The solidification of Pb-free solder joints is overviewed with a focus on the formation of the Sn grain structure and grain orientations. Three solders commonly used in electronics manufacturing, Sn-3Ag-0.5Cu, Sn-3.5Ag and Sn-0.7Cu-0.05Ni, are used as case studies to demonstrate that growth competition between primary dendrites and eutectic fronts during growth in undercooled melts is important in Pb-free solders, and that a metastable eutectic containing NiSn4 forms in Sn-3.5Ag/Ni joints. Additionally, it is shown that the substrate (metallization) has a strong influence on the nucleation and growth of tin. We identify Co, Pd and Pt substrates as having potential to control solidification and microstructure formation. In the case of Pd and Pt substrates, Sn is shown to nucleate on the PtSn4 or PdSn4 IMC reaction layer at relatively low undercooling of ~4K, even for small solder ball diameters down to <200 m.
IntroductionThe transition to Pb-free electronic interconnections has been underway for more than a decade and despite the exemptions to the RoHS Directive there are few applications where Pb-free solders are not being used. At the same time, electronic packaging technologies have been advancing and there is an ongoing need to develop next-generation Pb-free solders and substrates that are better suited to smaller joints that can operate at higher temperature and that are more reliable.The most commonly used Pb-free solders are hypoeutectic or near-eutectic compositions from the Sn-Ag-Cu (SAC), Sn-Ag or Sn-Cu-Ni alloy systems. These compositions solidify with significant differences to the near-eutectic Sn-Pb solders used previously. For example, where the Sn-37Pb