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Ni-Cu-Sn Intermetallic Another phenomenon reported to cause a similar failure is based on the formation of a Ni-Cu-Sn ternary intermetallic in the solder joint.20 The Ni-Sn intermetallic forms on the component side during ball attach. When the part is mounted on the board, copper migrates from the board pad side, across the BGA ball, to form a Ni-Cu-Sn intermetallic on the component side. The thickness of this ternary intermetallic, typically 3 to 5 mm thick, could grow with additional reflows.20 Clearly, an important factor contributing to this phenomenon is the surface finish on the PWB side. If the surface finish has a barrier like Ni to prevent copper from migrating across the BGA ball, this ternary intermetallic is less likely to form on the component side. Strain/Strain Rate It has also been observed that the strain to failure of solder joints is a strong function of the strain rate. The higher the strain rate, the lower the strain-to-failure. One theory to explain this strain rate dependency is that the stiffness of bulk solder itself is strain rate dependent: at low strain rates, solder tends to deform and absorb some of the applied strain. Thus, less strain is actually transferred to the Kirkendall void-rich region. At high strain rate levels (typically above 5000 u /sec.), bulk solder behaves more like a linear elastic material and transfers more of the applied strain to the voids, causing brittle solder joint fracture. A graph illustrating the relationship between strain and strain rate for solder joint failure is given in Chap. 59.

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Ni2-P-Sn Sn-Pb (b)

Sn-Pb Cu3-Sn (c)

The Einstein summation convention is a way to write sums in a shorthand format. When the same index appears twice in an expression, once raised and once lowered, a sum is implied. As a speci c example,

FIGURE 58.18 Solder joint intermetallic formation. (a) The constituent material stack up in a BGA substrate land pad. (b) After the ball is attached, a number of intermetallics are formed between the copper pad and the SnPb solder joint. Kirkendall voids are known to form at the phosphorus-rich Ni layer and Sn-Ni intermetallic interface. (c) After board level reflow, the interface region thickens and several more intermetallics are formed.19 (Reprinted with permission from Renesas Technology Corp./ [2003] IEEE ECTC.)

FIGURE 58.19 Brittle Solder Joint Failure.19 A clear separation between the P-rich phase and IMC on the package side is shown. (Reprinted with permission from Renesas Technology Corp./ [2003] IEEE ECTC.)

FIGURE 58.20 Intermetallics Formed In Solder Joint with Brittle Fracture.19 (Reprinted with permission from Renesas Technology Corp./ [2003] IEEE ECTC.)

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