Electromigration of Sn–37Pb and Sn–3Ag–1.5Cu/Sn–3Ag–0.5Cu composite flip–chip solder bumps with Ti/Ni(V)/Cu under bump metallurgy

We examine electromigration fatigue reliability and morphological patterns of Sn–37Pb and Sn–3Ag–1.5Cu/Sn–3Ag–0.5Cu composite solder bumps in a flip–chip package assembly with Ti/Ni(V)/Cu UBM. The flip–chip test vehicle was subjected to test conditions of five combinations of applied electric currents and ambient temperatures, namely, 0.4 A/150 °C, 0.5 A/150 °C, 0.6 A/125 °C, 0.6 A/135 °C, and 0.6 A/150 °C. The electrothermal coupling analysis was employed to investigate the current crowding effect and maximum temperature in the solder bump in order to correlate with the experimental electromigration reliability using the Black’s equation as a reliability model. From available electromigration reliability models, we also present a comparison between fatigue lives of Sn–37Pb solder bumps with Ti/Ni(V)/Cu and those with Al/Ni(V)/Cu UBM under different current stressing conditions.     

Improvement in high-temperature degradation by isotropic conductive adhesives including Ag–Sn alloy fillers

The reliability evaluation of Cu and Sn/Ni joined with isotropic conductive adhesives (ICAs) including Ag–Sn alloy fillers with or without Ag plating instead of Ag fillers was examined using tensile tests, electrical resistivity tests and microstructural observations. For an ICA, including Ag–Sn alloy fillers added to Sn–58wt%Bi fillers, the tensile strength was found to improve, but the electrical resistivity worsened with 150 °C heat exposure. An ICA, including, Ag–Sn alloy fillers with Ag plating, was able to maintain electrical resistivity after being subjected to 150 °C heat exposure. The Ag plating on the Ag–Sn fillers reacted with the Sn in the Ag–Sn fillers, leading to the joining of the fillers with each other though metallurgical connections, and the transformation of Ag into Ag₃Sn within a 1-h curing time at 150 °C, since the Ag plating was microscopic and active. After heat exposure, the Sn distributed itself along the substrate/ICA interface by the diffusion of Sn though the connected fillers, and Cu₃Sn formed at the Cu/ICA interface, in contrast with the Ag–Sn alloy fillers without Ag plating.     

The reliability study of selected Sn–Zn based lead-free solders on Au/Ni–P/Cu substrate

Since both Ag and In are important melting point depressants in Sn–Zn based solders, a series Sn–Zn based solders with various amounts of Ag and In additions was studied in the experiment. The melting behavior of solder alloys, wetting characteristics, coefficients of thermal expansion, microstructural evolution and long-term reliability of the selected Sn–Zn based solder on Au/Ni–P metallized copper substrate were examined. Based on the experimental result, there is little change in the melting range of Sn–Zn based solder alloys by minor addition of Ag. On the contrary, the melting point of Sn–Zn based alloys can be effectively decreased by In additions. However, the difference between solidus and liquidus temperature is broadened as the increment of In into Sn–Zn based solders. 76Sn–9Zn–15In has the lowest liquidus temperature among all alloys, and it can effectively bond the Au/Ni–P metallized copper substrate. The microstructure of 76Sn–9Zn–15In alloy soldered at 200 °C for 20 min is primarily comprised of Sn–In γ phase and needle-like ZnO₂. Since there is no flux usage during soldering, zinc oxide cannot be avoided even the process performed under 2×10⁻² mbar vacuum environment. It is also noted that there is no interfacial reaction layer between 76Sn–9Zn–15In and Au/Ni–P metallized copper substrate after soldering. However, there is a reaction layer between 76Sn–9Zn–15In and substrate as the soldered specimen aged at 90 °C for 168 h. Its chemical composition is close to Zn-rich γ phase (NiZn₃) alloyed with minor Sn, In, Cu and P. For the specimen further aged at 90 °C for 336 h, there are cracks along the interface between solder alloy and electroless Ni–P layer. The oxidation of the interfacial Zn-rich γ phase plays an important role in deterioration of the bonding between 76Sn–9Zn–15In and Au/Ni–P metallized copper substrate.     

Effects of fourth alloying additive on microstructures and tensile properties of Sn–Ag–Cu alloy and joints with Cu

The effects of the fourth elements, i.e., Fe, Ni, Co, Mn and Ti, on microstructural features, undercooling characteristics, and monotonic tensile properties of Sn–3 wt.%Ag–0.5 wt.%Cu lead-free solder were investigated. All quaternary alloys basically form third intermetallic compounds in addition to fine Ag₃Sn and Cu₆Sn₅ and exhibit improved solder structure. The precipitates of Sn–3Ag–0.5Cu (–0.1 wt.%X; X=Ni, Ti and Mn) alloy are very fine comparing with the other alloys. The effective elements for suppressing undercooling in solidification are Ti, Mn, Co and Ni. All quaternary bulk alloys exhibit similar or slightly larger tensile strengths; especially Mn and Ni can improve elongation without degrading strength. The interfacial phases of Sn–3Ag–0.5Cu (–0.1 wt.%X; X=Fe, Mn and Ti)/Cu joints are typical Cu₆Sn₅ scallops. Sn–3Ag–0.5Cu (–0.1 wt.%X; X=Ni and Co)/Cu joints form very fine Sn–Cu–Ni and Sn–Cu–Co scallops at interface. The Cu/Sn–3Ag–0.5Cu–0.1Ni/Cu joint exhibits improved tensile strength prior to thermal aging at 125 and 150 °C. The fracture surface of Cu/Sn–3Ag–0.5Cu/Cu joint exhibits mixture of ductile and brittle fractures, while Cu/Sn–3Ag–0.5Cu (–0.1X; X=Ni and Co)/Cu joints exhibit only brittle fracture at interface. The Sn–3Ag–0.5Cu–0.1Ni alloy is more reliable solder alloy with improved properties for all tests in the present work.     

Effect of displacement rate on ball shear properties for Sn–37Pb and Sn–3.5Ag BGA solder joints during isothermal aging

The interfacial reactions and ball shear properties of ball grid array (BGA) solder joints aged at 170 °C for up to 21 days were investigated with different displacement rates. Two different kinds of solders, Sn–37Pb and Sn–3.5Ag (all wt.%), and an electroplated Ni/Au BGA substrate were employed in this work. A continuous Ni₃Sn₄ intermetallic compound (IMC) layer was formed at the interfaces between both the Sn–37Pb and Sn–3.5Ag solders and the substrate during reflow. After aging, two different reaction layers, consisting of (Au_xNi_1−x)Sn₄ IMC and Pb-rich phase, were additionally observed between the Sn–37Pb solder and the Ni₃Sn₄ IMC layer. The thicknesses of these interfacial reaction layers increased with increasing aging time. After reflow, all the fractures occurred inside the bulk solder. The fracture location of the Sn–37Pb solder joints was shifted toward the solder/Ni interface with increasing aging time and displacement rate, whereas the fracture of the Sn–3.5Ag solder joints mainly occurred inside the bulk solder, irrespective of the aging time and displacement rate. Consequently, the shear properties of the Sn–37Pb solder joints significantly decreased with increasing aging time, whereas those of the Sn–3.5Ag solder joints slightly decreased. The tendency toward brittle fracture of the Sn–37Pb solder joints was intensified with increasing displacement rate. The shear properties of the ductile solder joints increased with increasing displacement rate, while the displacement until fracture, deformation energy and displacement rate sensitivity of the brittle solder joints significantly decreased with increasing displacement rate.     

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.     

Microstructure evolution of the Sn–Ag–y%Cu interconnect

The lead free Sn–Ag–y%Cu (y = 0.0, 0.5, 1.0 and 2.0) interconnect interfacial microstructures and the microstructure evolution under thermal treatment (isothermal aging, 150 °C/1000 h) were studied in detail by using surface microetching microscopy and cross section microscopy. The corresponding mechanical and reliability behaviors were evaluated by performing shear test and fracture mode analysis before and after the thermal treatment. The results indicate: (i) The interconnects could have different microstructures and intermetallic compound (IMC), depending on the Cu content. The Cu–Sn IMC could have microstructures that were clusters or protrusion-like, Augustine grass leaf-like, scissor-like, tweezers-like, etc. (ii) Ag₃Sn IMCs were not observed at time zero for any interconnect groups, but they occurred after the aging for all groups. The Ag₃Sn IMC could have different microstructures, again depending on Cu content. For low Cu content, the Ag₃Sn IMCs were granules or nodules; for higher Cu content, Ag₃Sn IMCs were plate-like. (iii) The growth of Ag₃Sn plates was promoted by the growth of Cu–Sn IMCs, but indirectly linked to the Cu content. (iv) High Cu content (1.0 wt% and higher) could degrade the mechanical and reliability performances of the LF interconnect by providing a brittle joint, which was mainly achieved through the substantial growth of Cu–Sn IMCs and Ag₃Sn plates.     

The formation and growth of intermetallic compounds and shear strength at Sn–Zn solder/Au–Ni–Cu interfaces

The microstructures and shear strength of the interface between Sn–Zn lead-free solders and Au/Ni/Cu interface under thermal aging conditions was investigated. The intermetallic compounds (IMCs) at the interface between Sn–Zn solders and Au/Ni/Cu interface were analyzed by field emission scanning electron microscopy and transmission electron microscopy. The results showed the decrease in the shear strength of the interface with aging time and temperature. The solder ball with highly activated flux had about 8.2% increased shear strength than that with BGA/CSP flux. Imperfect wetting and many voids were observed in the fracture surface of the latter flux. The decreased shear strength was influenced by IMC growth and Zn grain coarsening. In the solder layer, Zn reacted with Au and then was transformed to the β-AuZn compound. Although AuZn grew first, three diffusion layers of γ-Ni₅Zn₂₁ compounds were formed after aging for 600 h at 150 °C. The layers divided by Ni₅Zn₂₁ (1), (2), and (3) were formed with the thickness of 0.7 μm, 4 μm, and 2 μm, respectively.     

Effects of TMF heating rates on damage accumulation and resultant mechanical behavior of Sn–Ag based solder joints

Solder joint reliability depends on several service parameters such as temperature extremes encountered, dwell times at these temperatures, and the ramp-rates representing the rate at which the temperature changes are imposed. TMF of Sn–Ag based solder alloy joints of realistic dimensions were carried out with dwell of 115 min and 20 min at 150 °C and −15 °C, respectively. Different heating rates were obtained by controlling the power input during heating part of TMF cycles. Surface damage and residual mechanical strength of these solder joints were characterized after 0, 250, 500, and 1000 TMF cycles to evaluate the role of TMF heating rate on the solder joint integrity.     

Effect of different temperature cycling profiles on the crack initiation and propagation of Sn–3.5Ag wave soldered solder joints

Temperature cycling of a test board with different electronic components was carried out at two different temperature profiles in a single-chamber climate cabinet. The first temperature profile ranged between −55 and 100 °C and the second between 0 and 100 °C. Hole mounted components and secondary side SMD components were wave soldered with an Sn–3.5Ag alloy. Joints of both dual in line (DIL) packages and ceramic chip capacitors were investigated. Crack initiation and propagation was analysed after every 500 cycles. In total, 6500 cycles were run at both temperature profiles and the observations from each profile were compared.For both kinds of components analysed, cracks were first visible for the temperature profile ranging between −55 and 100 °C. For this temperature profile, and for DIL packages, cracks were visible already after 500 cycles, whereas for the other temperature profile, cracks initiated between 1000 and 1500 cycles. The cracks observed after 1500 cycles were visibly smaller for the temperature profile ranging between 0 and 100 °C, concluding that crack initiation and propagation was slightly slower for this temperature profile. For the chip capacitors, cracks were first visible after 2000 cycles.     

Effect of Ag micro-particles content on the mechanical strength of the interface formed between Sn–Zn binary solder and Au/Ni/Cu bond pads

In this study, addition of Ag micro-particles with a content in the range between 0 and 4 wt.% to a Sn–Zn eutectic solder, were examined in order to understand the effect of Ag additions on the microstructural and mechanical properties as well as the thermal behavior of the composite solder formed. The shear strengths and the interfacial reactions of Sn–Zn micro-composite eutectic solders with Au/Ni/Cu ball grid array (BGA) pad metallizations were systematically investigated. Three distinct intermetallic compound (IMC) layers were formed at the solder interface of the Au/electrolytic Ni/Cu bond pads with the Sn–Zn composite alloys. The more Ag particles that were added to the Sn–Zn solder, the more Ag–Zn compound formed to thicken the uppermost IMC layer. The dissolved Ag–Zn IMCs formed in the bulk solder redeposited over the initially formed interfacial Au–Zn IMC layer, which prevented the whole IMC layer lifting-off from the pad surface. Cross-sectional studies of the interfaces were also conducted to correlate with the fracture surfaces.     

Compound semiconductor activation energy in humidity

Product reliability investigations typically include accelerated humidity testing. Originally, the “standard” test was a biased 85 °C/85% relative humidity (RH) lifetest for 1000 h. Recently, a substitute accelerated version of this test has been used. The accelerated version is called highly accelerated stress test (HAST). The HAST conditions are also biased, at 130 °C, 85%RH, and approximately 18 PSI overpressure. The duration of the HAST test is normally 96–100 h – to be equivalent to the 85/85 test. This study is intended to investigate thermal acceleration and show that equivalent HAST tests on compound semiconductors are more highly accelerated and could be conducted with much shorter durations.     

Reliability study of Sn–Ag–Cu–Ce soldered joints in quad flat packages

The reliability of Sn–Ag–Cu–Ce lead-free soldered joints in quad flat packages under thermal cycling was investigated based on finite element simulation and experiments. The stress and strain response of fine pitch QFP device lead-free soldered joints were analyzed using finite element method based on Garofalo–Arrhenius model. The simulated results indicate that the creep distribution is not uniform, the heel of joints is the maximum creep strain concentrated sites. And comparisons were then made with experimental results of the cracks observed in the Sn–Ag–Cu–Ce soldered joints subjected to the temperature cycled experiment. In addition, the relative mechanical and metallurgical factors, which dominate the failure of soldered joints, were utilized to analyze the phenomena. The fracture surfaces indicate that crack initiate and propagate along the interface among bulk Cu₆Sn₅ phases in Sn–Ag–Cu–Ce soldered joints.     

High temperature reliability and interfacial reaction of eutectic Sn–0.7Cu/Ni solder joints during isothermal aging

The interfacial reactions and growth kinetics of intermetallic compound (IMC) layers formed between Sn–0.7Cu (wt.%) solder and Au/Ni/Cu substrate were investigated at aging temperatures of 185 and 200 °C for aging times of up to 60 days. After reflow, the IMC formed at the interface was (Cu, Ni)₆Sn₅. After aging at 185 °C for 3 days and at 200 °C for 1 day, two IMCs of (Cu, Ni)₆Sn₅ and (Ni, Cu)₃Sn₄ were observed. The growth of the (Ni, Cu)₃Sn₄ IMC consumed the (Cu, Ni)₆Sn₅ IMC at an aging temperature of 200 °C due to the restriction of supply of Cu atoms from the solder to interface. After aging at 200 °C for 60 days, the Ni layer of the substrate was completely consumed in many parts of the sample, at which point a Cu₃Sn IMC was formed. In the ball shear test, the shear strength decreased with increasing aging temperature and time. Until the aging at 185 °C for 15 days and at 200 °C for 3 days, fractures occurred in the bulk solder. After prolonged aging treatment, fractures partially occurred at the (Cu, Ni)₆Sn₅ + Au/solder interface for aging at 185 °C and at the (Ni, Cu)₃Sn₄/Ni interface for aging at 200 °C, respectively. Consequently, thick IMC layer and thermal loading history significantly affected the integrity of the Sn–0.7Cu/Ni BGA joints.     

Growth of tin whiskers for lead-free plated leadframe packages in high humid environments and during thermal cycling

Growth behavior of tin whiskers from pure tin and tin–bismuth plated leadframe (LF) packages for elevated temperature and high humidity storages and during thermal cycling was observed. In the storage at 60 °C/93% relative humidity (RH) and 85 °C/85%RH the galvanic corrosion occurred at the outer lead toes and shoulders where the base LF material is exposed, forming tin oxide layers of SnO₂. The corroded layers spread inside the film and formed whiskers around the corroded islands. Many whiskers were observed to grow from grain boundaries for the Fe–42Ni alloy (alloy42) LF packages. It was confirmed that the corrosion tends to occur on the side surfaces of outer leads adjacent to the mold flash. The contribution of ionic contaminants in epoxy mold compound (EMC) to the corrosion was not identified. During thermal cycling between −65 °C and +150 °C whiskers grew out of as-deposited grains for pure tin-plated alloy42 LF packages and they grew linearly with an increase of number of cycle. Growth mechanisms of the whiskers from grain boundaries and as-deposited grains were discussed from the deformation mechanism map for tin and mathematical calculation with a steady-state diffusion model.     

Study on low-Ag content Sn–Ag–Zn/Cu solder joints

The eutectic Sn–Ag–Cu solder is the most popular lead free solder. But reliability and cost issues limit its application. On the other hand, Sn–Ag–Zn system has many advantages comparing with Sn–Ag–Cu. In this paper, interfaces of Sn–xAg–1Zn/Cu and Sn–2Ag–xZn/Cu (x = 1, 2, 3), Sn–2Ag–2.5Zn/Cu and Sn–1.5Ag–2Zn/Cu solders joints were studied to understand effects of Ag and Zn contents. Results show that shearing strength of as-reflowed Sn–2Ag–2Zn/Cu and Sn–1.5Ag–2Zn/Cu joints is higher than other joints. Because of the strong Cu–Sn reaction and the formation of Ag₃Sn, the Sn–Ag–Zn series solder joints are not suitable for use above 150 °C temperature. After 250 °C soldering for 4 h, while the Zn content increased from 1 wt% to 2 wt%, the interfacial IMC of Sn–Ag–Zn/Cu altered from Cu₆Sn₅ to Cu₅Zn₈. The Cu₅Zn₈ interface has higher shearing strength than Cu₆Sn₅ interface. Relationships among microstructure, strength and aging condition are discussed.     

Thermal fatigue endurance of collapsible 95.5Sn4Ag0.5Cu spheres in LTCC/PWB assemblies

The behavior of thermomechanically loaded collapsible 95.5Sn4Ag0.5Cu spheres in LTCC/PWB assemblies with high (LTCC/FR-4; ΔCTE 10 ppm/°C) and low (LTCC/Arlon; ΔCTE < 10 ppm/°C) global thermal mismatches was studied by exposing the assemblies into two thermal cycling tests. The characteristic lifetimes of the LTCC/FR-4 assemblies, tested over the temperature ranges of 0–100 °C and −40 to 125 °C, were 1475 and 524 cycles, respectively, whereas the corresponding values of the LTCC/Arlon assemblies were 5424 and 1575 cycles. According to the typical requirements for the industrial lifetime duration of solder joints, the former values are inadequate, whereas the latter are at an acceptable level in a few cases. Furthermore, the global thermal mismatch affected the thermal fatigue behavior of the 95.5Sn4Ag0.5Cu spheres in the temperature range of −40 to 125 °C.     

Processability and reliability of epoxy adhesive used in microelectronic devices linked to effects of degree of cure and damp heat aging

In an effort to explicate the effects of degree of cure (conversion) and damp heat aging at 85 °C/85% RH on physical properties of the cured epoxy system consisting of diglycidyl ether of bisphenol F (DGBF) and imidazole as a curing agent, an experimental approach was systematically performed using a dynamic mechanical analyzer (DMA) and thermomechanical analyzer (TMA). Of interesting physical properties are the storage modulus, loss modulus, tan δ, glass transition temperature (T_g), and coefficient of thermal expansion (CTE). The die shear test was performed to evaluate changes in adhesion strength of the cured epoxy with and without an epoxy silane before and after the damp heat aging. We have found that the magnitude of storage modulus in a glass transition region and the onset temperature for degradation of storage modulus, DMA T_g, increase as the conversion of cure increases. Even though such benefits observed at ambient are lessened after extended exposure to the damp heat aging, higher conversion has less degradation than lower conversion. It is observed that T_g taken from DMA and TMA decreases approximately from 132 °C to 81 °C after 500 h of damp heat aging. Such large diminution is attributed to high moisture diffusivity of 2.0 × 10⁻⁸/cm²/s at 85 °C/85% RH and can cause large dimensional instability at the critical interface supported by the epoxy adhesive. We have also found that a 3-parameter exponential function is useful to predict the degradation of T_g under the given aging condition. Although the effect of an epoxy silane is negligible at ambient, it provides better adhesion strength after the damp heat aging. Finally, we intend to give process guidelines for the usage of DGBF/imidazole epoxy system to ensure stringent reliability in electronic device applications.     

New dielectric material system of Nd(Mg1/2Ti1/2)O3–CaTiO3 at microwave frequency

The microwave dielectric properties of (1 − x)CaTiO₃–xNd(Mg_1/2Ti_1/2)O₃ (0.1  x  1.0) ceramics prepared by the conventional solid state method have been investigated. The system forms a solid solution throughout the entire compositional range. The dielectric constant decreases from 152 to 27 as x varies from 0.1 to 1.0. In the (1 − x)CaTiO₃–xNd(Mg_1/2Ti_1/2)O₃ system, the microwave dielectric properties can be effectively controlled by varying the x value. At 1400 °C, 0.1CaTiO₃–0.9Nd(Mg_1/2Ti_1/2)O₃ has a dielectric constant (ε_r) of 42, a Q × f value of 35 000 GHz and a temperature coefficient of resonant frequency (τ_f) of −10 ppm/°C. As the content of Nd(Mg_1/2Ti_1/2)O₃ increases, the highest Q × f value of 43 000 GHz for x = 0.9 is achieved at the sintering temperature 1500 °C.     

Degradation by Sn diffusion applied to surface mounting with Ag-epoxy conductive adhesive with joining pressure

Shear and tensile tests were carried out on joints made with an isotropic conductive adhesive (ICA) consisting of Ag and epoxy: Sn–Pb plated components mounted on printed boards and tensile bars consisting of Sn plated Ni and Cu joined under various joining pressures. After 150 °C–100 h, shear strength degraded to 72% and Sn in the plating diffused slightly to the Ag fillers in the ICA for the component mounting. High joining pressure increased the initial tensile strength and volume percentage of Ag fillers in the ICA. After 150 °C–100 h, tensile strengths for all joining pressures degraded on average to 36% of the initial strengths. In the case of low joining pressures, an Ag–Sn intermetallic was formed at only the Ag–Sn contact points of the Sn/ICA interface; leading to reproducibility of the component mounting. The difference of degradation ratios between the mounted components and tensile bars could be explained by the offset of the Sn–Pb area at the component/ICA interface.