Search results

To investigate how jamming of particles in a solder paste varies as a function of the gap through which the particles flow, and to correlate this with skipping defects during the printing process.

Solder pastes with particle sizes of types 2, 3, 4 and 5 were sheared between the parallel plates of a rheometer. Jamming events that cause the solder particles to be forced against each other were detected by monitoring the electrical current flowing between the plates under a bias of 1.0 V or less. Solder paste printing trials were conducted with the same pastes, and solder paste skipping monitored.

Jamming was detected when the ratio of plate gap to largest particle diameter is reduced to a value between 3.8 and 5.0. Decreasing the gap further results in increased jamming. A strong correlation between levels of skipping and jamming was found.

More extensive printing trials are required before rheometric jamming detection can be used to predict printing performance.

The common rule of thumb used in solder paste printing that the aperture width should be no smaller than 4‐5 particle diameters is justified.

This paper presents a new technique for detecting jamming events which are too brief to be detected using normal rheometric techniques, but which have long been thought to be responsible for stochastic skipping defects during printing. Evidence supporting the link between jamming and this type of defect is presented.

This paper examines the rôle that the squeegee plays in the solder paste printing process. Although the printing of solder paste is only one stage of many in the surface mount assembly process, it is crucial to deposit the correct amounts of solder paste cleanly onto the substrate. The amount of solder paste deposited affects the reliability and strength of the reflowed solder joint. Surface mount component lead pitches are continually being reduced due to the requirements of packing more and more components into a given space on the PCB, and this necessitates a proper understanding of the printing process and in particular of the squeegee which plays an important part in determining paste heights and the occurrence of defects. The paper outlines a model which predicts scooping and skipping in the stencil printing of solder pastes used in the reflow soldering of surface mounted devices. The model is based on the forces acting on the squeegee blade, which determines the paste flow pattern ahead of the squeegee, and on the stencil aperture geometry. The paper also examines the interactions between the paste properties and squeegee material properties. These interactions produce printing defects such as scooping, skipping and wet bridging. Results of an experimental comparison of different types of squeegee blade used in the stencil printing of solder pastes for reflow soldering in SMT, as well as the experimental results for squeegee deformation into stencil apertures, were used for validating the model. The empirically enhanced model which results takes into account the force on the squeegee due to solder paste flow and some of the non‐Newtonian properties of the solder paste. The main utility of the proposed model is the control of solder paste printing quality.

This paper presents a technique for mapping the modelling of manufacturing processes, in which process maps are used to represent information on the models and modelling technique (including assumptions used), process and equipment parameters, physical sub‐processes, process variables, and the process performance in terms of quality and/or defects. The mapping approach uses the top‐down methodology, in which any manufacturing process can be represented in a structured, multi‐layered manner, with each layer representing a different level of the modelling spectrum. This structure is designed to provide a clear overview of the process and sub‐processes, and their interactions, while the finer details of the modelling process are still presented at the lower levels of the map. This mapping approach is illustrated with the modelling of the Printing of Solder Paste for the reflow soldering of SMT devices. This case study shows how the mapping process can be used to identify the key research issues, specify the experimental work required, and also identify the analytical modelling techniques which are appropriate for each process (and sub‐process).

The use of fine‐pitch SMD devices has increased the need for accurate and consistent solder paste deposits for reflow soldering. Continued miniaturisation in PCB and SMD lead sizes is presenting the user, paste supplier and print equipment manufacturer with paste printing challenges. Most of these challenges are user‐driven, and are generally met by enhancing associated print equipment and solder paste materials. Recent developments in fine‐particle pastes, water‐soluble and no‐clean pastes are among the improvements in materials. Vision‐assisted stencil aperture and PCB pad alignment, the use of metal squeegees and new stencil fabrication methods are among the latest developments on the equipment side. Printing tests have shown that there is a physical limit for the solder paste printing process, which is defined partly by the nature of the stencil fabrication process, the physical forces and the stencil's ability to meter a precise volume of paste. The challenge as SMD lead sizes decrease is to improve the printing process to match component lead sizes. There is a fear that we are now operating at the very limits of the solder paste printing process. To meet future component developments, there is a need to develop alternative printing processes for solder reflow.

Presents some experimental and theoretical results from research exploring the design rules and relevant process parameters in the assembly of electronic components using anisotropic conductive adhesive materials. The experimental configurations studies have geometries representative of flip‐chip and micro ball grid array chip scale packaging. Evaluates a range of materials combinations, including (random filled) adhesive materials based on both thermoplastic and thermo‐setting resin systems, combined with both glass reinforced polymer printed circuit board and silver palladium thick film on ceramic substrate materials. Also presents a summary of assembly experiments which have been conducted using a specially developed instrumented assembly system. This test rig allows the measurement of the process temperatures and pressures and their relationship with the consequent bondline thickness reduction and conductivity development. Finally summarizes the capabilities of models which have been developed of the assembly process and of the final joint properties.

This study aims to characterize the mechanical properties of sintered nano-silver under various sintering processes by nano-indentation tests.

Through microstructure observations and characterization, the influences of sintering process on the microstructure evolutions of sintered nano-silver were presented. And, the indentation load, indentation displacement curves of sintered silver under various sintering processes were measured by using nano-indentation test. Based on the nano-indentation test, a reverse analysis of the finite element calculation was used to determine the yielding stress and hardening exponent.

The porosity decreases with the increase of the sintering temperature, while the average particle size of sintered nano-silver increases with the increase of sintering temperature and sintering time. In addition, the porosity reduced from 34.88%, 30.52%, to 25.04% if the ramp rate was decreased from 25°C/min, 15°C/min, to 5°C/min, respectively. The particle size appears more frequently within 1 µm and 2 µm under the lower ramp rate. With reverse analysis, the strain hardening exponent gradually heightened with the increase of temperature, while the yielding stress value decreased significantly with the increase of temperature. When the sintering time increased, the strain hardening exponent increased slightly.

The mechanical properties of sintered nano-silver under different sintering processes are clearly understood.

This paper could provide a novel perspective on understanding the sintering process effects on the mechanical properties of sintered nano-silver.

The paste printing process accounts for the majority of assembly defects, and most defects originate from poor understanding of the effect of printing process parameters on the printing performance. As the current product miniaturisation trend continues, area array type package solutions are now being designed into products. The assembly of these devices requires the printing of very small solder paste deposits. The printing of solder pastes through small stencil apertures typically results in stencil clogging and incomplete transfer of paste to the PCB pads. At the very narrow aperture sizes required for flip‐chip applications, the paste rheology becomes crucial for consistent paste withdrawal. This is because, for smaller paste volumes, surface tension effects become dominant over viscous flow. Proper understanding of the effect of the key material, equipment and process parameters, and their interactions, is crucial for achieving high print yields. During the aperture filling and emptying sub‐process, the solder paste experiences forces/stresses as it interacts with the stencil aperture walls and the pad surfaces, which directly impact the paste flow within the apertures. As the substrate and stencil separate, the frictional/adhesive force on the stencil walls competes directly with the adhesives/pull force on the PCB pads, often resulting in incomplete paste transfer or skipping/clogged apertures. In this paper, we investigate the effect of stencil design on the printing process and in particular the effect on paste transfer efficiency.

The dissolution rate of a solid metal such as Cu, in contact with molten solder can be calculated with the use of the Nernst‐Brenner equation. We describe how this equation should be correctly used in cases when the solder is in contact with both the base metal and any intermetallic compounds that have formed. We also show that the concentration of solute in the solder will generally lie between the metastable solubility limit and the equilibrium solubility limit, illustrating these ideas with reference to a system comprising Nb as the base metal and eutectic In‐Sn as the solder, where the concentration levels can be directly correlated to the crystal growth rate.

Solder paste printing and reflow are well established processes for producing solder joints in electronic assemblies. Solder paste consists of a dense suspension of solder particles in a liquid medium (vehicle) that acts as an oxide reducing agent (flux) during reflow, cleaning the metal surfaces of oxides. This paper reports on attempts to model the physical and chemical processes occurring during solder paste reflow using computational fluid dynamics (CRD). Axisymmetric, 2 dimensional and 3‐dimensional models are described, and a method of reproducing oxide‐like behaviour in these models in introduced.

As the demand for flip‐chip products increases, the need for low cost high volume manufacturing processes also increases. Currently solder paste printing is the wafer bumping method of choice for device pitches down to 150‐200μm. However, limitations in print quality and stencil manufacture mean that this technology is not likely to move significantly below this pitch and new methods will be required to meet the demands predicted by the technology roadmaps. This paper describes experiments conducted on carriers made from silicon for bumping of die using solder paste. An anisotropic etching process was used to generate pockets in the silicon surface into which solder paste was printed. Die were then placed against the carrier and reflowed to transfer the solder directly to the bondpads. An assessment was carried out of the potential application and limitations of this technique for device pitches at 225 and 127μm.