Drive level acoustic defectoscopy for head disc interface (HDI) integration and manufacturing

A short product development cycle for modern hard disc drive (HDD) depends entirely on early defect characterization. However, deviations from desired HDI mechanical performance are not always manifested in electromagnetic read back or servo control signals. The best non-destructive tool to monitor HDI dynamics at the HDD level is a passive acoustic technique that tracks equilibrium of the head gimbal assembly and air bearing (AB) modes. This technique is capable of active head protrusion detection as well as detection of embedded particles. The drawback of the passive acoustic monitoring technique at drive level is that a noisy HDD environment makes the detectability of a useful signal challenging. The proposed HDD level in situ passive HDI acoustic monitoring technique consists of external AE sensors driven by adequate electronics. These are enhanced by advanced signal processing routines that include adaptive discrete wavelet transforms. The system is tuned to monitor acoustic HDI signatures during drive spin-up/spin-down cycles as well as during passive and active height across the data zones. In addition, integrated acoustic energy metrics can be used in AB design evaluation stages. In this work examples of HDD level passive acoustic monitoring applications for HDI development, and manufacturing defect tracking, are presented and supported by failure analysis results.