The effects of Ni doping on microstructural variations and interfacial reactions in Cu/Sn-3.0Ag-0.5Cu-xNi/Au/Ni sandwich structures were investigated. The sandwich structures, i.e., Cu/Sn-3.0Ag-0.5Cu/Au/Ni and Cu/Sn-3.0Ag-0.5Cu-0.1Ni/Au/Ni (wt.%), were reflowed and isothermally aged at 150°C for 500 h. The behavior of Ni and Cu migration in the solders before and after aging was investigated using field-emission electron probe microanalysis (FE-EPMA), and the microstructure evolution of the solders with Ni doping was investigated. It was observed that Ni migrated to the board Cu-side, while Cu tended to migrate toward the Ni/Au package side, and two different types of (Cu,Ni) 6 Sn 5 intermetallic compounds (IMCs), one with 19.8 at.% to 23.4 at.% Ni and the other with 1.3 at.% to 6.4 at.% Ni content, were found. Regarding interfacial reactions, it was identified that the local Ni and Cu concentrations affected the formation of (Cu,Ni) 6 Sn 5 . Redistribution of Ni and Cu was correlated with the formation mechanism of interfacial (Cu,Ni) 6 Sn 5 .
The interaction between isothermal aging and the long-term reliability of fine-pitch ball grid array (BGA) packages with Sn-3.0Ag-0.5Cu (wt.%) solder ball interconnects was investigated. In this study, 0.4-mm fine-pitch packages with 300-lm-diameter Sn-Ag-Cu solder balls were used. Two different package substrate surface finishes were selected to compare their effects on the final solder composition, especially the effect of Ni, during thermal cycling. To study the impact on thermal performance and long-term reliability, samples were isothermally aged and thermally cycled from 0°C to 100°C with 10 min dwell time. Based on Weibull plots for each aging condition, package lifetime was reduced by approximately 44% by aging at 150°C. Aging at 100°C showed a smaller impact but similar trend. The microstructure evolution was observed during thermal aging and thermal cycling with different phase microstructure transformations between electrolytic Ni/Au and organic solderability preservative (OSP) surface finishes, focusing on the microstructure evolution near the package-side interface. Different mechanisms after aging at various conditions were observed, and their impacts on the fatigue lifetime of solder joints are discussed.
The work reported here included preliminary tests on the influence of an imposed current on the creep rate of the Pb-free solder Sn-Ag-Cu 305 (Sn-3Ag-0.5Cu in wt.%). The samples employed were double-shear specimens that contained paired solder joints, 400 lm 9 400 lm in cross-section, 200 lm in thickness on Cu. Three tests were done. In the first, samples were tested under stress at room temperature with imposed current densities that ranged from 1 9 10 3 A/cm 2 up to 6.5 9 10 3 A/cm 2 . As expected, because of Joule heating, the results show a sharp increase in creep rate with the imposed current density. A second set of tests was done to determine whether Joule heating fixed the creep rate. The steady-state temperature of the solder joints was measured under current, and samples were creep-tested at that temperature. Surprisingly, the creep rate under current was significantly below that measured in isothermal tests at the same temperature. The third set of tests studied the influence of microstructure. Samples were prepared with three starting microstructures: as cast, thermally aged by long-term isothermal exposure, and current aged by long-term exposure to a fixed current density. The three microstructures were then tested with and without current at two ambient temperatures. The different microstructures had very different creep rates in the absence of current but, surprisingly, imposing a current (5.5 9 10 3 A/cm 2 ) increased the creep rate by very nearly the same factor ($79) in every case. Neither of these results is well understood at this time.
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