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the indices i, j will range only over (1, 2, 3). Typing a lot of Greek symbols is a bit of extra work, so we will stick to using Latin indices all the time. When possible, we will use early letters (a, b, c, . . .) to range over all possible values (0, 1, 2, 3) and use letters from the middle of the alphabet such as i, j to range only over the spatial components (1, 2, 3).

Heatsink Design Issues As PWB designs get more complex and more densely populated, the power dissipation from single cards can be on the order of 1000 W A lot of heat needs to be transferred from individual cards, and from the chassis as a whole Consequently, heatsinks are becoming larger and heavier Heatsinks as large as 10 sq in, weighing more than 1 lb are not unheard of If not designed correctly, large heatsinks could transfer a significant amount of compressive load to the packages they are meant to coolThis compressive load could result in cracks in the package/ silicon, or cause the solder joints to deform and bridge16 On the other hand, smaller heatsinks that are anchored to the package substrate could impart additional bending moments on the substrate that could negatively impact the reliability of the package.

17 For bolt-down heatsinks, a significant amount of the compressive load comes not from the heatsink weight but from the bolt down mechanism itself Tolerance variations in package height, warpage, heatsink stand offs, and so on only make the applied load worse The attachment mechanism should be such that it can accommodate these variations in tolerance without transferring excessive load to the package Some of the attachment methods that could help accommodate tolerance variations and minimize the amount of loading imparted on to the package are shown in Fig 5817 The trade offs of using each method are summarized in Table 582 Pressure-indicating film can be used to verify the amount of load applied on the package The film contains tiny microcapsules of colored dye These microcapsules rupture depending on the amount of pressure applied on the film, producing a pressure footprint.

The results are not extremely precise, but can be used to estimate the amount of load applied, as a first pass approximation To verify the impact of heatsink loading on package solder joint reliability, temperature cycling can be performed on packages with heatsinks and compared with control samples However, there are two caveats: 1 The heatsinks tend to cool the packages during temperature cycling, thus producing improved reliability data The improvement may simply be because the solder joints are cycled over a lower temperature range Thus it is important to either thermally shield the heatsink fins or calibrate the thermal cycling chamber such that the solder joints run at the same temperature range as control samples; in spite of the heatsinks 2 Packages thermal cycled under compressive load could undergo two failure mechanisms: cyclic loading (fatigue induced opens) and static compressive loading (bridges due to solder collapse).

Temperature cycling can accelerate the cyclic loading portion, but not the static loading portion Thus, simply performing temperature cycling and comparing with control samples may not suffice The static-loading component should also be accelerated, for instance, by dwelling at a high static temperature..

Heat Sink Spring Screw Thermal Interface Material Stand off Board Carrier Tray Spring-Loaded Solution. Heat Sink O-ring Screw Thermal Interface Material Stand off Board Carrier Tray O-Ring Solution. Heat Sink

Comparison of Different Heatsink Attachment Methods Advantage Useful for absorbing significant tolerance variations by varying spring constants. Less expensive. Less bulky. More versatile. Could be designed to absorb a wide range of expected loads. Disadvantage Relatively expensive. Bulky

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Marginal control in tolerance stack-up induced pressure. Requires custom heatsink design. Could be more cumbersome to install.

Surface Finish Issues In recent years, the role of package surface finish in the robustness of BGA packages has gained more prominence Several different surface finishes are used across the industry, and there are trade offs with the use of each oneThe surface finish used could impact intermetallics formed in the solder joints, which in turn can impact the thermomechanical and mechanical reliability of the package In recent years, a number of surface finishes have become more prevalent The surface finishes with which the effect on package reliability is relatively well known, are outlined in this section: 583111 Electroless Nickel Immersion Gold (ENIG) This has been the surface finish of choice for most high-end, flip-chip BGA packages It enables the routability of fine pitch traces in high pin count packages Historically, ENiG produces excellent board level solder joint reliability.