Predominant high melting point solders for high-temperature and harsh environment electronics (operating temperatures from 200 to 250 °C) are Pb-based systems, which are being subjected to RoHS regulations because of their toxic nature. In this study, high bismuth (Bi) alloy compositions with Bi-XSb-10Cu (X from 10 wt % to 20 wt %) were designed and developed to evaluate their potential as high-temperature, Pb-free replacements. Reflow processes were developed to make die-attach samples made from the cast Bi alloys. Die-attach joints made from Bi-15Sb-10Cu alloy exhibited an average shear strength of 24 MPa, which is comparable to that of commercially available high Pb solders. These alloy compositions also retained original shear strength even after thermal shock (TS) between −55 °C and +200 °C and high-temperature storage (HTS) at 200 °C. Brittle interfacial fracture sometimes occurred along the interfacial NiSb layer formed between Bi(Sb) matrix and Ni metallized surface. In addition, heat dissipation capabilities, using flash diffusivity, were measured on the die-attach assembly and were compared to the corresponding bulk alloys. The thermal conductivity of all the Bi–Sb alloys was higher than that of pure Bi. By creating high volume fraction of precipitates in a die-attach joint microstructure, it was feasible to further increase thermal conductivity of this joint to 24 W/m·K, which is three times higher than that of pure Bi (8 W/m·K). Bi–15Sb–10Cu alloy has so far shown the most promising performance as a die-attach material for high-temperature applications (operated over 200 °C). Hence, this alloy was further studied to evaluate its potential for plastic deformation. Bi–15Sb–10Cu alloy has shown limited plastic deformation in room temperature tensile testing in which premature fracture occurred via the cracks propagated on the (111) cleavage planes of rhombohedral crystal structure of the Bi(Sb) matrix. The same alloy has, however, shown up to 7% plastic strain under tension when tested at 175 °C. The cleavage planes, which became oriented at smaller angles to the tensile stress, contributed to improved plasticity in the high-temperature test.
Thermal interface materials (TIMs) are particulate composite materials widely used in the microelectronics industry to reduce the thermal resistance between the device and the heat sink. Predictive modeling using fundamental physical principles is critical to developing new TIMs, since it can be used to quantify the effect of polydispersivity, volume fraction and arrangements on the effective thermal conductivity. A random network model that can efficiently capture the near-percolation transport in these particle-filled systems was developed by the authors, which can take into account the interparticle interactions and random size distributions. In this paper, a Java-based code is used to generate the microstructures at different volume fraction and different particle-size distribution (PSD). COMSOL was used to investigate the impact of polydispersivity on the effective thermal conductivity of particulate TIMs. The log-normal distribution was used to capture the filler PSD. From the simulation results, there exists an optimum value of the polydispersivity which has the largest thermal conductivity for a given volume fraction.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.