Assessment of acceleration models used for BGA solder joint reliability studies

Abstract

Solder joint reliability was one of the top priorities when evaluating the reliability of electronic packages. In general, an acceleration model would be used to predict solder joint fatigue life in the use conditions. However, the accuracy of the model was difficult to validate. As a result, the fatigue life of the solder joints could be over-designed with added cost or time, or under-estimated with a compromised reliability performance. It was an important goal for engineers to use valid and accurate life models to predict the field life of the solder joints and reduce development cost and time. Many empirical models including Norris–Landzberg model and its modifications usually considered the effects of temperature range, the cycle frequency, and the maximum temperature. No matter what the package structures were or the materials were used, engineers had been using the same model parameters for many years. Moreover, little was done to validate the models for modern packages structures and materials. In this article, a variety of package was studied and the failure data was analyzed through a reliability engineering approach. The results showed that the available model parameters were not suitable to predict the solder joint life of test samples exclusively. A new set of model parameters might be required for certain cases. Also, the acceleration factor models would depend on the solder joint materials and microstructures. The solder joint fatigue life performance was too complicated to be assumed as a fixed empirical model. One of the reasons was there were too many factors affecting the strain which the solder joints would endure. In the future study, critical factors such as materials or structures could be integrated into the current model format. Additionally, the ramp rate could be a concern especially when dealing with cases under thermal shock conditions. The methodology to develop an acceleration factor model and the demonstration of their weakness would help achieve reliable solder connections in the future.