Early life failures in marginal devices are a severe reliability threat in current nano-scaled CMOS devices. While small delay faults are an effective indicator of marginalities, their detection requires special efforts in testing by so-called Faster-than-At-Speed Test (FAST). In a similar way, delay degradation is an indicator that a device reaches the wear-out phase due to aging. Programmable delay monitors provide the possibility to detect gradual performance changes in a system and allow to observe device degradation.This paper presents a unified approach to test small delay faults related to wear-out and early-life failures by reuse of existing programmable delay monitors within FAST. The approach is complemented by a test-scheduling which optimally selects frequencies and delay configurations to significantly increase the fault coverage of small delays and to reduce the test time.

Marginal hardware introduces severe reliability threats throughout the life cycle of a system. Although marginalities may not affect the functionality of a circuit immediately after manufacturing, they can degrade into hard failures and must be screened out during manufacturing test to prevent early life failures. Furthermore, their evolution in the field must be proactively monitored by periodic tests before actual failures occur. In recent years, small delay faults (SDFs) have gained increasing attention as possible indicators of marginal hardware. However, SDFs on short paths may be undetectable even with advanced timing aware ATPG. Faster-than-at-speed test (FAST) can detect such hidden delay faults (HDFs), but so far FAST has mainly been restricted to manufacturing test. This paper presents a fully autonomous built-in self-test approach for FAST, which supports in-field testing by appropriate strategies for test generation and response compaction. In particular, the required test frequencies for HDF detection are selected, such that hardware overhead and test time are minimized. Furthermore, test response compaction handles the large number of unknowns (X-values) on long paths by storing intermediate MISR-signatures in a small on-chip memory for later analysis using X-canceling transformations. A comprehensive experimental study demonstrates the effectiveness of the presented approach. In particular, the impact of the considered fault size is studied in detail.

Aging monitors can indicate the wear-out phase of a semi-conductor device before it will actually fail, and allow the use of integrated circuits in applications with high safety and reliability demands. In the early phase of the lifecycle of integrated systems, small delay faults may indicate reliability problems and early life failures, even if they are smaller than the slack of any path and neither alter the functional behavior of a system nor violate any aging guardband. One option to detect this type of hidden delay faults (HDFs) is the application of a faster-than-at-speed-test (FAST). This paper shows that aging monitors can be extended at low cost to achieve high HDF test coverage with a reduction in test time during FAST. The result is a unified strategy to improve the reliability in both early and late phases of the system lifecycle.

Small delay faults receive more and more attention, since they may indicate a circuit reliability marginality even if they do not violate the timing at the time of production. At-speed test and faster-than-at-speed test (FAST) are rather expensive tasks to test for such faults. The paper at hand avoids complex on-chip structures or expensive high-speed ATE for test response evaluation, if aging monitors which are integrated into the device under test anyway are reused. The main challenge in reusing aging monitors for FAST consists in possible false alerts at higher frequencies. While a certain test vector pair makes a delay fault observable at one monitor, it may also exceed the time slack in the fault free case at a different monitor which has to be masked. Therefore, a multidimensional optimizing problem has to be solved for minimizing the masking overhead and the number of test vectors while maximizing delay fault coverage.

Circuit aging causes a performance degradation and eventually a functional failure. It depends on the workload and the environmental condition of the system, which are hard to predict in early design phases resulting in pessimistic design. Existing delay monitoring schemes measure the remaining slack of paths in the circuit, but have a high hardware penalty including global wiring. More importantly, a low sensitization ratio of long paths in applications may lead to a very low measurement frequency or even unmonitored timing violations. In this work, we propose a delay monitor placement method by analyzing the topological circuit structure and sensitization of paths. The delay monitors are inserted at meticulously selected positions in the circuit, named observation points (OPs). This OP monitor placement method can reduce the number of inserted monitors by up to 98% compared to a placement at the end of long paths. The experimental validation shows the effectiveness of this aging indication, i.e. a monitor issues an alert always earlier than any imminent timing failure.

Small delay faults may be an indicator of a reliability threat, even if they do not affect the system functionality yet. In recent years, Faster-than-at-Speed-Test (FAST) has become a feasible method to detect faults, which are hidden by the timing slack or by long critical paths in the combinational logic. FAST poses severe challenges to the automatic test equipment with respect to timing, performance, and resolution. In this paper, it is shown how logic built-in self-test (BIST) or embedded deterministic test can be used for an efficient FAST application. Running BIST just at a higher frequency is not an option, as outputs of long paths will receive undefined values due to set time violations and destroy the content of the signature registers. Instead, for a given test pattern sequence, faults are classified according to the optimal detection frequency. For each class, a MISR-based compaction scheme is adapted, such that the critical bits to be observed can be determined by algebraic computations. Experiments show that rather a small number of inter-mediate signatures have to be evaluated to observe a large fraction of hidden delay faults testable by the given test sequence.