Sinter
pastes for rapid and low-temperature die-attach bonding
are developed to enable sintering under a nitrogen atmosphere. First,
microscale brass metal pigment flakes are stirred in hydrochloric
acid to selectively etch zinc from the alloy composition, creating
surface modifications. A binder mixture of α-terpineol and polyethylene
glycol 600 (PEG600) is used to prepare the sinter paste. The surface
modifications provide accelerated material transport, leading to improved
sintering capabilities even at low sintering temperatures (≤275
°C). A bulk-like sintered microstructure with <10% porosity
is achieved with a low solid content of 60 wt % in the paste formulation
due to improved coarsening and densification behavior as a result
of the surface modifications. PEG 600 is observed to be effective
in reducing the copper oxides in situ during the
sinter process. A shear strength of 30 MPa is achieved while sintering
with 10 MPa bonding pressure at 275 °C for just 1 min, which
is comparable to the performance of sintering under the same bonding
conditions with commercially available silver pastes. The characterization
of the flakes involved in the etching phenomenon and the influence
of sintering parameters on the development of the microstructure are
discussed in detail.