As-cast Sn-0.4Co-0.7Cu solder contains both (Cu 0.98 Co 0.02 ) 6 Sn 5 and (Co 0.85 Cu 0.15 ) Sn 3 intermetallic phases in the matrix. After reflowing, the Au thin film in the electroless Ni/immersion Au (ENIG) surface-finished Sn-0.4Co-0.7Cu solder ball grid array (BGA) packages dissolved rapidly into the solder matrix to form AuSn 4 intermetallics, and a thin layer of (Cu 0.57 Ni 0.35 Au 0.08 ) 6 Sn 5 intermetallic compound appeared at the solder/pad interface, growing very slowly during aging at 100°C. Increasing the aging temperature to 150°C caused the formation of a new intermetallic layer, (Ni 0.79 Cu 0.21 ) 3 Sn 4 , at the (Cu 0.57-Ni 0.35 Au 0.08 ) 6 Sn 5 /Ni interface. The reflowed Sn-0.4Co-0.7Cu BGA packages have a ball shear strength of 6.8 N, which decreases to about 5.7 N and 5.5 N after aging at 100°C and 150°C, respectively. The reflowed and aged solder joints fractured across the solder balls with ductile characteristics in ball shear tests.