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Effect of Compression Loads On The Solder Joint Reliability of F
Effect of Compression Loads On The Solder Joint Reliability of F
Effect of Compression Loads On The Solder Joint Reliability of F
Luke Garner, Charles Zhang, Keh Shin Beh, Kayleen Helms, and Yew Lip Tan
Intel Corporation
5000W Chandler Blvd, CH5-157, Chandler AZ 85226
1uke.j.garner@intel.com
02004 IEEE
0~7803-8365-6/04/$20.00 692 2004 Electronic Components and Technology Conierence
stamped metal or bent wire heat sink clips. To minimize over induced electrical shorting or into thermal cycle chambers for
constraining the board, the fixture uses dome washers to thermo-mechanical fatigue.
support the board from one side only.
Finite Element Analysis
The thermal solution hardware may also include a stiff
To firther understand the mechanisms of failure, finite
back plate to minimize board flexure. To simulate this type of
element analysis (FEA) has been used. Figure 2 shows a
thermal solution, a thick back plate with threaded through
typical mesh of the board and FCBGA package. The elements
holes is used instead of the dome washers and nuts.
used are reduced integration 2nd order elements: bricks
(C3D20R) and wedges (used only in the die fillet). The
ABAQUS standard solver has been used for all simulations.
The symmetry of the load and the package allow the use of a
quarter-symmetric model. As the most critical solder joints
are those near the die corner and the package comer, the mesh
was refined in these areas to improve accuracy, as shown in
Figure 3. For this sensitivity analysis, the details of the solder
Tlrennal Grpm joint pad design have been excluded.
P
KTB
Board
when the cross head is raised the desired load continues to be Figure 2. Quarter symmetric finite element model of the
applied to the component. The 50% load reduction technique FCBGA package on test boards.
was determined through experimentation using a load cell as
the component in the fixture.
‘me loaded fixture is then placed into the accelerated
thermal testing chambers. The thermal mass of the fixture has
been minimized; however the use of the fixture does
adwrsely affect the chamber capacity. All chambers were
profiled to ensure that the component temperatures were
with in the accelerated test specification. Two standard
JEDEC thermal cycle conditions were used: TCQ (-25 to
100°C and TCJ (0 to 100°C). High-end temperature was
limiired to 100 O C to avoid exceeding the board glass
transition temperature which would cause excessive damage
to the joints and board. The high-end temperature was kept
the same in both thermal cycle conditions to eliminate the
introduction of high-end temperature effect suggested by
some three-parameter solder fatigue models [2]. The two Figure 3. Detail of solder joint mesh: 4 layers of second order
thennal cycle conditions also have the same fiequency that elements, 5 elements per layer. Top layer used for averaging.
allows a single parameter model to be used for reliability
prediction. Linear elastic constitutive models are used for all package
At each thermal cycle readout, both electrical test and components expect for the solder joints. The solder behavior
dye & pry failure analysis were conducted to monitor the is simulated by a model from Hong and Burrell [3]. This
performance of the BGA solder joints. The test package and model includes isotropic hardening plasticity and power law
board were designed in such way that all of the solder joints creep. Since the board is known to creep during these tests,
in the critical areas (under the die and package corners) can be the long-term Young’s modulus is used for the board
hlly tested electrically. In addition, dye and pry provides an properties. Internal tests have noted that the long-term
accurate measurement of solder joint fatigue crack area. modulus is about 80% of the instantaneous modulus.
Lrsing these test fixtures, surface-mounted test vehicles Two basic analyses were run, one for solder joint creep
were loaded into either “bake” conditions to assess creep shorting and the other for thermal cycle fatigue. In both
693 2004 Electronic Components and Technology Conference
:
analyses, the thermally induced stresses from board surface board thickness, the expected maximum sustained 13GA
mount and package assembly were included by first temperature and enabling hardware stiffness.
completing a cool down step from the reflow temperature to
room temperature. After the cool down from assembly, the
compression load is applied to the top of the die and the board
constrained at the desired support point. These support
locations are highlighted in Figure 2. For each analysis, all of
the nodes in one of the highlighted elements were constrained
in the vertical direction only. For models where a back plate
is included, all nodes on the bottom surface of the board were
constrained in the vertical direction. For the creep tests, the
model was then ramped to the desired uniform temperature
q
04
01
4
and held until a BGA short was detected. For thermal fatigue,
the model simulates three complete thermal cycles to allow
the creep and plasticity response to stabilize. The dwell time
at the high and low ends of the thermal cycling were included I O'
R a d hrt #
i
2.67 1.33 2.67 1.33 2.67 Load Rccel
to capture creep effects.
. 1.13 1.33 1.67 Tew
Solder Joint Creep Results 1 I 1 I I
As mentioned previously, a primary concern of high
compression loads on FCBGA packages is the risk of creep -
Legend
FEAMdel
+ exp.daia
induced ball shorting. It has been difficult to fit the results of
accelerated creep tests with standard statistical reliability Figure 4. Comparison of finite element prediction with creep
models. A finite element model is therefore used to make the test results for ball-to-ball gap for various temperature and
reliability assessment. Five experimental test legs were used load conditions over time.
to validate the creep model for the PbSn eutectic solder.
These included three elevated temperatures and two elevated
loads. Elevated loads and temperatures were used to ensure 1
that measurable amounts ball deformation would occur during U 0.9
the testing period. The lowest temperature and load
w
= 0.8
combination was not included since little creep was expected E 0.7
0
in the duration of the test. For each test leg, the specimens & 0.6
were removed at defined time intervals, and x-ray 0 0.5
measurements were taken to measure the minimum ball-to- c3
7 0.4
ball gap. Figure 4 shows the experimental results of these
tests compared to the prediction of the finite element model. 0.3
B
Using the Hong and Burrell creep model referenced above, = 0.2
the fit of the FEA model is reasonably good. The model 0.1
appears to become more conservative for lower temperatures, 0
which should lead to conservative estimates for reliability in
use, where lower solder ball temperatures are expected.
Since the temperatures used in this test were near the glass
transition temperature of the board, the back plate Figure 5 Comparison of solder joint creep with and without
configuration of the fixture was used. In some systems the back plate support.
board may be allowed to deflect. A FEA simulation was done Thermo-mechanical Fatigue Results
to compare the relative risk of failure with and without the
back plate. With a rigid back plate, the solder joints beneath Package Corner Analysis
the die deformed most. Without the back plate, the solder When no compression load is applied on a FCBGA
joints at the package corners had the greatest creep package, the solder joints at greatest risk for thermo-
deformation due to the board flexure. Figure 5 shows the mechanical fatigue are those under the die. In this area, there
comparison results. The gap decreases faster for the center is a local coefficient of thermal expansion (CTE) mismatch
joints with a back plate than for the comer joints without a created by the silicon being tightly bonded to the substrate.
back plate. The back plate extends the time to failure 50%. The solder joints in this area see additional shear and axial
The calibrated creep model can be used predict the risk of strain due to this mismatch. The solder joints at the package
electrical shorting as a function of load, expected solder joint corner are not likely to fail since there is no significant CTE
temperature, and board support configuration. Compression mismatch between the FR4-like substrate and the very similar
load limits should be specified for the component to prevent board materials. This very unlike the behavior observed in
solder joint shorts. This load limit will be a function of the ceramic packages. In these packages, the large package-board
CTE mismatch leads to fatigue cracking at the package
corners.
Board Thickess
Figure 7 Effect of board thickness for fixed span and
compression load on failure rate for experimental data and
FEA simulation predictions.
0.5 This observation does not agree at first pass with the FEA
model. Figure 11 shows the ratio of the per cyclme. ISED
0.0 increment between the package corner and the die shadow.
0 0.2 0.4 0.6 0.8 1 1.2 1.4 For even very low loads this ratio is very large. Theory would
predict much faster growth at the package comer than at the
Load (Normalized)
die shadow. While this is true in high load and span cases in
Figure 8 Effect of compression load for fixed span and more a moderate case such as the one shown in Figure 10, it
thickness on failure rate for experimental data and FEA is not. A closer examination of the loading state of the solder
simulation predictions. joints may be able to explain this inconsistency.
14 6.0 I
I
I
I
I
I
1
h 12
U
0)
N
"m 10
zE 8
i---------
0
.-
s 6
2' e
-$m 4
.-
k 2
0
0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 0.0 0.5 1.o 1.5
Thermal Load (Normalized)
Support Span (Normalized)
Figure 11 Comparison of predicted ISED between di.e region
Figure 9 Effect of support span for fixed board thickness and and package corner as function of load.
compression load on failure rate for experimental data and
FEA simulation predictions. The predicted axial strains between the package comer
and die shadow behave quite differently. Figure 12 shows the
-1.2
+Shear Strain - Die
-1.o +-Axial Strain - Comer
! ” / I
.- -0.8
m
b
$ -0.6
al
-N
.-
E -0.4
b
z -0.2 Loaded 1 Unloaded
Readout within Loading, Ib
0.0
Figure 13. Comparison of normalized solder joint damage for
I I
I I load vs unload configuration as function of thermal cycles.(-
0.2 I , 25 to 100°C)
0.0 0.5 1 .o 1.5
Thermal Load (Normalized)
As shown in Figure 13 and 14, both loading conditions
Figure 12. Predicted strain state for the package comer and exhibited very similar solder joint damage behavior
die shadow solder joints as a function of load characterized by two stages. In Stage I, no visual damage was
observed. This stage ends with the initiation of a crack. Stage
These significant spatial differences in the strain state may I covers -40% of the total thermal cycle test period in this
require that a more advanced fatigue law be developed. To study. Stage I1 is solder crack propagation. The crack
adequately predict behavior, the fatigue law must account for propagation had a linear relationship with number of cycles
the multi-axial loading state of the solder balls under load and after initiation in all conditions tested except for the loaded
the distribution loading states within the solder joint array. TCJ condition.
Failure rate predictions in Figures 7-9 show that an energy- The load appears to change the solder joint damage
based model may still be used to gain understanding and behavior for less severe thermal cycle condition TCJ. Instead
predict solder joint performance. However, the model of having a linearly proportional relationship, the damage
gene)-atedcannot be applied to other areas in the BGA array appears to be decelerated by the load. This is not the case in
where the loading state is dissimilar. For the energy-based TCQ, which has a lower low-end temperature. As mentioned
methods to work, a predictive model would have to be created above, a tensile load is imposed on the joints in the die
at each location in the array.
1 I 1 I:I 1
4. Darveaux, R, “Effect of Simulation Methodology on
Solder Joint Crack Growth Correlation”, Proc. Elect.
Table 1 Damage Growth Model Fitting Summarv
Comp. and Tech. Conf. 1997, pp. 1068-1075.
Cyc1esto Cycles to
Model Fitting
Condition
Initiation
Transformed
LoadedTCJ
5:
IUnloadedTCJl
I
Linear I
I
0.88 I
I
540 I
I
2350 I
LoadedTCQ I Linear I 0.93 I 550 I 1700
Unloaded
Linear 0.94 485 1700
TCQ