超声换能系统电特性实验研究

超声换能系统是引线键合设备的核心部件,对其工作特性的深入了解有助于理解引线键合过程.通过实验,观察分析了超声引线键合过程中不同劈刀安装长度对换能系统电流、电压及功率的影响,发现电流及功率在不同劈刀安装长度时有较为明显的变化.并进一步采用小波分析方法展现了电流信号在时频域内变化的细节情况,为充分了解换能系统电学特性提供了可靠依据和新的方法.     

25μm Au丝引线键合正交试验研究

通过分析键合工艺参数,为25μm Au丝引线键合的应用提供实验依据。采用正交试验法对键合工艺参数进行试验研究。起决定性作用的是因素间的交互作用和劈刀的安装长度,其次为压力、超声功率、超声时间、热台温度、劈刀温度。各因素影响力大小为A>B>F>C>D>E,较优工艺方案为A_2B_2C_1D_2E_1F_1,回归模型为Y=13.124+0.731A-0.393B-0.057C+0.022D+0.013F。除以上主要影响因素,Au丝弧度也是需要考虑的。给进一步研究引线键合提供重要依据。     

楔焊键合工艺焊点完整性控制研究

以引线键合机为对象，研究了引线键合工艺过程中设备机构、工艺流程及参数对焊点完整性的影响。经实验验证，在断丝前，减小劈刀对焊点的压力，同时加以小超声辅助断丝，即可保证焊点的完整性。     

LTCC基板金丝热超声楔焊正交试验分析

引线键合是微组装技术中的关键工艺,广泛应用于军品和民品芯片的封装。特殊类型基板的引线键合失效问题是键合工艺研究的重要方向。低温共烧陶瓷(LTCC)电路基板在微波多芯片组件中使用广泛,相对于电镀纯金基板,该基板上金焊盘楔形键合强度对于参数设置非常敏感。文章进行了LTCC基板上金丝热超声楔焊的正交试验,在热台温度、劈刀安装长度等条件不变的情况下,分别设置第一键合点和第二键合点的超声功率、超声时间和键合力三因素水平,试验结果表明第一点超声功率和第二点超声时间对键合强度影响明显。     

LTCC电路基板上金丝热超声楔焊正交试验分析

进行了LTCC基板上金丝热超声楔焊的正交试验,在热台温度和劈刀安装长度等条件不变的情况下,分别设置第一键合点和第二键合点的超声功率、超声时间和键合力三因素水平,试验结果表明第一点超声功率和第二点超声时间对键合强度影响明显。     

欠键合/过键合与功率设置及温度关系的研究

在热超声引线键合过程中,低功率设置和低温下容易导致欠键合,高功率设置和高温下则容易出现过键合。通过实验采集了不同超声功率设置、不同温度下大量键合过程中换能杆末端轴向的速度信号、换能杆两端驱动电压和电流信号,并测量其键合强度,计算得到不同温度下换能杆的振幅。分析了超声功率和键合温度对振幅的影响规律,解释了功率设置和键合温度导致欠键合和过键合的可能原因,建立了功率设置和温度对换能杆振幅影响的模型。这些实验数据和结果有助于进一步研究键合过程中参数间的相互影响规律。     

键合工具对超声换能器系统谐振频率的影响

建立了超声引线键合机换能器系统振动分析有限元模型,利用ANSYS软件分析了换能器系统与键合工具组成的纵-弯复合振动系统的振动特性。计算结果表明,键合工具的弯曲振动与换能器系统纵向振动存在耦合关系,劈刀长度增加50%将使换能器系统谐振频率下降5.6%;实验中测试了换能器系统的阻抗与导纳特性,发现当劈刀长度为16 mm时系统的阻抗匹配较为理想;换能器系统的谐振频率的实测值与有限元分析结果一致,最大误差为3.51%。     

金丝引线键合的影响因素探究

键合对设备性能和人员技能的要求极高，属于关键控制工序，键合质量的好坏直接影响电路的可靠性。工艺人员需对键合的影响因素进行整体把控，有针对性地控制好各个关键点，提升产品键合的质量和可靠性。通过对金丝引线键合整个生产过程的全面深入研究，分析了键合设备调试、劈刀选型、超声、温度、压力、劈刀清洗和产品的可键合性7个主要影响因素，并且通过实际经验针对各个影响因素给出了合理的改善建议。     

基于DOE和BP神经网络对Al线键合工艺优化

Al丝超声引线键合工艺被广泛地应用在大功率器件封装中,以实现大功率芯片与引 线框架之间的电互连.Al丝引线键合的质量严重影响功率器件的整体封装水平,对其工艺参数的优化具有重要工业应用意义.利用正交实验设计方法,对Al丝引线键合工艺中的三个最重要影响因数(超声功率P/DAC、键合时间t/ms、键合压力F/g)进行了正交实验设计,实验表明拉力优化后的工艺参数为:键合时间为40 ms,超声功率为25 DAC,键合压力为120g;剪切推力优化的工艺参数为:键合时间为50 ms,超声功率为40 DAC,键合压力为120 g.基于BP神经网络系统,建立了铝丝超声引线键合工艺的预测模型,揭示了Al丝超声键合工艺参数与键合质量之间的内在联系.网络训练结果表明训练预测值与实验值之间符合很好,检验样本的结果也符合较好,其误差基本控制在10%以内.     

基于IC封装的Au凸点剪切断丝模拟及实验

为提高IC封装过程中钉头Au凸点制备效率,需对Au凸点的形成机理进行分析,得出影响Au凸点质量的各种工艺参数。采用有限元仿真与实验相结合的方法,针对不同的劈刀剪切速度模拟剪切断丝过程,并在实际的引线键合机上进行实验。结果显示劈刀剪切速度越大,劈刀剪切Au丝时所受的作用力越小,但减小幅度不大。分析表明,当劈刀以较低速度进行剪切断丝时,需要克服较大的位错滑移能,而随着速度提高,滑移系增多,Au丝获得的热量增多,使得材料的塑性降低,从而能够减小剪切断丝时的剪切力,但由于Au丝的直径较小,剪切速度相对剪切距离又较大,所以剪切力的减小幅度对剪切过程影响有限,而且不同的剪切速度均能得到共面性较好的钉头Au凸点。     

金丝楔形键合强度的影响规律分析

金丝楔形键合是一种通过超声振动和键合力协同作用来实现芯片与电路引出互连的技术。现今,此引线键合技术是微电子封装领域最重要、应用最广泛的技术之一。引线键合互连的质量是影响红外探测器组件可靠性和可信性的重要因素。基于红外探测器组件,对金丝楔形键合强度的多维影响因素进行探究。从键合焊盘质量和金丝楔焊焊点形貌对键合强度的影响入手,开展了超声功率、键合压力及键合时间对金丝楔形键合强度的影响研究。根据金丝楔焊原理及工艺过程,选取红外探测器组件进行强度影响规律试验及分析,指导实际金丝楔焊工艺,并对最佳工艺参数下的金丝键合拉力均匀性进行探究,验证了金丝楔形键合强度工艺一致性。     

Two capillary solutions for ultra-fine-pitch wire bonding and insulated wire bonding

In this article, the new challenges and requirements in wire bonding are discussed, the problems in ultra-fine-pitch wire bonding and insulated wire bonding are analyzed, and then two capillary solutions to the problems are presented. Actual bonding experiments using the new capillaries were carried out and the results were satisfactory. Compared to the standard design, a new capillary design has a larger inner chamfer, a larger chamfer diameter and a smaller chamfer angle. This new capillary design has proved to improve the ball bondability and smaller ball size control for ultra-fine pitch wire bonding. A unique surface characteristic on the capillary tip surface has also been derived. The new finishing process developed creates a new surface morphology, which has relatively deep lines with no fixed directions. Compared to the standard capillary, this capillary has less slipping between the wire and the capillary tip surface in contact, and provides better coupling effect between them and better ultrasonic energy transfer. This capillary has been used to effectively improve the bondability of the stitch bonds for insulated wire bonding.     

Investigation of ultrasonic vibrations of wire-bonding capillaries

Ultrasonic energy is widely used in wire bonding for microelectronics packaging. It is necessary to ensure that the maximum ultrasonic vibration displacement occurs at or near the tip of the bonding tool (capillary) for optimal performance. In this study, amplitude profiles of ultrasonic vibrations along capillaries were measured with load using a laser interferometer. This provided valuable information in understanding and improving capillary performance. The method was applied to real time applications to optimize capillary designs and bonding processes for specific bonding applications. First, the application of a new capillary material with different zirconia compositions was evaluated. The new material with certain amount of zirconia composition showed that it was the capillary material of choice for ultra-fine pitch wire bonding. Next, comparative analysis was conducted to investigate the ultrasonic energy transfer of a new ‘slimline’ bottleneck and the conventional bottleneck. The actual bonding response of the molded slimline bottleneck showed comparable performance with the ground conventional bottleneck using the same bonding parameters. Finally, optimization of a 60-μm-bond-pad-pitch process was performed on a wire bonder. Within the optimized parameter ranges, the ultrasonic displacement of the capillary was monitored. For all possible combinations of bond force and bond power, the ultrasonic displacement of the capillary increased with increasing bond power, without drastic changes caused by bond force changes. This indicated that the selected process window was located in a stable region.     

键合压力对粗铝丝引线键合强度的实验研究

在超声引线键合过程中,键合压力是影响键合强度的重要因素之一。通过实验,研究了键合强度与键合压力间的关系。通过高频采集装置对键合压力进行了标定并分析了其对键合强度以及电流电压产生的影响。实验发现,只有在键合压力适中的情况下,键合强度才能达到最大。     

引线键合技术进展

引线键合以工艺简单、成本低廉、适合多种封装形式而在连接方式中占主导地位.对引线键合工艺、材料、设备和超声引线键合机理的研究进展进行了论述与分析,列出了主要的键合工艺参数和优化方法,球键合和楔键合是引线键合的两种基本形式,热压超声波键合工艺因其加热温度低、键合强度高、有利于器件可靠性等优势而取代热压键合和超声波键合成为键合法的主流,提出了该技术的发展趋势,劈刀设计、键合材料和键合设备的有效集成是获得引线键合完整解决方案的关键.     

Reliability of thick Al wire: A study of the effects of wire bonding parameters on thermal cycling degradation rate using non-destructive methods

The effect of bonding parameters on the reliability of thick Al wire bond is investigated. Samples were prepared with 25 different designs with 5 different bonding parameters such as time, ultrasonic power, begin-force, end-force and touch-down steps (pre-compression) with 5 levels. The bond signals of ultrasonic generator were collected during bonding in order to obtain prior quality information of bonded wires. 3D X-ray tomography was then used to evaluate bond quality during passive thermal cycling between −55 °C and 125 °C. Tomography datasets were obtained from the as-bonded condition and during cycling. The results clearly show ultrasonic power, appropriate levels of begin-force and touch-down steps are all important for achieving a well attached and reliable bond. Analysis of the virtual cross-sections indicates a good correlation between the bond signal (i.e. the initial bond quality) and wire bond damage/degradation rate. An improved understanding of the wire bonding process was achieved by observing the effect of the complex interaction of bonding parameters on the ultrasonic generator signals and degradation rate under thermal cycling.     

Advanced process characterization for 125 kHz wire bonder ultrasonic transducers

A high frequency ultrasonic transducer for wire bonding is conceived, designed, prototyped, tested and industrially produced. The influence of each feature of the ultrasonic transducer design, such as constituent material, amplifier geometry, mounting flange, capillary fixing, on the wire bonding process results is clearly identified and carefully analyzed through thorough process tests. The assembly and aging characteristics of the transducers are measured and the scattering of the vibration properties in the mass production is statistically quantified by laser interferometer measurements and compared with that of conventional horns. The transducer is mounted on the wire bonder with a flange whose special geometry is calculated by means of FEM simulations and patented. This flange allows the mechanical stiffness of the coupling transducer-wire bonder to be dramatically increased and the parasitic mechanical dynamical vibrations at the horn tip to be significantly reduced. Process tests show that the reduction in mechanical vibrations obtained in this way allows a wire bonder scarcely capable normally to attain the 80 /spl mu/m fine pitch process, to perform easily the 60 /spl mu/m fine pitch process. A beneficial impact of the mechanical coupling horn-wire bonder on the process performance is ascertained. The use of titanium as horn material, characterized by a low thermal expansion coefficient, is proven by process tests to be effective in improving the placement accuracy of the wire bonder. The high vibration frequency of the transducer (125 kHz) is proven by process tests to be effective in improving the ball roundness and the fine pitch wire bonding capabilities of the wire bonder and in decreasing the minimum wire bonding temperature and the applied bond force. The new approach to characterize the process performance of new ultrasonic transducer designs is of general importance for wire bonding technology.