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Although wire‐bonding is an established and well‐known technique for micro‐joining on leadframes, direct die‐attach without housing on printed circuit boards has some new requirements for the surface of the bond pads and the PCB itself. The best choice of material for the bond pads is a pure gold metallisation. The quality of the surface can be tested during wire‐bonding using the ultrasonic‐power process window. It will be shown that the surface and the PCB itself have a considerable influence on the ultrasonic and thermosonic bonding process.

The influence of process heat, with regard to wire‐ and substrate‐materials, on the adhesion of wire‐bonds was investigated. Temperature increases up to 200°C were measured on the interface between surface and wire. This temperature is the basis for demonstrating the important influence of dissipated process heat on the cold welding process of wire‐bonding. Complementary calculations to evaluate the equation of thermal conductivity were carried out using the finite element (FE) method. Bonding tests were able to verify the calculations. These thermodynamical considerations give us a new method to optimize the construction and the choice of materials within the wire‐bond process.