基于稳健设计的PBGA器件焊点热机械疲劳可靠性的优化设计

基于稳健设计与有限元法,研究了加速热循环测试条件下塑封球栅阵列(PBGA)焊点的热机械疲劳可靠性.考虑PCB大小(A)、基板厚度(D)、硅片热膨胀系数(G)、焊点热膨胀系数(H)等八个控制因素,使用L₁₈(2¹×3⁷)混合正交表,以对焊点热机械疲劳寿命的考核为目标,对PBGA焊点进行了优化设计.结果表明,影响焊点可靠性的显著性因素依次是基板热膨胀系数、焊点的热膨胀系数、基板厚度、芯片的热膨胀系数;最优方案组合为A1B2C3D1E2F1G3H1.进一步的验证试验结果表明,与原始方案相比,该优化方案的最大等效应变降低了66%,信噪比提高了22.4％.     

PBGA无铅焊点热可靠性优化研究

在田口实验法的基础上,采用非线性有限元建模,对温度循环载荷作用下的PBGA无铅焊点进行可靠性优化研究。L18(21×37)田口正交表被选用来分析PBGA封装体的8个控制因子,包括PCB的尺寸和厚度、基板的尺寸和厚度、焊点的直径和高度、芯片以及塑封的厚度。通过田口实验法,得出了关于PBGA最佳的结构参数组合,其中最重要的控制因子为基板厚度和焊点高度,最佳参数分别为0.66mm和0.60mm。     

PBGA器件焊点的可靠性分析研究

根据PBGA器件组装特点,分析了器件焊点的失效机理,并针对实际应用中失效的PBGA器件在温度循环前后,分别使用染色试验、切片分析、X-射线分析等方法进行失效分析.分析结果显示样品PBGA焊点存在不同程度的焊接问题,并且焊接质量的好坏直接影响器件焊点抵抗外界应变应力的能力.最后,开展了PBGA器件焊接工艺研究和可靠性试验,试验结果显示焊接工艺改进后焊点的可靠性良好.     

不同基板的CBGA焊点在热循环下的力学特性研究

采用粘塑性本构Anand方程描述SnPb钎料的变形行为,用有限元方法对CBGA组件焊点结构进行二维模型分析;同时,选用不同的基板材料(Al2O3、AlN、SiC),考察焊点在热循环加载过程中的应力应变等力学行为.研究结果表明,最外侧焊点受到的应力应变最大,所以裂纹最有可能从最外侧焊点处萌生,并沿着基板一侧扩展;焊点的高应力发生在热循环的低温阶段,升降温过程中的蠕变和非弹性应变的累积显著,应力应变迟滞环在热循环的最初几个周期内就能很快稳定.模拟结果得出,采用BeO基板材料时焊点的应力应变最小,其可靠性最高.     

焊盘尺寸对FC—PBGA焊点可靠性的影响

影响封装可靠性的因素很多,其中对封装及供货厂商相关的封装设计方面的各种变量应该给予足够的重视。焊盘尺寸是影响焊点可靠性的关键因素之一,不同供货厂商的各种工艺造成焊盘尺寸方面的差异,对可靠性造成了极大的影响。有限元应力分析、波纹干涉测量试验及可靠性试验表明,基板厚度影响封装可靠性。文章采用有限元模拟来定量分析焊盘尺寸对PBGA封装可靠性的影响,把空气对空气热循环试验结果与FEM预测进行比较,讨论最佳焊盘尺寸,并预测对焊点可靠性的影响。     

热循环加载条件下焊点形态参数对板级光互连模块对准偏移影响分析

建立光互连模块有限元分析模型并进行热循环加载有限元分析,获取了垂直腔面发射激光器(Vertical Cavity Surface Emitting Laser,VCSEL)与耦合元件间的位置偏移;采用正交实验设计法设计了不同焊点结构参数组合并建立有限元模型,计算相应焊点形态参数组合下的位置偏移数据并进行方差分析.结果表明:在一个热循环周期内低温保温结束时刻位置偏移最大;外端光通道的位置偏移比中间光通道的偏移值大;在置信度为95%时VCSEL焊点高度对对准偏移具有显著影响,因素显著性排序由大到小依次为:VCSEL焊点高度、陶瓷基板焊点高度、VCSEL焊点体积和陶瓷基板焊点体积;单因子变量分析表明,位置偏移随VCSEL焊点高度增加而增大.     

冲击载荷下航天用PBGA焊点的优化设计

从动力学角度考虑PBGA焊点承受不同加速度情况下冲击载荷的情况,对PBGA焊点尺寸建立了正交设计表。运用有限元分析技术对该表中各种因素和水平分别进行有限元分析,运用数理统计对正交结果进行分析,在现有尺寸结构上提出了最优化设计。对各种因素进行了显著性分析及比较,得出在动力载荷下,焊点直径、高度等参数对焊点可靠性的影响比焊点位置参数对焊点可靠性的影响要低得多。在动力载荷下,焊点位置、形状变为可靠性设计的主要考虑因素。并通过扩大参数取值范围得到二次正交设计表验证了其正确性。     

PBGA组件振动疲劳寿命的实验研究

为了得到在基频激励下PBGA封装的可靠度特性,设计制作了一块包含不同结构和材料参数的PBGA组件样品,利用可靠性实验的方法测试了PBGA组件在正弦单频激励条件下的疲劳特性,同时运用Manson-Coffin方程经验公式及雨流计数法得到了相对应的焊点疲劳寿命.最后利用疲劳统计中威布尔分布得到了当PBGA芯片位于PCB不同位置、不同激励时可靠度-循环失效圈数曲线(R-N曲线).结果表明,大直径焊点芯片、分布在约束较多PCB上的芯片、无铅焊点芯片的焊点可靠度较高.     

倒装焊器件尺寸参数对低k层及焊点的影响

当前。集成电路制造中低k介质与铜互连集成工艺的引入已经成为一种趋势,因此分析封装器件中低矗结构的可靠性是很有必要的。利用有限元软件分析了倒装焊器件的尺寸参数对低k层及焊点的影响。结果表明：减薄芯片,减小PI层厚度,增加焊点高度,增加焊盘高度,减小基板厚度能够缓解低k层上的最大等效应力;而减薄芯片,增加PI层厚度,增加焊点高度,减小焊盘高度,减小基板厚度能够降低焊点的等效塑性应变。     

热循环条件下空洞对PBGA焊点热疲劳寿命的影响

球栅阵列(ball grid array, BGA)封装器件的广泛应用使空洞对焊点可靠性的影响成为业界关注的焦点之一.采用非线性有限元分析方法和统一型粘塑性本构方程,以PBGA组装焊点为对象,建立了互连焊点热应变损伤的三维有限元模型,并基于修正的Coffin-Manson方程,分析了在热循环加裁条件下不同位置和大小的空洞对焊点疲劳寿命的影响.研究结果显示,位于原应力集中区的空洞将降低焊点疲劳寿命,基于应变失效机理,焊点裂纹易在该类空洞周围萌生和扩展;位于焊球中心和远离原应力集中区的空洞,在一定程度上可提高焊点的疲劳寿命.     

PBGA封装热可靠性分析

对PBGA封装体建立了有限元数值模拟分析模型。模型采用无铅焊点,完全焊点阵列形式。研究了封装体在经历IPC9701标准下的五种不同温度循环加载后,受到的热应力、应变,以及可能的失效形式。结果表明,焊点是封装体结构失效的关键环节,焊点所受应力大小与焊点位置有关。比较了不同温度循环下封装体的疲劳寿命。其结果为提高封装体的可靠性和优化设计提供了理论依据。     

Effect of substrate flexibility on solder joint reliability. Part II: finite element modeling

Solder joint fatigue failure is a serious reliability concern in area array technologies, such as flip chip and ball grid array packages of integrated-circuit chips. The selection of different substrate materials could affect solder joint thermal fatigue life significantly. The mechanism of substrate flexibility on improving solder joint thermal fatigue was investigated by thermal mechanical analysis (TMA) technique and finite element modeling. The reliability of solder joints in real flip chip assembly with both rigid and compliant substrates was evaluated by accelerated temperature cycling test. Finite element simulations were conducted to study the reliability of solder joints in flip chip on flex assembly (FCOF) and flip chip on rigid board assembly (FCOB) applying Anand model. Based on the finite element analysis results, the fatigue lives of solder joints were obtained by Darveaux’s crack initiation and growth model. The thermal strain/stress in solder joints of flip chip assemblies with different substrates were compared. The results of finite element analysis showed a good agreement with the experimental results. It was found that the thermal fatigue lifetime of FCOF solder joints was much longer than that of FCOB solder joints. The thermal strain/stress in solder joints could be reduced by flex buckling or bending and flex substrates could dissipate energy that otherwise would be absorbed by solder joints. It was concluded that substrate flexibility has a great effect on solder joint reliability and the reliability improvement was attributed to flex buckling or bending during temperature cycling.     

Effects of process conditions on reliability, microstructure evolution and failure modes of SnAgCu solder joints

In this study, microstructure evolution at intermetallic interfaces in SnAgCu solder joints of an area array component was investigated at various stages of a thermal cycling test. Failure modes of solder joints were analyzed to determine the effects of process conditions on crack propagation. Lead-free printed-circuit-board (PCB) assemblies were carried out using different foot print designs on PCBs, solder paste deposition volume and reflow profiles. Lead-free SnAgCu plastic-ball-grid-array (PBGA) components were assembled onto PCBs using SnAgCu solder paste. The assembled boards were subjected to the thermal cycling test (−40 °C/+125 °C), and crack initiation and crack propagation during the test were studied. Microstructure analysis and measurements of interface intermetallic growth were conducted using samples after 0, 1000, 2000 and 3000 thermal cycles. Failures were not found before 5700 thermal cycles and the characteristic lives of all solder joints produced using different process and design parameters were more than 7200 thermal cycles, indicating robust solder joints produced with a wide process window. In addition, the intermetallic interfaces were found to have Sn–Ni–Cu. The solder joints consisted of two Ag–Sn compounds exhibiting unique structures of Sn-rich and Ag-rich compounds. A crystalline star-shaped structure of Sn–Ni–Cu–P was also observed in a solder joint. The intermetallic thicknesses were less than 3 μm. The intermetallics growth was about 10% after 3000 thermal cycles. However, these compounds did not affect the reliability of the solder joints. Furthermore, findings in this study were compared with those in previous studies, and the comparison proved the validity of this study.     

Mechanical deflection system (MDS) test and methodology for PBGAsolder joint reliability

A mechanical deflection system (MDS) was developed for highly accelerated tests to evaluate the solder joint fatigue performance in printed circuit board assemblies. The MDS test system can be used for design verification and qualification tests for solder joint reliability. Cyclic twisting deformation is imposed on an assembled printed circuit board (PCB) at isothermal conditions. The MDS test technique makes a significant contribution to reducing solder joint reliability testing cycle time. Fatigue performance of the PBGA solder joints subjected to the MDS test was investigated by three-dimensional finite element modeling. The solder joint fatigue lives were computed for several different MDS test conditions     

片式元件焊点的热循环应力应变模拟技术研究

采用ANSYS软件,以0402片式元件焊点为对象,系统探讨了焊点热应变损伤的有限元仿真方法,分析了焊点在热循环过程中的应力应变响应,并基于修正的Coffin-Manson方程,预测了焊点的热疲劳寿命。结果显示:焊点应力集中区域和应变最大区域均位于焊点与PCB焊盘的交界面,基于应变失效原则,推断焊点裂纹将在此界面萌生和扩展,直至失效。指出了焊点有限元热应变损伤模拟技术的不足及未来的研究方向。     

热循环条件下无铅焊点可靠性的有限元分析

通过有限元数值模拟对Sn3.5Ag0.75Cu无铅焊料焊点的可靠性问题进行了分析。采用统一粘塑性Anand本构方程对焊料焊点结构进行有限元分析,研究焊点在热循环加载过程中的应力应变等力学行为。研究结果表明,在焊点内部焊点与基板结合处的应力较大,而焊点中央的应力较小;焊点在低温阶段的应力最大,在高温阶段应变最大;在升降温阶段的应力应变变化较大,而在保温阶段的应力应变变化较小。     

Impact of solder pad size on solder joint reliability in flip chipPBGA packages

A variety of parameters impact package reliability. One set of parameters that does not get much attention is the variations in package design that are assembly and vendor related. This study shows that solder pad size is important in solder joint reliability. Differences in solder pad size due to different vendors and processes can affect the reliability considerably. The impact of substrate thickness on package reliability has been shown in finite element stress analysis, moire interferometry experiments, and reliability tests. However, in certain cases, the pad size effect can be so significant that it overrides the impact of substrate thickness. This work indicates that in order to obtain good correlation between predictive engineering results and reliability tests data, this factor should not be ignored. In this study, finite element simulation has been used to quantify the pad size effect on the BGA reliability in the PBGA package. Air-to-air thermal cycling test results were compared with FEM predictions. Optimized pad sizes are discussed and the impact on the solder joint reliability is predicted. Solder pad size effect was found to be a dominant feature in correlating test data with predictions     

热循环加载片式元器件带空洞无铅焊点的可靠性

建立了片式元器件带空洞无铅焊点有限元分析模型,研究了热循环加载条件下空洞位置和空洞面积对焊点热疲劳寿命的影响.结果表明:热循环加载条件下空洞位置和空洞面积显著影响焊点热疲劳寿命.空洞位置固定于焊点中部且面积分别为7.065×10-4,1.256×10-3,1.963×10-3和2.826×10-3mm2时,焊点热疲劳寿...