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Effect of substrate flexibility on solder joint reliability
Xingsheng Liu a,*,1, Shuangyan Xu b, Guo-Quan Lu a, David A. Dillard b
a Materials Science and Engineering Department and Center for Power Electronics Systems, Virginia Tech, Blacksburg, VA 24061, USAb Engineering Science and Mechanics Department, Adhension Mechanics Laboratory, Virginia Tech, Blacksburg, VA 24061, USA
Received 4 December 2001; received in revised form 5 June 2002
Abstract
Solder joint fatigue failure is a serious reliability concern in area array technologies, such as flip chip and ball grid
array packages of integrated-circuit chips. The selection of different substrate materials could affect solder joint thermal
fatigue lifetime significantly. The reliability of solder joint in flip chip assembly for both rigid and compliant substrates
was evaluated by accelerated temperature cycling test. Experimental results strongly showed that the thermal fatigue
lifetime of solder joints in flip chip on flex assembly was much improved over that in flip chip on rigid substrate as-
sembly. Debonding area of solder joints in flip chip on rigid board and flip chip on flex assemblies were investigated,
and it was found that flex substrate could slow down solder joint crack propagation rate. The mechanism of substrate
flexibility on improving solder joint thermal fatigue was investigated by thermal mechanical analysis (TMA) technique.
TMA results showed that flex substrate buckles or bends during temperature cycling and this phenomenon was dis-
cussed from the point of view of mechanics of the flip chip assembly during temperature cycling process. It was in-
dicated that the thermal strain and stress in solder joints could be reduced by flex buckling or bending and flex
substrates could dissipate energy that otherwise would be absorbed by solder joints. It was concluded that substrate
flexibility has a great effect on solder joint reliability and the reliability improvement was attributed to flex buckling or
bending during temperature cycling.
� 2002 Elsevier Science Ltd. All rights reserved.
1. Introduction
Solder joint area array technologies, such as flip chip
and ball-grid array, have emerged as low-cost, high
density, and high performance techniques for both chip-
level and board-level interconnections [1–4]. However,
solder joint fatigue is a serious concern in area array
packages. Thermal strains and stresses caused by coef-
ficient of thermal expansion (CTE) mismatch are the
main cause of failure in solder joint interconnections.
Numerous factors affect solder joint fatigue perfor-
mance, such as joint geometry, chip size, interface met-
allurgy, underfill and substrate materials. Of these
factors, mechanical properties of substrate materials
could play an important role. A proper substrate ma-
terial could reduce the thermal strains and stresses in
solder joints and improve solder joint thermal fatigue
lifetime significantly.
Flex substrates are quite popular in the electronics
industry. Flex circuits have been utilized in integrated
circuit packaging and automotive and medical elec-
tronics applications with considerable success in reduc-
ing costs, minimizing package volume, saving space
for the system, improving packaging density, and
maintaining electrical performance. The excellent per-
formance of flex substrates, especially under hostile
operating conditions, and the features of high insula-
tion, low weight, high density, and, more importantly,
the flexibility make flex attractive in power electronics
packaging applications. We have developed a three-
dimensional flip chip on flex package for power elec-
tronics applications [5–7]. In this paper, the influence of
a flex substrate on solder joint reliability is investigated
Microelectronics Reliability 42 (2002) 1883–1891
www.elsevier.com/locate/microrel
* Corresponding author. Tel.: +1-607-248-1110; fax: +1-607-
974-0440.
E-mail address: [email protected] (X. Liu).1 Current address: Corning Incorporated, Science and Tech-
nology Center, Corning, NY 14831, USA.
0026-2714/02/$ - see front matter � 2002 Elsevier Science Ltd. All rights reserved.
PII: S0026-2714 (02 )00269-X
and the mechanism of substrate flexibility for improving
solder joint reliability is studied.
Basically, a flex substrate consists of a metal layer
such as Cu and a polyimide layer. The metal layer could
be electroplated or laminated. In the latter case, some-
times, an adhesive layer is used between the metal and
polyimide layer to enhance the adhesion. The flex sub-
strate could be one-sided or double-sided. In order to
protect the copper layer from oxidation, Ni and/or Au
could be electroplated as the final surface finish. The flex
substrate used in this research is a commercially avail-
able, double-sided, copper-clad laminate of polyimide
film bonded to two copper foil without an adhesive. This
laminate has excellent handling characteristics for fab-
rication, outstanding dimensional stability, excellent
assembly performance over a wide range of processing
temperatures, a CTE quite similar to that of traditional
printed circuit boards (PCB), excellent thermal resis-
tance for high temperature assembly processes, and is
compatible with conventional oxide treatments and wet
chemical plated-through-hole desmear processes. The
thickness of both the polyimide film and copper foils is
50 lm (2 mil). The pattern of Cu traces can be formed byphotolithography and chemical etching. After process-
ing, the substrate retains very good bend and crease
flexibility.
In this study, accelerated temperature cycling was
imposed to evaluate the influence of the flex substrate on
solder joint fatigue lifetime. In-process electrical re-
sistance measurements, acoustic microscopy imaging
(nondestructive evaluation), and optical microscopy
were utilized to examine the integrity of the joint and to
detect cracks and other defects before and during ac-
celerated fatigue tests. The mechanism of substrate
flexibility on improving solder joint thermal fatigue was
investigated by a thermal mechanical analysis (TMA)
technique. In this paper, the influence of flex substrate
(flip chip on flex) on solder joint reliability is first sum-
marized (the details will be presented elsewhere [8]), then
the TMA study on the behavior of the flex substrate
during thermal cycling is presented and, finally, the ex-
perimental results are discussed.
2. Influence of flex substrate on solder joint reliability
The reliability of fabricated solder joints in this study
was evaluated by accelerated temperature cycling tests.
During the temperature cycling, in-process electrical
resistance measurements and nondestructive evalua-
tions, such as scanning acoustic microscopy and optical
microscopy, were conducted to monitor solder joint
failure behavior. The electrical resistance of the solder
joint interconnections, which is measured by the four-
point probe method, is used as the failure criterion. We
set the evaluation criterion such that a 20% increase in
electrical resistance is regarded as solder bump inter-
connection failure [9].
The chip dimensions [16] and solder joint configura-
tion are shown in Fig. 1(a). There are seven solder joints
on each silicon chip. The solder material used in this
study is eutectic Sn37/Pb63 lead-tin solder. All the test
samples were flip chip attached to a test vehicle as shown
in Fig. 1(b). Solder joints were fabricated using stan-
dard stencil-printing technique. Two temperature cy-
cling conditions were used. The first condition was
temperature range: 0 and 100 �C; temperature raise time:10 min; dwell time at 100 �C: 5 min; temperature falltime: 10 min; dwell time at 0 �C: 5 min. The secondcondition was temperature range: �40 and 125 �C;temperature raise time: 25 min; dwell time at 125 �C: 5min; temperature fall time: 25 min; dwell time at �40 �C:5 min. Both flex substrates and rigid PCB were used for
making the test vehicle for comparison purposes, that is,
both flip chip on flex and flip chip on rigid board were
tested under the same temperature cycling conditions.
For each case, 21 solder joints were evaluated.
Fig. 2 shows the typical electrical resistance (nor-
malized) increases of solder joints (seven solder joints of
one test chip on a PCB rigid board) during temperature
cycling (the first temperature cycling condition). Simi-
Fig. 1. (a) Dimensions and solder joint locations of tempera-
ture cycling test chips [16] and (b) thermal cycling vehicle.
1884 X. Liu et al. / Microelectronics Reliability 42 (2002) 1883–1891
larly, we have obtained electrical resistance vs. temper-
ature cycling curves for all the samples for the four cases
introduced above. From Fig. 2, it can be clearly seen
that the curves can be divided into three periods, cor-
responding to three different fatigue degradation phases
which are crack initiation, crack propagation and cata-
strophic failure. During the crack initiation phase, there
is no significant electrical resistance increase while in the
crack propagation period, electrical resistance increases
gradually. On the other hand, electrical resistance in-
creases dramatically in the catastrophic failure period.
Note that we set a 20% resistance increase as the failure
criterion and solder joint fatigue lives can be estimated
based on the normalized electrical resistance vs. tem-
perature cycle curves. Fig. 3 is a comparison of the fa-
tigue life of flip chip on flex (FCOF) and flip chip on
PCB board (FCOB) assemblies with the commonly used
barrel-shaped solder joints under the first and the second
temperature cycling conditions, where the fatigue life is
the average lifetime of 21 solder joints. We know that
the major difference between flip chip on PCB and flip
chip on flex assemblies is the substrate flexibility.
Therefore, we can attribute the solder joint fatigue life-
time difference to substrate flexibility. We can see from
Fig. 3 that the flex substrate improves solder joint reli-
ability significantly under both the first and second
thermal cycling conditions. This indicates that substrate
flexibility could affect flip chip solder joint significantly.
C-mode scanning acoustic microscopy (C-SAM)
(Sonix system) was used to detect cracks and monitor
crack propagation in flip chip solder joints during tem-
perature cycling. A 75 MHz transducer was utilized in
this research. Fig. 4 shows typical C-SAM images of the
interface between solder joints and chip of a typical flip
chip on flex assembly after 1400, 2000, 2400, 2800 and
3000 temperature cycles, respectively, under the sec-
ond temperature cycling condition. The C-SAM results
showed that the images of some parts of the solder joints
had faded or were not present at all after 1400 temper-
ature cycles. This indicated that solder joints begin to
crack after 1400 cycles, which was confirmed by elec-
trical resistance measurements. More and more areas of
C-SAM images became faded or were disappeared af-
terwards. From the C-SAM images, crack areas can be
monitored during thermal cycling and changes in bond
area can be determined. The National Instruments
IMAQ Vision Builder software is used to process the C-
SAM images and calculate crack areas of the processed
images. The image processing is based on the percent
threshold values of different colored regions within the
user-defined area of an image. The threshold was set to
the same value in processing all the C-SAM images. Fig.
5 shows an example of an acoustic image of a flip chip
Fig. 3. A comparison of the average fatigue life of FCOF and
FCOB assemblies under the first and the second thermal cycling
conditions.
Fig. 2. Typical electrical resistance increases of solder joints in a flip chip on rigid PCB assembly under the first temperature cycling
condition.
X. Liu et al. / Microelectronics Reliability 42 (2002) 1883–1891 1885
assembly and the processed picture of that image by
IMAQ Vision Builder software.
C-SAM imaging was periodically conducted on both
the FCOF and FCOB assemblies to monitor the crack
initiation and propagation process during thermal cy-
cling. Fig. 6 is a comparison of the average crack area
increase of FCOF and FCOB assemblies during tem-
perature cycling under the second temperature cycling
condition for 21 solder joints. It is obvious that the
crack area in FCOF assemblies increases slower than
that in FCOB assemblies. This is in consistent with the
thermal fatigue results shown in Fig. 3. The experi-
mental results indicated that flex substrate slows down
the crack propagation rate and thus improves overall
fatigue life.
3. Mechanism of substrate flexibility on improving solder
joint reliability
It was shown in the previous section that the flip chip
on flex assembly has a longer thermal fatigue lifetime
than the flip chip on rigid PCB assembly and lifetime
improvement was attributed to the increased compliance
of the flex substrate. This section investigates the flex
substrate behavior during temperature cycling and
studies the mechanism by which the substrate flexibility
improves solder joint reliability. Flex substrate behavior
during temperature cycling was characterized by the
displacement of flex at different locations in the assem-
bly, which was detected by a TA instruments dynamic
mechanical analyzer (DMA).
3.1. Sample preparation and flex substrate displacement
measurement
To simplify the problem and better study the flex
substrate behavior in the flip chip assembly during
thermal cycling, one-dimensional flex strip samples, il-
lustrated in Fig. 7, were prepared and investigated.
Two solder joints with the same standoff height located
at the two ends of the silicon piece were used to in-
terconnect the silicon and flex substrate strip. The same
solder and flex substrate materials were used as those
in the thermal cycling test sample. Therefore, the major
difference between the flex strip samples and the reli-
ability study samples shown in Fig. 1 is that the flex
strip samples are one-dimensional, while the reliability
study samples are two-dimensional. The flex substrate
behavior during thermal cycling in the flex strip sample
is a simplified representation of that of the flex in
thermal cycling samples. Displacement of flex at dif-
ferent locations in the assembly, illustrated by the nine
points uniformly distributed along the flex strip, during
thermal cycling was considered to be an indicator and
Fig. 4. C-SAM images of the interface between single barrel-shaped solder joints and chip of a typical FCOF assembly during
temperature cycling.
1886 X. Liu et al. / Microelectronics Reliability 42 (2002) 1883–1891
characteristic of flex behavior that would influence
solder joint reliability.
A TA instruments 2980 DMA was used to detect the
displacement of flex at different locations in the as-
sembly under thermal cycling. DMA is an analytical
instrument used to test the physical properties of many
different materials. Fig. 8 shows the TA instruments
dynamic mechanical analyzer clamp assembly [10]. The
clamp assembly is placed in a chamber which can be
programmed for temperature cycling. The TMA con-
trolled-force mode was used to measure the displace-
ment of a sample as a function of time, temperature,
and applied force. Force can be applied in one of three
manners: constant force, stepped force, or continuous
force ramp. The clamp assembly of the DMA consists
of a fixed clamp and a moveable clamp. On the
moveable clamp, there is a probe which moves with
clamp. The test sample was placed on the fixed clamp
with the flex side facing up and the moveable clamp
was above the sample, as shown in Fig. 8, and there
were not any restraints between the test sample and the
fixed clamp. To keep the probe on the movable clamp
in touch with the test sample all the way during the
test, a static force of 0.005 N, which is very small and
should play negligible effect in the stress–strain re-
sponse of the test sample, was applied to the flex in our
experiments. The DMA system monitors and measures
the probe displacements dynamically during the oper-
ation. The probe displacement resolution is 0.01 lm.Thus, we can know the vertical displacement of the flex
during temperature cycling from the displacement of
the probe.
The thermal cycling program for the DMA chamber
was programmed to be
Equilibrate at 30.00 �C, Isothermal for 3.00 min;Ramp 1.00 �C/min to 150.00 �C, Isothermal for 10.00min;
Ramp 1.00 �C/min to 50.00 �C, Isothermal for 10.00min;
Repeat for 3 cycles;
End of method.
Therefore, the sample inside the DMA goes through
three temperature cycles between 50 and 150 �C. Thedisplacement of the flex during thermal cycling was
probed only at the left five of the nine locations uni-
formly distributed along the flex strip as shown in Fig.
7(b), considering the symmetry of the nine points. Two
such samples were tested.
3.2. Experimental results
In the TMA test, the probe was placed at one point
on the flex and the sample was subjected to tempera-
ture cycling. Displacements can be measured as a
Fig. 5. (a) C-SAM image of a flip chip assembly; (b) processed
picture of the image by IMAQ Vision Builder software which is
used to calculate crack or contact area.
Fig. 6. A comparison of the average crack area increase of
FCOF and FCOB assemblies during temperature cycling under
the second temperature cycling condition.
X. Liu et al. / Microelectronics Reliability 42 (2002) 1883–1891 1887
function of temperature, time and applied force si-
multaneously. We were more interested in the flex
displacement change as a function of temperature. Fig.
9 shows a typical TMA trace of the flex displacement
at one point of a flex strip sample through three tem-
perature cycles. We can clearly see from the TMA trace
that the point of the flex at which the probe is located
has different positions at different temperatures during
one temperature cycling, that is, the flex moves up and
down during temperature cycling. Note that the origin
of the y-axis position of the DMA system is at the
upper limit of the probe range, that is, when the probe
goes up, the value of the y-axis decreases and viceversa. We can see from the typical trace of flex dis-
placement shown in Fig. 9 that the flex strip between
the two solder joints moves up (outward) as the tem-
perature increases. The flex moves down when the
temperature cools down. Therefore, during temperature
cycling, the flex substrate deforms up and down. The
initial heating cycle produces results that are different
from those of the subsequent cycles. This difference is
believed to be due to the thermal history of the flex and
also to physical aging and other viscoelastic processes.
Subsequent heating/cooling cycles are quite consistent
indicating that reproducibility of the TMA method.
The hysteresis loop is believed to be associated with the
differential thermal lag, as it tends to vanish at slower
heating/cooling rates [11].
We obtained the TMA traces of the flex displacement
at the five locations for both samples. Fig. 10 shows a
comparison of the flex displacements at different loca-
tions in the flex strip during temperature cycling for one
of the samples. Note that the TMA traces were corrected
for the DMA clamp system expansion during thermal
cycling. We can see from the TMA curves that the flex
has the largest displacement at point 5 which is at the
Fig. 7. Schematic drawing of the one-dimensional flex strip sample (in mm unit); (a) 3-D drawing; (b) cross-section.
Fig. 8. The TA instruments DMA clamp assembly [10] and schematic picture of probe and sample under test.
1888 X. Liu et al. / Microelectronics Reliability 42 (2002) 1883–1891
center of the flex strip, and has the smallest displacement
at point 1 which is right on top of the solder joint, with
the points in between having intermediate displace-
ments. Both of the samples showed the same trend that
those locations closer to solder joints have smaller dis-
placements and those locations farther away from the
solder joints have larger displacements, though the dis-
placement value at one specific location may be different
for those two samples. Fig. 11 is the summary of the
TMA test results for the one-dimensional flex strip
samples. The displacement values at different flex loca-
tions in the figure are the average values and the error
bars are the standard deviations of the two samples
(each sample had three TMA runs).
4. Discussion
The TMA results on flex behavior during thermal
cycling strongly indicate that flex buckles during tem-
perature cycling. In a temperature cycle, when the tem-
perature increases, the flex substrate expands more than
the silicon chip, and thus the flex between two solder
joints buckles up and the probe goes up accordingly. As
a result, the points that are closer to buckling center
Fig. 10. Comparison of the flex displacements at different lo-
cations in a flex strip during temperature cycling.
Fig. 11. Summary of the TMA test result for the one-dimen-
sional flex strip samples.
Fig. 9. Typical TMA trace of the flex displacement at point 2 of a flex strip sample through three temperature cycles.
X. Liu et al. / Microelectronics Reliability 42 (2002) 1883–1891 1889
have greater displacements, while those closer to the
fixed ends (solder joints) have smaller displacements. On
the contrary, when the temperature cools down, the flex
substrate shrinks more and the flex between two solder
joints becomes more and more flat and the probe goes
down.
The phenomenon of flex buckling during thermal
cycling could be explained when we consider the flip chip
on flex structure assembling process and the mechanics
of the assembly during temperature cycling process. The
flip chip attach process is at elevated temperature to
accomplish solder reflow, so the stress-free equilibrium
state for the package is at the solidification temperature
for the solder. Upon further cooling, due to the CTE
mismatch between the silicon chip and the substrate, the
substrate tends to shrink more than the chip, thus there
is strain and residual stresses built in the solder joint
interconnection after the reflow process. The solder
joints are deformed in a shear-dominant mode as shown
in Fig. 12. However, residual stress inside solder joints
can be much reduced after some time due to the creep of
soft Pb/Sn solders and/or the residual stress is forgotten
during thermal cycling [1,2,4], and residual stress is not
the dominant cause for solder joints failure in most
cases. Therefore, we can regard solder joints are in near
stress-free state at room temperature some times after
they were processed. For flip chip on rigid substrates,
there is cyclic thermal strain in the solder joints during
thermal cycling. This is the major mechanism of solder
joint fatigue failure. On the other hand, the situation is
quite different if we attach the flip chip assembly on flex
substrate. The strain and stress inside solder joints can
be much reduced by flex buckling. The buckling of flex
can be interpreted satisfactorily if we regard solder joints
are the fixed ends of the buckling and the flex in between
the solder joints was initially flat at room temperature.
In the heating process of temperature cycling, the flex
substrate expands more than silicon chip due to its
greater CTE, and thus the flex tends to push the solder
joints outward. In the other words, the solder joints try
to pull the flex substrate inward, as illustrated in Fig.
13(a). However, these compressive forces exerted by
solder joints on the flex substrate are offset from the
center of the flex substrate, and thus they induce bending
moments on the flex, which in turn cause flex bending or
buckling because of the compliant characteristic of the
flex. Fig. 13(a) illustrates the flex buckling mechanism.
Actually, the mechanics situation for the rigid substrate
is the same, but because the rigid substrate is much
stiffer than solder, solder is deformed instead of the rigid
substrate. Fig. 13(b) illustrates exaggerated thermal
bending of flex substrate in a flip chip on flex assembly.
As illustrated in Fig. 13(b), solder joint deformation
and thus strain and stress in solder joint are much re-
duced because of the flex buckling. Therefore, solder
joint reliability can be improved. This situation is very
similar to the underfill encapsulant effect on flip chip
assembly. Underfill encapsulant forces substrate (even
rigid ones) bending and thus reduce thermal strain in
solder joints [12]. Finite element analysis of flip chips on
both ceramic and FR-4 substrates has obtained the same
results that thermal strain can be reduced by bending of
substrates by underfilling [13,14]. Our accelerated tem-
perature cycling tests show that solder joint reliability is
much improved by using flex substrates. Meanwhile,
TMA results show that the compliant flex substrate
deforms under thermal cycling. We believe that a certain
amount of the thermal strain in solder joint is trans-
ferred to the compliant flex substrate during thermal
cycling and the flex substrate deformation can release
the strain and stress in the solder joints. Therefore, we
attribute the reliability improvement of flip chip on flex
assembly to flex buckling or bending under temperature
cycling.Fig. 12. Schematic of exaggerated thermal displacements in flip
chip on substrate structure.
Fig. 13. Flex buckling in flip chip on flex assembly. (a) The
buckling mechanism; (b) schematic of exaggerated thermal
bending of flex substrate in flip chip on flex package.
1890 X. Liu et al. / Microelectronics Reliability 42 (2002) 1883–1891
On the other hand, finite element modeling showed
that flip chip solder joint fatigue lifetime could be much
improved by reducing die thickness and thus reducing
the effective stiffness of the die, when die thickness
approaches zero, the fatigue life goes to infinity [15].
Similarly, we believe that making the other side (sub-
strate) of the solder joint compliant should also improve
reliability. Hence, the worst-case scenario for a solder
joint occurs when both the die and substrate have a
relatively high stiffness such that the amount of flexi-
bility in both is minimized.
5. Conclusion
The effect of substrate flexibility on solder joint reli-
ability has been studied. Temperature cycling results
showed that the thermal fatigue lifetime of solder joints
was improved by using flex substrates. TMA with static
force mode of a DAM system was used to monitor the
flex displacement during thermal cycling, and it was
found that the flex substrate buckles during temperature
cycling. It was indicated that the thermal strain and
stress in solder joints could be reduced by flex buckling
or bending that otherwise would be severe if a stiffer
substrate is used. The reliability improvement of flip
chip on flex assembly over flip chip on rigid board was
attributed to flex buckling or bending under temperature
cycling.
Acknowledgement
This work was supported in part by the ERC Pro-
gram of the National Science Foundation under award
number EEC-9731677.
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