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Temp cycling range Clearly, the higher the temperature cycling range, the lower the fatigue life of the solder joints Some studies have also indicated that an increased average temperature could also result in a reduction in the fatigue life of lead-free solder joints In other words, both factors high maximum temperature and high average temperature could contribute to a reduction in solder fatigue life24 The Distance from neutral point (DNP) effect This is the effective distance along the diagonal of the package, from the center to its outermost corner Some studies have indicated that the DNP plays a significant role in altering the acceleration transforms of a leadfree package24 Size and Orientation of tin (Sn) grains29 Depending on the cooling rate, Pb free solders containing a high percentage of Sn tend to have very large Sn grains with varied orientation.

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Sn has very anisotropic material properties, and consequently, the bulk properties of the Pb free solder joints could change significantly depending on the size and orientation of the Sn grains in any given solder joint Consequently, the strength of the solder joints within a single BGA could vary significantly In other words, the joints at the high stress regions may not be the first to fail This random orientation of Sn grains within a solder joint poses a significant challenge in determining the fatigue life and acceleration factors of Pb free solder joints29.

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It has also been observed that while the ductility of Pb/Sn increases with aging, the ductility of lead-free solders tends to decrease with aging.30 In other words, the strain/strain rate characteristics of lead-free solders could change with aging. Further studies are also needed to quantify fully the aging effect and incorporate it into long-term field life prediction models. 59.2.4.5 Backward Compatibility. On small PWBs with relatively few components, it is possible to convert all the components to lead-free assemblies at once. However, in the transition to lead-free assemblies, there will be instances where not all the components on a complex

PWB can be converted to lead-free solder. This would inevitably create situations where both tin-lead and lead-free parts are attached on the same board. Consequently, the use of Pb/Sn paste to assemble lead-free components (backward compatibility) would have to be studied. Component suppliers do not recommend the use of mixed solder metallurgies for a variety of reasons:

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The peak reflow temperature of lead-free solders is higher than that of tin-lead solders. Assembling lead-free components with Pb/Sn paste would involve limiting the peak reflow temperature to that of Pb/Sn components (~220 C). Consequently, the lead-free solders may not fully melt during reflow, resulting in unpredictable long-term solder joint reliability. The thermal gradients across components and the PWB could vary significantly, and as a result, it is difficult to ensure that the microstructure formed across the solder joints is consistent. There are no known and validated acceleration transforms to predict the field reliability of lead-free components assembled with Pb/Sn paste. Thus, even if the assembled parts pass temperature cycling relative to their Pb/Sn and lead-free counterparts, it is difficult to extrapolate to field conditions and predict how they will perform when subjected to actual end-use conditions. There is very little data on the bend/shock resistance of mixed-metallurgy solder joints. The intermetallics formed at the package-joint and PWB-joint interfaces can be quite complex and different. The resistance of these intermetallics to mechanical loading has not been characterized.

There is very little information in the literature on the process consistency of backwardcompatible assemblies and their consequent long-term reliability Some information can be found in References 28, 31, 32 and 34 Some reliability data have been shown to indicate that the reliability of backward-compatible assemblies can be significantly improved if the SnAgCu ball melts fully and good dissolution with the Pb/Sn paste is achieved31 However, the factors that influence the degree of dissolution, such as the peak temperature and time above liquidus (TAL), are generally difficult to control consistently Moreover, the amount of dissolution obtained is a function of the solder ball volume relative to the volume of paste used Consequently, packages with smaller solder ball pitch could also be more sensitive to assembly process variations in backward-compatible assemblies.

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