This paper presents the results of comparative testing of standard encapsulants versus inorganic hermeticequivalent protective coatings in a full factorial study that also compares wire-bond assembly versus flip-chip assembly, and supplemental encapsulant/underjlI die protections versus no encapsulant/underJilI protection. The Demonstration MultiChip Modules (MCMs) included two design versions, flip-chip and wire-bond, of a General Aviation Data Accumulator MCM. Full wafer probe testing was performed both before and afer the supplemental ChipSeal TMprocessing and flip-chip wafer bump processing steps. ChipSeal mandflip-chip wafer processing steps were shown to cause no yield degradation on the two different wafers types used in the MCMs. Known-Good-Die (KGD) screening of all integrated circuits in the modules was utilized to keep infant mortality failures out of the reliability test results. Preliminary substrate reliability investigations determined that laminate materials BT and Polyimide are suitable for robust MCM-L applications.Reliability testing includes vibration in step-stress exposures j-om 2 to 44 g(rms), thermal cycling for 2000 cycles j-om -55 to 4-125 "c, 85 W85% RH high humidity testing accelerated by pre-conditioning and power cycling, and 130 "c bias Highly Accelerated Stress Testing (HAST). Comparative reliability results will be presented on identical circuit designs in flip-chip versus wire-bonded assemblies, with and without the protective inorganic coatings, and with and without organic encapsulant/underj?ll protection.
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