Failures associated with thermo-mechanical fatigue are one of the dominant reasons for faults in power electronic converter-based electrical systems. This review explores such thermal stress-induced reliability challenges in power converters, focusing on key package-related failure mechanisms such as bond-wire fatigue, solder degradation, and chip metallization wear-out. The study emphasizes the importance of mission-profile-based reliability assessment, highlighting the effects of operational and environmental conditions on the long-term performance of power modules. Key findings reveal how repetitive thermal cycling and environmental variations lead to critical failures, underscoring the need for effective thermal management and design-for-reliability strategies. The primary goal of this paper is the quantitative, comparative reliability analysis across multiple high-power applications, moving beyond qualitative summaries. This review aims to support future research on predictive reliability modeling, mission-profile-based lifetime estimation, and robust design strategies for wide-bandgap-based high-power converters. Ultimately, the insights provided are intended to guide the development of more robust power electronic systems for emerging energy and mobility infrastructures.

Properly addressing uncertainties in reliability analysis is essential for realistic lifetime predictions of power devices. This paper investigates parameter uncertainties on the lifetime estimation of power devices using an empirical lifetime model and Monte Carlo simulations. Key parameters such as junction temperature swings (ΔT _j), minimum junction temperature (T _{j, min}), and lifetime model constants are analyzed for their impacts on lifetime outcomes. Sensitivity analysis reveals significant effects from variations in parameters like β ₁ and ΔT _j on the expected lifetime and its variability. Simultaneous variations across all parameters further highlight the dominant influence of β ₁ on lifetime predictions. The analysis suggests that a 5 % uncertainty margin appears to offer a balanced trade-off between realistic lifetime estimations and predictability. This Study underscores the importance of considering parameter uncertainties for precise reliability evaluations. It addresses a critical gap by examining the rationale behind commonly assumed 5 %, and 10 % uncertainty margins in lifetime modeling. By systematically evaluating these margins’ impacts on key reliability parameters, the study provides a framework for selecting reasonable assumptions based on physical insights and variability analysis, advancing the reliability modeling of power devices.

Power electronics converters are essential for power generation, transmission, and distribution. The modular multilevel converter (MMC) is highly valued for its versatility, high efficiency, and robust control capabilities. Since MMC is composed of many components, its reliability is crucial for maintaining the availability of electrical power systems. The reliability of the MMC can be evaluated using different methods, such as the military handbook (MIL) and the Mission Profile (MP) methods. By comparing the reliability estimation of the MMC using the MIL and MP methods, this study offers insights into the effectiveness of these approaches. Also, it shows the significant difference in final results between the two applied methods. These findings contribute to the understanding and improvement of the reliability assessment of power electronics converters. Also, the impact of redundancy is scrutinized to make the comparison more thorough.

In the realm of electric mobility, fast chargers for electric vehicles (EVs) play a critical role in mitigating range anxiety while driving. The converter in these chargers usually has a load profile consisting of a high-current pulse to swiftly recharge the EV battery, followed by a cooling-off phase when the charging process is over. This pattern results in thermal cycles on the devices resulting in mechanical fatigue that leads to gradual deterioration of the power electronic components. Consequently, evaluating the power electronic converters reliability is critical to facilitating fast EV charging. This paper focuses on the reliability analysis of the phase-shifted full-bridge DC/DC converter within EV fast chargers, with a specific emphasis on the battery charging profile. The primary objective is to demonstrate how the charger load characteristics and number of charging sessions influence device reliability and, consequently, overall system reliability. Additionally, the investigation explores the effects of altering devices heatsinks and current ratings on system reliability. It was observed that in worst-case scenarios, increasing devices current rates extended the system lifetime from 0.7 to about 23 years, with 3p.u. ratings achieving 10.8 years, meeting industry targets, while reducing heatsink thermal resistance improves that to around 2 years.