Effect of Ag Content and the Minor Alloying Element Fe on the Mechanical Properties and Microstructural Stability of Sn-Ag-Cu Solder Alloy Under High-Temperature Annealing

This study compares the high-Ag-content Sn-3Ag-0.5Cu with the low- Ag-content Sn-1Ag-0.5Cu solder alloy and the three quaternary solder alloys Sn-1Ag-0.5Cu-0.1Fe, Sn-1Ag-0.5Cu-0.3Fe, and Sn-1Ag-0.5Cu-0.5Fe to understand the beneficial effects of Fe on the microstructural stability, mechanical properties, and thermal behavior of the low-Ag-content Sn-1Ag-0.5Cu solder alloy. The results indicate that the Sn-3Ag-0.5Cu solder alloy possesses small primary β-Sn dendrites and wide interdendritic regions consisting of a large number of fine Ag₃Sn intermetallic compound (IMC) particles. However, the Sn-1Ag-0.5Cu solder alloy possesses large primary β-Sn dendrites and narrow interdendritic regions of sparsely distributed Ag₃Sn IMC particles. The Fe-bearing SAC105 solder alloys possess large primary β-Sn dendrites and narrow interdendritic regions of sparsely distributed Ag₃Sn IMC particles containing a small amount of Fe. Moreover, the addition of Fe leads to the formation of large circular FeSn₂ IMC particles located in the interdendritic regions. On the one hand, tensile tests indicate that the elastic modulus, yield strength, and ultimate tensile strength (UTS) increase with increasing Ag content. On the other hand, increasing the Ag content reduces the total elongation. The addition of Fe decreases the elastic modulus, yield strength, and UTS, while the total elongation is still maintained at the Sn-1Ag-0.5Cu level. The effect of aging on the mechanical behavior was studied. After 720 h and 24 h of aging at 100°C and 180°C, respectively, the Sn-1Ag-0.5Cu solder alloy experienced a large degradation in its mechanical properties after both of the aging conditions, whereas the mechanical properties of the Sn-3Ag-0.5Cu solder alloy degraded more dramatically after 24 h of aging at 180°C. However, the Fe-bearing SAC105 solder alloys exhibited only slight changes in their mechanical properties after both aging procedures. The inclusion of Fe in the Ag₃Sn IMC particles suppresses their IMC coarsening, which stabilizes the mechanical properties of the Fe-bearing SAC105 solder alloys after aging. The results from differential scanning calorimetry (DSC) tests indicate that the addition of Fe has a negligible effect on the melting behavior. However, the addition of Fe significantly reduces the solidification onset temperature and consequently increases the degree of undercooling. In addition, fracture surface analysis indicates that the addition of Fe to the Sn-1Ag-0.5Cu alloy does not affect the mode of fracture, and all tested alloys exhibited large ductile dimples on the fracture surface.     

A review on thermal cycling and drop impact reliability of SAC solder joint in portable electronic products

Currently, the portable electronic products trend to high speed, light weight, miniaturization and multifunctionality. In that field, solder joint reliability in term of both drop impact and thermal cycling loading conditions is a great concern for portable electronic products. The transition to lead-free solder happened to coincide with a dramatic increase in portable electronic products. Sn–Ag–Cu (SAC) is now recognized as the standard lead free solder alloy for packaging interconnects in the electronics industry. The present study reviews the reliability of different Ag-content SAC solder joints in term of both thermal cycling and drop impact from the viewpoints of bulk alloy microstructure and tensile properties. The finding of the study indicates that the best SAC composition for drop impact performance is not necessarily the best composition for optimum thermal cycling reliability. The level of Ag-content in SAC solder alloy can be an advantage or a disadvantage depending on the application, package and reliability requirements. As a result, most component assemblers are using at least two (and in many cases even more) lead-free solder sphere alloys to meet various package requirements.     

High-Reliability Low-Ag-Content Sn-Ag-Cu Solder Joints for Electronics Applications

Sn-Ag-Cu (SAC) alloy is currently recognized as the standard lead-free solder alloy for packaging of interconnects in the electronics industry, and high- Ag-content SAC alloys are the most popular choice. However, this choice has been encumbered by the fragility of the solder joints that has been observed in drop testing as well as the high cost of the Ag itself. Therefore, low-Ag-content SAC alloy was considered as a solution for both issues. However, this approach may compromise the thermal-cycling performance of the solders. Therefore, to enhance the thermal-cycling reliability of low-Ag-content SAC alloys without sacrificing their drop-impact performance, alloying elements such as Mn, Ce, Ti, Bi, In, Sb, Ni, Zn, Al, Fe, and Co were selected as additions to these alloys. However, research reports related to these modified SAC alloys are limited. To address this paucity, the present study reviews the effect of these minor alloying elements on the solder joint reliability of low-Ag-content SAC alloys in terms of thermal cycling and drop impact. Addition of Mn, Ce, Bi, and Ni to low-Ag-content SAC solder effectively improves the thermal-cycling reliability of joints without sacrificing the drop-impact performance. Taking into consideration the improvement in the bulk alloy microstructure and mechanical properties, wetting properties, and growth suppression of the interface intermetallic compound (IMC) layers, addition of Ti, In, Sb, Zn, Al, Fe, and Co to low-Ag-content SAC solder has the potential to improve the thermal-cycling reliability of joints without sacrificing the drop-impact performance. Consequently, further investigations of both thermal-cycling and drop reliability of these modified solder joints must be carried out in future work.     

Microstructure and Tensile Properties of Sn-1Ag-0.5Cu Solder Alloy Bearing Al for Electronics Applications

This work investigates the effects of 0.1?wt.% and 0.5?wt.% Al additions on bulk alloy microstructure and tensile properties as well as on the thermal behavior of Sn-1Ag-0.5Cu (SAC105) lead-free solder alloy. The addition of 0.1?wt.% Al reduces the amount of Ag₃Sn intermetallic compound (IMC) particles and leads to the formation of larger ternary Sn-Ag-Al IMC particles. However, the addition of 0.5?wt.% Al suppresses the formation of Ag₃Sn IMC particles and leads to a large amount of fine Al-Ag IMC particles. Moreover, both 0.1?wt.% and 0.5?wt.% Al additions suppress the formation of Cu₆Sn₅ IMC particles and lead to the formation of larger Al-Cu IMC particles. The 0.1?wt.% Al-added solder shows a microstructure with coarse ??-Sn dendrites. However, the addition of 0.5?wt.% Al has a great effect on suppressing the undercooling and refinement of the ??-Sn dendrites. In addition to coarse ??-Sn dendrites, the formation of large Sn-Ag-Al and Al-Cu IMC particles significantly reduces the elastic modulus and yield strength for the SAC105 alloy containing 0.1?wt.% Al. On the other hand, the fine ??-Sn dendrite and the second-phase dispersion strengthening mechanism through the formation of fine Al-Ag IMC particles significantly increases the elastic modulus and yield strength of the SAC105 alloy containing 0.5?wt.% Al. Moreover, both 0.1?wt.% and 0.5?wt.% Al additions worsen the elongation. However, the reduction in elongation is much stronger, and brittle fracture occurs instead of ductile fracture, with 0.5?wt.% Al addition. The two additions of Al increase both solidus and liquidus temperatures. With 0.5?wt.% Al addition the pasty range is significantly reduced and the differential scanning calorimetry (DSC) endotherm curve gradually shifts from a dual to a single endothermic peak.     

The bulk alloy microstructure and mechanical properties of Sn–1Ag–0.5Cu–xAl solders (x?=?0, 0.1 and 0.2?wt.?%)

This work investigates the effects of 0.1 and 0.2?wt.?% Al additions on bulk alloy microstructure and tensile properties as well as on the thermal behavior of Sn–1Ag–0.5Cu (SAC105) lead-free solder alloy. The addition of Al reduces the amount of Ag₃Sn intermetallic compound (IMC) particles and leads to the formation of larger Al–Ag IMC particles. Moreover, the addition of Al suppresses the formation of Cu₆Sn₅ IMC particles and leads to the formation of larger Al–Cu IMC particles. The Al added solders show a microstructure with large primary β-Sn grains. The tensile tests show that the 0.1?wt.?% Al addition reduces the elastic modulus, yield strength and ultimate tensile strength (UTS). However, the 0.2?wt.?% Al addition brings the yield strength up to SAC105 level and the UTS up to level slightly higher than that of SAC105, while its effect on reducing the elastic modulus becomes less dependent compared with the 0.1?wt.?% Al addition. Moreover, both 0.1 and 0.2?wt.?% Al additions deteriorate the total elongation. The two additions of Al slightly increase the solidus and liquids temperatures, while slightly reduce the pasty range, hence allowing the use of the Al-containing Sn–1Ag–0.5Cu alloys, to be consistent with the conditions of usage for conventional Sn–Ag–Cu solder alloys.     

Enhancement of Thermoelectric Behavior of La0.5Co4Sb12−x Te x Skutterudite Materials

Metallurgical and Materials Transactions A - In this work, the effects of Te doping on the microstructure and thermoelectric properties of the partially filled skutterudite La0.5Co4Sb12 compounds...