It has been widely reported in the literature that for packages that are required to pass thermal cycling test, the SnAgCu solder joints should have high Ag content. In this study, thermal cycling performance of a wafer level chip-scale package was evaluated with different combinations of high Ag solder (Sn3.9Ag0.6Cu) and low Ag solder (Sn1.2Ag0.5Cu) with thick and thin PCB. It was found that with the low Ag solder ball the package mounted on a thin PCB had better performance. Metallurgical analysis of solder joints, mechanical modeling of the package mounted on boards, and coplanarity measurement of the printed circuit boards were performed to understand the results. Because of the CTE mismatch between PCB and die, PCB warpage resulted in high tensile stress in solder joints in the central area, causing cracking of re-distribution layer Cu. The softer solder alloy Sn1.2Ag0.5Cu helped reduce the stress, leading to better performance in thermal cycling test.
IntroductionWafer level chip-scale package (WLCSP) brings benefit to the miniaturization of devices and low cost. Compared to μBGA, the printed circuitry board (PCB) assembly with WLCSP has simpler structure and but greater stress in solder joints. See Fig. 1. In μBGA, Si die is glued on a polymer substrate and wire bonded to the pads on the substrate. Solder balls are between two polymer materials. Since the die is attached on polymer substrate by adhesive, the stress due to mismatch of coefficien of thermal expansion (CTE) between die and polymer substrate can be largely released by the glue and wires. However, for WLCSP, solder balls are placed on die. It is flip chip assembled directly on the PCB. The CTE mismatch between Si die and PCB is much larger than between substrate and PCB in the case of μBGA. The solder balls between die and PCB are under higher stress than the ones between μBGA substrate and PCB. The CTE of RF-4 PCB is about 16 ppm/°C [1], but it is only 2.5 ppm/°C for die [2]. Because of this, underfill encapsulate is recommended for WLCSP to get better package reliability. However, because of