The developments of SiC power devices have been dramatically advanced for the last several years, and are gaining much attention as a key technology for the low carbon society. These SiC power devices are expected to work under the high temperature condition of 250-300 °C because of the wide band-gap energy and the high heat resistance. To meet the high temperature operations, the diebonding materials must have sufficient reliability under the extreme thermal environments. The present study hence focuses on the thermal reliability of the die-attach technology with using Ag flake paste, which can be sintered at about 200 °C. For Si die-attachment on the Cu substrate, the Ag paste displays excellent reliability in the thermal cycles from −40 °C to 180 °C, and no serious degradation such as crack growth or interfacial debonding happens at either Si/Ag or Ag/Cu interfaces. The tested SiC die-attach samples maintained the high die-bonding strength up to 750 thermal cycles of −40 °C and 250 °C. However, thermal cracks and many voids appeared after 1000 cycles, and thus these damages due to thermal fatigue decreased the joining strength. These results indicate that the sintered Ag flake paste can withstand at the high operating temperature of new power devices, and our Ag paste can be employed as dieattach materials for both Si and SiC semiconductor power devices.
IntroductionRecently, developments of SiC power semiconductor devices are dramatically advanced, and SiC power devices have gradually appeared on the market for a couple of years. SiC has excellent properties such as wide band gap energy, high voltage capacity, heat resistance, electrical conductivity, and heat conductivity. Therefore, these devices are expected to exhibit lower power loss, higher current density, and using without a cooling system, and have gained much attention as a key technology for the low carbon society [1-6]. However, many challenges that must be resolved still remain; SiC wafer quality, SiC wafer cost, and development of high heatresistant packaging materials. The packaging materials, particularly die-bonding materials, must have sufficient ability under the severe environments. Several types of high temperature solders; Au alloys [7-9], Bi alloys [10][11][12], and Zn alloys [13][14][15][16] have been proposed for new power devices, but almost all these alloys have low melting points, and hence cannot be applied in the operation temperature range above 250 °C. Moreover, these high temperature solders have additional disadvantages such as high cost, low electrical and