMW3191 Connector Tests ................................................................................................................... 84

9.3.8 Connector Installation Abuse – Side Force ............................................................................................ 85

9.3.9 Connector Installation Abuse – Foot Load ............................................................................................. 86

9.3.10 Free Fall ............................................................................................................................................... 87

9.3.11 Fretting Corrosion Degradation ............................................................................................................ 87

9.4 Climatic ...................................................................................................................................................... 88

9.4.1 High Temperature Degradation .............................................................................................................. 88

9.4.2 Thermal Shock Air-To-Air (TS) ............................................................................................................... 89

9.4.3 Power Temperature Cycle (PTC) ........................................................................................................... 91

9.4.4 Thermal Shock/Water Splash ................................................................................................................. 92

9.4.5 Humid Heat Cyclic (HHC) ....................................................................................................................... 92

9.4.6 Humid Heat Constant (HHCO) ............................................................................................................... 94

9.4.7 Salt Mist .................................................................................................................................................. 95

9.4.8 Salt Spray ............................................................................................................................................... 96

9.5 Enclosure ................................................................................................................................................... 97

9.5.1 Dust ........................................................................................................................................................ 97

9.5.2 Water ...................................................................................................................................................... 97

9.5.3 Seal ......................................................................................................................................................... 98

9.5.4 Leakage Check ....................................................................................................................................... 99

9.5.5 Water Freeze ........................................................................................................................................ 100

9.5.6 Sugar Water Function Impairment ....................................................................................................... 100

9.6 Material .................................................................................................................................................... 100

10 Product Validation (PV) ............................................................................................................................ 100

10.1 PV Mission ............................................................................................................................................. 100

10.2 Electrical ................................................................................................................................................ 100

10.3 Mechanical ............................................................................................................................................ 101

10.3.1 Shipping Vibration .............................................................................................................................. 101

10.4 Climatic .................................................................................................................................................. 102

10.5 Enclosure ............................................................................................................................................... 102

10.6 Material .................................................................................................................................................. 102

11 Notes ........................................................................................................................................................ 102

11.1 Glossary................................................................................................................................................. 102

11.2 Acronyms, Abbreviations, and Symbols ................................................................................................ 102

12 Additional Paragraphs .............................................................................................................................. 104

12.1 Restricted and Reportable Substances for Parts .................................................................................. 104

12.2 Environmental References .................................................................................................................... 104

13 Coding System ......................................................................................................................................... 104

GM WORLDWIDE ENGINEERING STANDARDS

GMW3172

GM Confidential

October 2014

Page 5 of 116

14 Release and Revisions ............................................................................................................................. 105

Appendix A .................................................................................................................................................... 106

A1 Lead-Free Solder Considerations ............................................................................................................ 106

Appendix B .................................................................................................................................................... 107

B1 GMW3172 Component DV/PV Environmental Test Plan (CG3043) ....................................................... 107

B1.1 Introduction ........................................................................................................................................... 108

B1.2.1 Purpose .............................................................................................................................................. 108

B1.2.2 Guideline for Test Descriptions .......................................................................................................... 108

Appendix C .................................................................................................................................................... 110

C1 Requirements for GMW3172 Test Reporting .......................................................................................... 110

C1.1 Foreword ............................................................................................................................................... 110

C1.2 Test Report Contents ............................................................................................................................ 110

C1.3 Elements of the Test Report ................................................................................................................. 111

C1.3.1 Title Page ........................................................................................................................................... 111

C1.3.2 Test Set-Up Documentation .............................................................................................................. 111

C1.3.2.1 Equipment Lists – Calibration and Traceability .............................................................................. 111

C1.3.2.2 Photographs .................................................................................................................................... 112

C1.3.3 Description of Test Procedure ........................................................................................................... 112

C1.3.4 Reporting of Stress Inputs ................................................................................................................. 113

C1.3.5 Test Results ....................................................................................................................................... 113

C1.3.5.1 Tests Requiring Continuous Monitoring.......................................................................................... 113

C1.3.5.2 Conformance to FSC (Functional Status Classification) Criteria .................................................... 113

C1.3.5.3 Test Requiring 1-Point Functional / Parametric Check ................................................................... 114

C1.3.5.4 Initial and Final 5-Point Functional / Parametric Check Results ..................................................... 114

C1.3.5.5 Visible Inspection and Dissection - DRBTR Results ...................................................................... 115

C1.3.6 Pass/Fail Summary Report ................................................................................................................ 115

C1.3.7 Description of Non-Conformances ..................................................................................................... 115

C1.4 Storage of Records ............................................................................................................................... 116

1 Introduction

Note: Nothing in this standard supercedes applicable laws and regulations.

Note: In the event of conflict between the English and domestic language, the English language shall take

precedence.

Note: Requirements stated in any applicable Component Technical Specification (CTS), Subsystem Technical

Specification (SSTS), and/or other relevant General Motors requirements document shall take precedence over

GMW3172.

1.1 Purpose. This standard applies to Electrical/Electronic (E/E) components for passenger or commercial

vehicles and trucks. The standard describes the environmental and durability tests for E/E components based

on mounting location.

1.2 Applicability. This standard specifies Environmental/Durability requirements and

Analysis/Development/Validation (A/D/V) activities for E/E components that are used in a vehicle environment

to ensure reliability over a life time.

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