The Relationship of Life Prediction for Quad Flat No-Lead Package
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THE RELATIONSHIP OF LIFE PREDICTION FOR QUAD FLAT NO-LEAD PACKAGE (QFN) PACKAGES USING 4 POINT CYCLIC BEND TETSING AND THERMAL CYCLE TESTING by MONISHA MOHAN Presented to the Faculty of the Graduate School of The University of Texas at Arlington in Partial Fulfillment of the Requirements for the Degree of MASTER OF SCIENCE IN MECHANICAL ENGINEERING THE UNIVERSITY OF TEXAS AT ARLINGTON December 2015 Copyright © by Monisha Mohan 2015 All Rights Reserved ii Acknowledgements First and foremost, I would like to start by thanking the almighty for giving me this wonderful opportunity and the strength to tread this path. If there is one person that I would like to thank right next to almighty, it would be Dr. Dereje Agonafer for his continuous guidance and motivation from the time I joined his research group. He was very patient during the tough times and always provided me with plenty of resource and contacts whenever in need. Secondly, I would like to thank Mr. Alok Lohia and Mr. Andy Zhang from Texas Instruments for giving me a deeper insight and understanding about the experimental set-up and sample preparations. They made it very easy to contact them and always considered my input and ideas from the time this thesis began to grow up. I would sincerely like to mention my heartfelt thanks to Dr. Andrew Makeev and Dr.Ashfaq Adnan of the Mechanical and Aerospace Department at University of Texas at Arlington for permitting me to use their research and testing facilities in times of need even though they had a pretty tight schedule. My thanks to Mr. Kermit, who has played a major role in the fabrication process of the fixtures. He was patient with my corrections and always kept up his time schedule which made it easy to plan further. I would also like to thank Dr. Haji Sheik and Dr. Fahad Mirza for taking time out of their busy schedule to be a part of my Defense committee. Their interest and insightful comments during the review process gave few different perspectives to the objective of this research. A Special thanks to all the departmental staff especially Ms. Sally, Ms. Debi, Ms. Lanie, Ms. Flora who never failed to support in times of need. I also owe a lot of thanks to my EMNSPC team for the brainstorming sessions and discussions regarding research which helped me a lot during the initial stages of my research. I would like to acknowledge all my friends in UT Arlington for being my pillar of support. iii And above all I would like to thank my parents and my sister, for all the efforts and sacrifices they had to go through for my education. Without their immediate support at times of need it would have been impossible for me to focus completely on my studies. I am definitely indebt to my dog Kikki for all the sleepless nights where she never failed to give me company. Last but not least I would like to Mr.Nandakumar for inspiring me to take this journey and for being with me through every breakdowns, panic attacks and joy. November 12, 2015 iv Abstract THE RELATIONSHIP OF LIFE PREDICTION FOR QUAD FLAT NO-LEAD PACKAGE (QFN) PACKAGES USING 4 POINT CYCLIC BEND TETSING AND THERMAL CYCLE TESTING Monisha Mohan, MS The University of Texas at Arlington, 2015 Supervising Professor: Dereje Agonafer In the structural design of the Printed Circuit Boards, the stiffness modulus of the involved Fr4 and Cu layers play an important role. The 4 point bend test is one of the few test methods which is included in the JEDEC standard for the Monotonic Bend characterization for board level interconnects. The study in the past has shown that the damage mechanism of these two testing methods is similar. And also, correlation had been drawn by observation of failure mechanism through Scanning Electron Microscope (SEM). The purpose of this study is to create a methodology for co-relating 4 point bend test and thermal cycling and to understand the failure displacement on the solder joint. The printed circuit board assembly with the devices and solder joints aligned in the same direction was subjected to cyclic loading conditions and their behavior under the stress was analyzed. The test component contains daisy-chain connection to allow in-situ continuity monitoring of the device board level interconnects during the test. The daisy chain link in the outermost package is connected to a corresponding Printed Wiring Board(PWB) daisy chain link and electrically monitored. v The electrical resistance was monitored to realize the amount of resistance the board can withstand before the solder joint starts to fail. It has been noticed from the experiment that the increase in displacement leads to decrease in the fatigue life of the solder joint. Among the many environmental accelerated testing methodologies for assessing reliability of electronic systems, thermal cycling is the most commonly used for the characterization of devices as well as interconnections. Therefore, the assembly was subjected to thermal cycling simulations to estimate the number of cycles that would be needed for the accumulation of plastic work (energy density) in the critical solder joint. This will give us the methodology for correlating the 4 point bend test and thermal cycling. vi Table of Contents Acknowledgements ........................................................................................................ iii Abstract .......................................................................................................................... v List of Illustrations .......................................................................................................... ix List of Tables ................................................................................................................. xi Chapter 1 Introduction .................................................................................................... 1 Moore's Law .............................................................................................................. 2 Quad Flat No-Lead Package ...................................................................................... 3 Chapter 2 Reliability ....................................................................................................... 4 Chapter 3 Mechanical Fatigue Testing ........................................................................... 7 3 Point Bend Test Vs 4 Point Bend Test ....................................................................11 Chapter 4 Fatigue .........................................................................................................12 Fatigue as a Phenomenon in Materials .....................................................................12 Different Phases of Fatigue Life ................................................................................12 Crack initiation (Ni) ...............................................................................................14 Crack growth (Np) .................................................................................................14 Rapid fracture .......................................................................................................14 Fatigue Properties of Materials..............................................................................15 Chapter 5 Fixtures ........................................................................................................16 ASTM Test Standard ................................................................................................16 Designed 3 point and 4 point Test Fixtures................................................................17 Modified Fixture Head ...........................................................................................18 Fabricated Fixture .....................................................................................................19 Benchmarking Of Fabricated Fixtures .......................................................................20 Al Sample Specifications .......................................................................................21 vii Stress-Strain Relation ...........................................................................................22 Strain:- .............................................................................................................22 Stress:-.............................................................................................................22 Young's Modulus - Tensile Modulus, Modulus of Elasticity:- ..............................23 Chapter 6 Monotonic Bend Test Characterization ..........................................................25 QFN Test Sample .....................................................................................................26 Description:- .........................................................................................................26 Design Test Condition of Experiment ........................................................................27 Chapter 7 Strain Gauges ...............................................................................................29 Wheatstone Bridge ...................................................................................................31 Selected Strain Gauge ..............................................................................................32 Chapter 8 Event Detector ..............................................................................................33 Chapter 9 Experimental Test Setup ...............................................................................35