Package Qualification Guideline Specification

IBM Engineering Specification: 57G9271 EC: N81528

Responsible Engineer: C. Grosskopf ([email protected])

Technical Approvals: Actives, Optics, Passives: G. Catucci ([email protected])

Logic CPU: W. Bornstein ([email protected])

Logic Standard: J. Drummond ([email protected])

Memory: L.Dahl ([email protected])

Document Liaison: S.Jumat ([email protected])

Previous EC Previous EC Previous EC Previous EC Current EC Level Level Level Level Level F02220 J90459 J37579 J38428 N81528 04-03-01 05-19-06 11-14-08 9-8-11 04-15-13

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Table of Contents

Section Section Title Page 1 Scope 3 2 Applicability 3 3 Referenced Documents 3 4 Exceptions 4 5 Testing Requirements 4 5.1 General Requirements for New Qualifications and PCNs 4 5.2 Requirements for Conversions from Gold to Copper (Cu) 6 Thermosonic Wirebonds 6 Test Definitions 7 7 Reliability Tests for Packages 9 8 Reliability Tests, Devices Affected by Second Level Interaction 10 9 Preconditioning 10 10 Fail Handling Procedure for Qualifications 11 11 Tab DIMM Module - Minimum Requirements for Substrate 12 and Assembly Qualification Appendix A Recommended Preconditioning Flows for PTH (Pin Through 18 Hole) Components Appendix B Recommended Preconditioning Flows for Backside Wave 19 Attach of SMT Components Appendix C Drop Test 20 Appendix D Airflow Susceptibility Test for Copper Wire Bonding 21 Appendix E Audit Checklist for Copper Wire Bonding 24

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1. Scope

This document defines package and module test requirements for new qualifications, and process changes. To determine the tests required, refer to Sections 5 and 11. Tests are described in Sections 6, 7, 8 and 11. All of the testing requirements of this document need not be performed if an alternate qualification plan has been previously approved by IBM or substitute data is provided to IBM which adequately addresses the identical fail mode.

IBM recommends that suppliers develop their internal qualification process using one of the JEDEC qualification methodologies: JESD94 or JESD47, and the following JEDEC publications may also be incorporated: JEP131, JEP143, JEP148, and JEP150.

2. Applicability

This entire document, except for Appendix B, is applicable to devices in packages and modules from the memory, logic, power conversion, oscillator, optics, and actives commodities. Appendix B is only applicable for the active commodities. This document is not applicable to other commodities unless specifically called out by another IBM document.

2.1 Terms & Definitions

Package - A carrier containing a singular IC (Integrated Chip) that is connected using only first level interconnect. May also include a package with 2 or more ICs, but the package type is primarily used to contain only one IC. A few examples: a PQFP with 2 or more ICs mounted inside it (stacked die, or dual die), a BGA or PGA with on board decoupling capacitors.

Module - A carrier containing multiple ICs and possibly passives components that are connected using either first level and/or second level interconnect. Modules are typically socketed or soldered to a larger planar/motherboard. Some examples of modules include: Memory Modules (DIMMs, flash cards, etc.,), MCMs (Multi-Chip Modules), and Board Mounted Power assemblies.

3. Referenced Documents

This revision references the following IBM documents and industry standard documents.

Document Number Document Title IBM P/N 0873444 Product Quality Addendum [PQA] For Purchased Electronic Components IBM P/N 77P3021 Additions, Exceptions, and Limitations to Industry Standards to be Applied to IBM Custom DIMMs IBM P/N 61X5956 Printed Circuit Contact Tab Requirements for Wiping Contacts IBM P/N 21H5140 Test Coupon Design and Impedance Measurement Specification IBM P/N 78P2860 IBM Logic Technology and Component Qualification Guidelines MIL Standard 883 Test Methods and Procedures for Microelectronics JEP 131 Process Failure Mode and Effects Analysis (FMEA) JEP 143 Solid State Reliability Assessment and Qualification Methodologies JEP 148 Reliability Qualification of Semiconductor Devices Based on Physics of Failure Risk and Opportunity Assessment JEP 150 Stress-Test-Driven Qualification of and Failure Mechanisms Associated with Assembled Solid State Surface-Mount Components JEP 154 Guideline for Characterizing Solder Bump Electromigration under Constant Current and Temperature Stress JESD22-A113 Preconditioning of Plastic Surface Mount Devices Prior to Reliability Testing Page 3 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528

Document Number Document Title JESD22-A122 Power Cycling JESD22-B116 Wire Bond Shear Test Method JESD 47 Stress-Test-Driven Qualification of Integrated Circuits JESD 69 Information Requirements for the Qualification of Silicon Devices JESD 94 Application Specific Qualification Using Knowledge Based Test Methodology J-STD-020 Moisture/Reflow Sensitivity Classification for Plastic Integrated Circuit Surface (IPC & JEDEC) Mount Devices J-STD-035 (IPC & JEDEC) Acoustic Microscopy for Non-Hermetic Encapsulated Electronic Components IPC A-600 Acceptability of Printed Boards IPC TM-650 Test Methods Manual IPC 6012 Qualification and Performance Specification for Rigid Printed Boards IPC SM-840 Qualification and Performance of Permanent Solder Mask

Copyrighted standards are available through many sources, including the following:

Agency (Abbreviation) Name Internet Address IPC http://www.ipc.org/default.aspx (JEDEC) Joint Electron Device Engineering Council http://www.jedec.org/ (Mil) Military Standard Specifications http://dodssp.daps.dla.mil/

4. Exceptions

Any exceptions to the requirements in this document must be approved and documented by the appropriate IBM procurement organization, prior to supplier implementation.

Any changes to previous agreements (sample sizes, preconditioning, etc.,) between the component supplier and IBM must be approved by the appropriate technical personnel within IBM procurement. New suppliers must review their qualification process with IBM. This document is IBM's initial request.

5. Testing Requirements

5.1 General Requirements for New Qualifications and PCNs

The tests referenced below are described in IBM specifications 0873444 and this document. In the table below, the number(s) or letter(s) following the specification number denote which sections of that specification are required. The introduction to each test describes that test(s), and will determine the applicability of each section within the test to the package being tested.

The recommended test sample sizes are as follows: (samples should come from 3 assembly lots)

Total Quantity Physical outline dimensions which can be affected by handling/shipping 150 pieces All other physical outline dimensions & solderability 15 pieces All other tests where the quantity is not specified in the referenced specification 3 pieces

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Affected Change to Testing Requirement Packages All Packages New Assembly Site, New Assembly Supplier, or 0873444 - All of Section 6, except 6.17 and Modules New Package/Module Family 57G9271 - S, C, Rel, 2nd L All Packages New Package (Lead count, body size, lead pitch, 087344 - 6.3, 6.5, 6.10, 6.13 etc.) in Previously Qualified Package Family 57G9271 - S, C, Rel All Packages Any material change that alters the existing 0873444 – 5.1.1 environmental material declaration (Provide access to updated material declaration document) All Memory Any material change that alters the SER (Soft 0873444 – 5.1.3 Devices and all Error Rate) classification for a device (Verify emissivity rate of new material is < Logic Devices - Use of ultra low alpha (ULA) materials for 0.002 cph/cm2) with Imbedded encapsulant, underfill, solder mask, flip chip Memory or bump, pre-solder, and SOP (solder on pad) Technology Node of  90nm All Packages Die Passivation 0873444 - 6.13 57G9271 - 2C, Rel (Rel not required for Hermetic packages) All Packages Die Coat (including wafer coat) 087344 - 6.5, 6.13 57G9271 - 1C, 2C, 3C, 4C, 7C, Rel (Rel not requirement for Hermetic package) All Packages Device Thickness and/or 087344 - 6.5, 6.10, 6.13 Die Thickness or size (area) increase 57G9271 - 4C Wirebonded Conversion of thermosonic wirebonder from Au 57G9271 – 5.2 IC wire to Cu wire. This also covers wirebonder conversion of bonder models and manufacturers, and conversion kits not covered by initial qual Wirebonded Chip Bond Pad Design or Metallurgy, or Bond 0873444 - 6.5, 6.10, 6.13 IC Pad Diffusion Barrier Metal 57G9271 - 1C, 3C, Rel Flip Chip IC Flip Chip - Under Bump Metallurgy (UBM), 0873444 - 6.5, 6.13 Bump Metallurgy and/or Design 57G9271 - EM, 1C, Rel, 2nd L Flip Chip IC Underfill Material or Process 0873444 - 6.3, 6.5, 6.13 57G9271 - 5C, 6C, 7C, Rel, 2nd L All Packages Die Backside Metallurgy or Finish 0873444 - 6.5, 6.13 57G9271 - 5C, Rel Wirebonded Die Attach Adhesive Material or Process 0873444 - 6.5, 6.10, 6.13 IC 57G9271 - 4C, 5C, 7C, 9C, Rel Leaded Lead/Leadframe Material, Design, or Fabrication 0873444 - 6.3, 6.4, 6.5, 6.13 Module/Pkgs Method (i.e., etched vs. stamped) 57G9271 - 6C, 7C, 8C, 9C, Rel All Packages Heat Spreader, Heat Slug, Stiffener, and (flip chip) 0873444 - 6.3, 6.4, 6.5, 6.13 Lid Material or Design 57G9271 - S, 4C, 6C, 7C, Rel Flip Chip Pkg Thermal Interface Material (TIM) change 0873444 - 6.5, 6.13 w/heatslug 57G9271 - 12C, Rel – T/C or Power Cycling only Organic Organic Substrate Material, Supplier, layer count, 0873444 - 6.2, 6.3, 6.4, 6.5, 6.9, 6.13 Substrate Pkgs or stack up 57G9271 - 5C, 6C, 7C, 11C, Rel, 2nd L Organic Organic Substrate Pad Design or Metallurgy (incl. 0873444 - 6.5, 6.13 Substrate Pkgs solder ball/joint, flip chip, wirebond, and die bond) 57G9271 - 1C, 5C, 7C, 11C, Rel, 2nd L BGA BGA Solder Ball Material or Composition 0873444 - 6.3, 6.13 57G9271 - 10C, 11C, 2nd L BGA and BGA/PGA Passive or Active Component (i.e., 0873444 - 6.3, 6.6, 6.13 PGA decoupling cap.) Value, Supplier, or Number of 57G9271 - F Devices Used

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Wirebonded Bonding Wire Diameter, Material, or Technique 0873444 - 6.5, 6.10, 6.13 Packages and 57G9271 - 1C, 3C, 4C, Rel Modules High Temp. Storage Test, followed by 1C Leaded and External Finish 0873444 - 6.3, 6.4, 6.13 Leadless 57G9271 - 5C, Rel - THB or HAST only Module/Pkgs Plastic Molding Compound 0873444 – 6.2, 6.3, 6.4, 6.5, 6.9, 6.13 Encapsulated 57G9271 - 10C, Rel Non-Hermetic Moisture Sensitive Class 0873444 - 6.5 Module/Pkgs 57G9271 - S, 1C, 6C, 7C, Rel Ceramic New Ceramic Manufacturer or Plant 0873444 – 6.2, 6.3, 6.4, 6.5, 6.6, 6.10 Module/Pkgs 57G9271 - 1C, 3C, 4C, 5C, 8C, 9C, 10C, Rel Ceramic Ceramic/ Seal Material or Method 0873444 - 6.5, 6.10, 6.13 57G9271 - 1C, 3C, 4C, 8C, 9C, 10C, Rel Ceramic Ceramic Composition 0873444 – 6.2, 6.3, 6.4, 6.5, 6.6, 6.10, 6.13 57G9271 - 3C, 4C, 8C, 9C Modules Substrate Supplier, Material, Layer Count, Stack- 0873444 – 6.2, 6.3, 6.4, 6.9, 6.13, 6.14 up, via, or imbedded passives 57G9271 - 5C, 2nd L Modules Supplier of or Type of Component(s) in Module, 0873444 - 6.3, 6.13 or Physical Layout (components and wiring) 57G9271 - F Modules Solder Paste Metallurgy, Flux, or Supplier (i.e., 0873444 - 6.4, (For pinned cards), 6.13, 6.14 change from water soluble to no clean) 57G9271 - 5C, 2nd L Modules Component underfill, card encapsulating material, 0873444 – 6.2, 6.4, 6.5, 6.9, 6.13, 6.14 or potting material 57G9271 - 5C, 2nd L Modules Manufacturing Process that is significant. (i.e., 0873444 - 6.3, 6.4, 6.14 point solder automation, card singulation method) 57G9271 - 2nd L All Package Marking Process / Material 0873444 – 6.2 Tape + Reel Tape & Reel Material, Sealing Equipment, or 0873444 - 6.3 Hub/Reel Dimensions 57G9271 - S and Drop Test All Shipping Tube, Tray, or Clamshell 0873444 - 6.3 57G9271 - S and Drop Test

5.2 Requirements for Conversions from Gold to Copper (Cu) Thermosonic Wirebonds

For conversions to copper wirebonds the qualification report is to include the results from the following test requirements:

5.2.1 Mechanical Requirements

Line monitor data can be used to support this requirement:

Test Sample Size Criteria Wirebond pull test 30 wires/unit from Force & mode per Mil-std 883 Method 2011.7, 5 units/lot x 3 lots Ppk 1.67 or Cpk 1.33 (See Note) Ball bond shear test 30 ball bonds/unit from 5 units/lot x 3 Force and mode per JESD22-B116, lots Ppk 1.67 or Cpk 1.33 (See Note) Bond cratering test 20 pads/unit from 5 units/lot x 3 lots No evidence of damage to silicon under bond pads (etch bond pads)

If the device being qualified has less than 30 wirebonds, increase the number of units to ensure that at least 150 wires/bonds per lot are tested for wire pull and bond shear.

If the device being qualified has less than 20 bond pads, increase the number of units to ensure that at least 100 pads per lot are tested for bond cratering.

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Note: Process Performance (Ppk) and Process Capability (Cpk) are calculated with the following formula: n 2 (xi  x) USL     LSL  For Ppk, is calculated (estimated) with i1 where individual x’s are used. Min ,     3 3  n 1 R s For Cpk,  is calculated (estimated) within-subgroup variations; e.g., or in control charts. d 2 c4 Per JESD47H, use of Cpk should be limited to data on more than 30 lots.

5.2.2 Construction Analysis Requirements

The requirements below are in addition to those in section 6.3 of this document for wirebonded packages.

1C - Visual integrity of wire (check for corrosion) and for evidence of bond cratering 3C – Include following additional items for internal inspection: Al splash, bond placement

5.2.3 Reliability Stress Tests Requirements

Must meet requirements in Section 7 of this specification, with the following two additional requirements:

1. Wirebond pull and ball bond shear testing at the end of each stress. Pull/shear 10 wires/bonds per unit from 5 units from each of the 3 lots. Force values and mode after stress must meet fail criteria as stated in Mil-std 883 Method 2011.7 for wire bond pull and JESD22-B116 for ball bond shear.

2. Unbiased HAST and unbiased T&H will not be accepted in lieu of biased HAST and/or biased T&H.

5.2.4 Process Audit Requirements

As part of qualification report, provide the results of the test described in Appendix D and filled out questionnaire in Appendix E.

- Airflow Susceptibility Test for Copper Wire Bonding (Appendix D) - Preaudit checklist/questionnaire (Appendix E)

IBM has noted differences in ambient airflow rates around wirebonders as well as transient rates due to human actions. Some conversion kits are able to handles flow rates of 2 m/sec, while others only 1 m/sec. Therefore, all designs and locations need to be evaluated, to ensure that the forming gas will surround the Cu bonding area 100% of the time.

Air flow measurements shall be recorded for ambient airflow around the bonding stations. Measurements shall also be recorded for various human induced (transient) airflow rates. Such actions may include, but are not limited to: - an operator walking or running by a bonder, - a large cart being pushed past a bonder, - a clipboard or other rigid object being waived near the bonding head, Identify all possible actions that could occur at your facility and measure the airflow rates created by such actions.

The results of the Airflow Susceptibility Test should be reviewed to ensure that high quality bonds will be made for all measured ambient and transient airflow rates.

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5.2.5 Additional PCN Requirements for Cu Thermosonic Bonding

Prior to implementation, IBM requires that a PCN notice be submitted for any design change to the wire bonding equipment that could impact thermosonic copper wire bondability and/or reliability. Some examples of such changes include:  a design change to forming gas nozzles  a design change to shielding  converting bonders to bond copper wires of another manufacturer or different models from the same manufacturer after the initial qualification and were not covered by the initial qualification.

IBM requires such changes to have been qualified to the same requirements as the initial copper wire qualification and that all qualification documentation be provided to IBM with the PCN notice.

NOTE: IBM’s PCN requirements are stated in IBM engineering specification 873444.

6. Test Definitions

6.1 Shipping And Handling - 'S' Tests

Shipping and handling requirements are defined in section 6.17 of IBM specification 0873444. See Appendix C for 'Drop Test' test method.

6.2 Device Functionality - 'F' Tests

The device(s) must be electrically tested to verify that it still meets the functional specification and that the distribution of the test results (within the specification) has not significantly changed.

The definition of a significant change is either a shift in the mean value of +/- 15% or an increase of the standard deviation by more than 15%.

IBM must be notified if the distribution of any electrical parameter has significantly shifted (>15%) due to a process change, even though it is still within specification.

6.3 Package Construction Analysis - 'C' Tests

The minimum list of IBM coverage is as follows (consult Mil STD 883 for details of analysis procedures for appropriate test methods):

Test Description and Requirements (Wirebond Packages) Using preconditioned samples, Decap one sample, perform Wire Bond Pull (Mil-Std 883 Method 2011) and Ball Bond Shear (JESD22-B116) tests. (Wirebond Packages) Cross-section wire ball bond to examine the intermetallic formation, ball diameter, any evidence of necking, clearance to package edge, and loop shape/height. 1C (TAB bonded Packages) Cross section bond pads to examine intermetallic formation (Waferscale & post fab redistribution) Cross-section to look at redistribution via contacts, trace lift-off angle and configuration (Flipchip) Cross-section to check UBM (Under Bump Metallurgy) integrity and for bump composition, configuration, and pitch. 2C Passivation Integrity Test performed on preconditioned sample(s) 3C Internal Visual Inspection of Wire Bonds, Die Perimeter, and Die Surface 4C X-ray of package showing die placement on lead frame/substrate, wire sweep, wire loop height, lid seal, and die attach.

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(Wirebonded Packages) Cross sections showing die attach area, and die attach and mold material voids. (TAB bonded Packages) Cross sections showing die encapsulant adhesion and voiding (Leadframe Packages) Cross sections showing plated material thickness' on leadframe and location of leadframe in package (BGAs) Cross-section solderball for ball intermetallics and barrier metal integrity, and cross-section 5C substrate for via-to-interplane or microvia separation (Substrates - BGAs and Modules) Cross-section substrate for via-to-interplane or microvia separation, for plating integrity of substrate via, for minimum pitch of adjacent vias, and drill smear clearance via to via (or IPC 600, Section 33.1-9 with preconditioned samples) (Modules) Cross-section of component/substrate solder joints for good formation and for integrity of underfill used with FBGA/uBGA. 6C (Non-Hermetic) Dye Penetration Test- Not required if 7C shows no leadframe delamination (Non-Hermetic) Acoustic Microscopy Inspection per J-STD-035 7C (Flipchip) Inspection for underfill voiding/delamination. Use of high frequency (transducer) acoustic microscopy, soft x-ray, or parallel cross-section of underfill. 8C Materials Identification, characterization, and thickness. May require use of XRF and/or SEM 9C (Hermetic Ceramic Packages) Residual Gas Analysis (Mil-Std 883 Method 1018) 10C External package inspection for deflash, marking and surface defects. 11C (BGA) Solder Ball Shear, on aged and non-aged devices per section 6.4.6 of 0873444. See also 6.4.7 12C (Thermally enhanced Packages & Modules) Perform C-SAM, X-ray, and/or cross-section of thermal joint integrity checking for delamination, voids, coverage and thickness.

6.4 Electromigration (EM) of 1st Level Interconnect - 'EM' Tests

The flip chip bump / UBM (under bump metallurgy) system for devices with flip chip 1st level interconnect needs to be evaluated for the potential of electromigration during the projected life of the product. The resistance to electromigration for 1st level interconnect is a combination of the under bump metallurgy (UBM) and the flip chip bump solder material, thus a change to either may impact the EM rating for the system and thus any device that uses that system. IBM recommends that a characterization of the system be performed per JEP154. See section 4.1.2 of IBM specification 78P2860 for additional requirements.

7. Reliability Tests for Packages (Rel)

See Section 8 for addition reliability requirements for the following package types: Memory TSOP1, FC-PBGA (laminate), and all TAB-bonded packages.

When (Rel) Reliability testing is required, IBM recommends the following:

Total device quantity to come from 3 separate assembly Week Codes

1. Plastic Reliability Tests (For Plastic and non-Hermetic Packages) - 600 Devices Total, if SMT, precondition devices per JESD22-A113, with flux. 200 devices Biased Humidity Testing (THB or HAST) 200 devices Temperature Cycling 200 devices High Temperature Storage Life*

* JESD47 and IBM allow the use of a modified preconditioning flow (moisture soak not required) on samples for HTSL stress.

2. Hermetic Reliability Tests (For Hermetic Packages) - 200 Devices Total, if SMT, precondition devices per JESD22-A113 All devices Temperature Cycling All devices to be hermeticity tested, fine and gross leak, at time zero and after last read point.

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3. Additional Reliability Test Requirements (For Packages with Flip Chip Interconnect and typical power consumption of the device is >25 watts. These are devices that experience significant, non-uniform, internal, temperature distributions due to self heating during standard use conditions.)

- 50 Devices Additional, if SMT, precondition devices per JESD22-A113 50 devices Power Cycling (Ref. JESD22-A122)

If for production the component will be burned-in, then all package reliability test samples must be burned-in for the following stresses: loose and mounted T/C, biased T&H, HTSL, and Power Cycling. (Note: If the mounted T/C stress is performed using “daisy chain” die, then burn-in is not required.)

RELIABILITY TESTS FOR PACKAGES Test Descriptions Conditions Readouts (Test devices at each readout point) Per appropriate Test Method: Minimum Interim Minimum End Point JESD22-A or MIL Std 883 Readouts Biased Temperature & Humidity 85C/85%RH 168, 500 hours 1000 hours Alternate Pin Biased Maximum rated voltage or higher Biased HAST 110C/85% RH 100 hours 200 hours At maximum rated voltage 120C/85% RH 50 hours 100 hours 130C/85% RH 24 hours 50 hours Temperature Cycling (T/C) 0 to 125C 500, 1000 cycles 1500 cycles (Air to Air) -55 to 125C 300, 500 cycles 700 cycles Loose Samples -65 to 150C 100, 300 cycles 500 cycles High Temperature Storage Life 125C 500, 1000 hours 2000 hours 150C 168, 500 hours 1000 hours 200C 12, 36 hours 72 hours Power Cycling Ambient to max. 1000, 3000, 5000 cycles 10,000 cycles For Flip Chip Packages Only operating temp.

The following are optional tests not typically required by IBM, unless called out by a commodity or device specific qualification plan, but may need to be used to validate a package's design, materials and/or assembly process.

Pressure Pot (Autoclave) 121C @ 2 ATM 48, 96, 168 hours Unbiased HAST 110C/85% RH 100 hours 200 hours 120C/85% RH 50 hours 100 hours 130C/85% RH 24 hours 50 hours Thermal Shock -55 to 125C 300, 500 cycles (Liquid to Liquid) -65 to 150C 100, 300, 500 cycles Other Reliability Tests May be used pending engineering judgment

8. Reliability Tests, Devices Affected by Second Level (2nd L) Interaction

The reliability of some package types are more affected by thermal cycling when they are soldered to a board (actual application) than when they are “loose” samples (typical device stress condition) due to the stresses applied on the device by the board. For all such packages whose chip/package interaction is negatively impacted when soldered to a card, the following additional testing is required. (Ref. JEP150.)

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Additionally, new package styles that exhibit a device level coefficient of thermal expansion that are significantly different from industry standard printed circuit boards to the extent that it may not meet 2nd level reliability expectations require the following additional testing.

Total device quantity to come from multiple assembly lots, if possible.

Packages need to be soldered onto test boards

Required for QFN, DFN, TSOP with Alloy42 leadframe, FBGA with ball pitch < 0.8mm, FC-PBGA (organic laminate), and all TAB bonded packages (including uBGA). 100 Devices Total, (may be in lieu of part of the T/C sample size requirement) 100 devices - Mounted Temperature Cycling Devices to be daisy chain mechanical samples with the die being included in the circuit.

RELIABILITY TESTS, SECOND LEVEL Test Descriptions Conditions Readouts (Test devices at each readout point) Per appropriate Test Method: Minimum Interim Minimum End Point JESD22-A or MIL Std 883 Readouts

Mounted Temp. Cycling* ** 0 to 100C, 2 cycles/hour 300, 500 cycles 1000 cycles Package soldered to a PCB to evaluate both Package and -20 to 90C, 2 cycles/hour 300, 500 cycles 1000 cycles Solder Joint Fails -40 to 60C, 2 cycles/hour 300, 500 cycles 1000 cycles

* Minimum 4 layer substrate, 0.062 inch thick. ** For devices intended for double sided applications, this stress should be run double sided.

9. Preconditioning

Preconditioning is the simulation of the effects of the board mount soldering process and is performed on devices intended for reliability stress testing. Preconditioning is to be performed per the requirements of JESD22-A113.

Flux is required per JESD22-A113. IBM recommends that a highly active, water soluble flux be used. Fluxes with a pH of around 7 (neutral) are not acceptable. Please note that fluxes have low flash points, please use them at the recommended temperatures.

Note: Use of acoustic microscopy is highly recommended before and after preconditioning to evaluate package integrity, when applicable.

9.1 IBM Must Be Notified:

 Of devices with a moisture classification according to J-STD-020 of 5, 5a, or 6 prior to qualification.  Of devices that are not capable of being water washed after card assembly (‘No Clean’ processing only). See section 6.7.1 in 873444.

9.2 Special Preconditioning Flows

If non-standard assembly processes are required, IBM will initiate a request that one of the following Preconditioning flows be performed:

1. Paste in Hole: If PTH product is to be assembled to a card by a convection reflow oven (paste in hole method), it must be evaluated as a Level 1 component per J-STD-020 and preconditioned per JESD22-A113 for SMT product. Page 11 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528

2. Backside Wave: If an SMT package is to be qualified for attaching to the backside of a card by immersion into a solder wave, it must be evaluated as a Level 1 component per J-STD-020 at a reflow (classification) temperature of 260C. For preconditioning prior to reliability stress testing, the peak reflow (classification) temperature must also be 260C. See Appendix B for preconditioning flow.

10. Qualification Reports and Fail Handling Procedure for Qualifications

IBM recommends that suppliers use JESD69 as the template for the qualification reports they provide to IBM, or integrate all of the reporting requirements stated in JESD69 into their standard qualification reports.

Failure analysis must be complete for IBM to consider the Qualification complete. Failure analysis is defined as electrical, hermeticity or visual inspection test diagnosis followed by physical analysis to determine root cause. IBM requires a detailed summary of this information for each failing unit. For data reporting purposes a simple statement of fail mode and root cause is adequate. Below is an example of the recommended format and required information.

Stress Test Week Preconditioning 168 hours 500 hours 1000 Hours Code THB 85/85, 3.6V bias 9926 0/67 1/67 A 0/66 0/66 THB 85/85, 3.6V bias 9927 0/67 0/67 1/67 C 0/66 THB 85/85, 3.6V bias 9928 0/67 0/67 0/67 0/67

Stress Test Week Code Preconditioning 10 cycles 300 cycles 500 cycles TC (-65 to 150) 9926 0/6 0/67 0/66 (E) 0/67 TC (-65 to 150) 9927 0/67 1/67 B 0/66 0/66 TC (-65 to 150) 9928 0/67 2/67 D & F 0/65 0/65

Fails: A - Ball lift, poor intermetallics B - Ball lift, chip out C - Aluminum pad corrosion, chlorine contamination D - Die corner crack, package stress E - 1 Device removed. Missing ball due to handling during stress testing prevented functional testing. F - Package Fail Fail descriptions A through E are acceptable to IBM. The description for fail F is not acceptable.

All fails must be analyzed to determine root cause of failure. A corrective action plan must be in place and approved by IBM Procurement prior to shipment of production product.

Page 12 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528 11. TAB DIMM - Minimum Requirements for Substrate and Assembly Qualifications

11.1 General

 Satisfactory audits of the module and module substrate assembly process are required.  A completed IBM DIMM Assembly questionnaire must be provided to IBM.  For modules where the JEDEC or IBM designs are modified, substrate designs in .BRD format showing the stackup must be provided.  For new technology elements covered by this qualification, a Failure Mode Effects analysis done according to JEDEC JEP 131 must be supplied to IBM along with the qualification data.  Qualification Hardware Requirements- All hardware shall be of approved subcomponents built on the production line using production processes. Hardware shall represent as wide a range of vintages of substrate materials, assembly process and subcomponent vintages as possible. At least 2 distinct lots of module substrates, DRAMs, and assembly dates should be used. Different functional Designs may be substituted provided they are equivalent in terms of substrate layer counts, ground rules, materials, and module assembly counts.  Hardware may be reused to satisfy multiple visual requirements. Visual hardware may be reused as functional product or for reliability testing. Reliability test hardware may not be reused.

11.2 Qualification Test Requirements

For tables 11.3.1 - 11.3.4, in column 1 ‘Test (When Used)”, tests are identified by number and an alphabetic character. These characters, listed below, define the technology changes which demand that a specific qualification test be performed. A. New/changed assembly process including DRAM or other device footprint, solder mask or solderable surface finish, solder paste metallurgy, new flux or flux combination (primary and rework fluxes) B. New/changed DIMM module substrate ground rules (lines and spaces, via size, type, minimum pitch, design, stack up, raw material, laminator, manufacturing process, solder mask or solderable surface finish) C. Significantly increased assembly process temperature, including lead-free.

Qualification is contingent based on completion of testing and satisfactory resolution of any fails.

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11.3.1 Module Substrate and Assembly Reliability Tests Test Test Test Vehicle Sample Size Specification Defining Specification (When Description Test Requirements Defining Pass/Fail used) Criteria 1.1 Module Bare DIMM 50 See detail info. IPC TM 650, B,C Substrate Module 50C/85% RH 2.6.25 Insulation Substrate Bias ground and all Fail= decade Resistance powers only resistance drop. (IR or CAF) (section 5.3.2) IPC TM 650 2.6.25 Bias and test at 2x Perform physical maximum rated voltage or analysis on fails. IBM approved equivalent 1.2 Module DIMM Modules 10 See detail info Functional test A,C Insulation 50C/85% RH Resistance or equivalent Bias at 2X maximum rated voltage 1.3 Module Preconditioned 20 0-100C Visual inspection, A,B,C Thermal (see detail) functional or equivalent - Delta functional test. Cycling functional assemblies T=100C min, in the range Readouts at 24, 100, DIMM Modules from 2 lots, -30 to 125C and every 200 cycles reworked through stress. (1200 cycles) Precondition each DIMM module substrate or test coupon by subjecting to 3 passes of assembly reflow simulation, including those necessary for assembly of modules used in stress testing.

Precondition each DIMM module to represent the stresses imposed by customer assembly by inserting and removing from an application socket 10 times.

Rework precondition – 1/3 of assembled DIMM modules in each stress: Rework to the maximum extent permitted by supplier or IBM requirements, whichever is most limited. IBM requires that rework be limited to no more than one time per DRAM or other component site, no more than 3 component sites per DIMM. Mark reworked modules for traceability. For Surface Insulation Resistance testing, simulate rework by applying primary paste and rework flux, reflow, and any cleaning process.

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11.3.2 Visual and Finish, Substrate and Assembly Requirements Test Test Test Vehicle Sample Size Specification Specification (When Description Defining Test Defining Pass/Fail used) Requirements Criteria 2.1 Assembly Assembled 10 Pieces total IBM Physical Outline IBM Physical Outline A visual DIMM 2 lots, 5 pieces from Drawing, Drawing, Including each lot IPC 610 Class 2 * IPC 610 Class 2 * Gold Tab IBM 61X5956 IBM 61X5956, Section 3.5 section 3.5 2.2 Ni/Au DIMM module 10 Substrates total IBM ES 61X5956 IBM ES 61X5956, B Porosity substrates, 2 lots, 5 pieces each Sec 3.3 Section 3.3.2 2.3 Ni/Au DIMM module 4 Substrates total XRF Reference IBM ES 61X5956 B Thickness substrates, 2 lots, 2 pieces each ASTM 568 or Section 3.2.1 equivalent and IBM ES61X5956 2.4 Module Water or 2 pieces EIA/IPC J-Std 001, EIA/IPC J-Std 001, A Ionic solvent clean C-22 clean, Cleanliness flux assembled contamination < than modules only 1.56 ug/cm2 NaCl equivalent. 2.5 Substrate DIMM module 4 Substrates total IPC TM 650, 2.3.25.1 Total ionic B Cleanliness substrates, 2 per panel, contamination< 2 lots 1.0 ug/cm2 NaCl equivalent. 2.6 Substrate DIMM 20 Substrates total IPC 6012 IPC 6012 Class 2 * B Visual module  2 lots - 10 pieces IBM 61X5956 for Au IBM 61X5956 for Au Inspection substrates each tabs tabs  4 panels per lot See Additional Detail See Additional Detail  5 per panel - 4 corners and center 2.7 Substrate DIMM 4 Substrates total IPC 650 IPC 6012C, Section B bow and module  2 per panel Method 2.4.2.2 3.4.3 Neither bow nor twist Substrates  2 lots twist shall exceed 0.75% 2.8 Substrate DIMM 32 Coupons total IPC A-600H Sections IPC A-600H, B Micro- module 4 per panel 3.1.7 Sections 3.1.7, 3.3.1 section substrates on panel corners 3.3.1 Class 2 * visual, 4 panels per lot Minimum via wall to including 2 lots voltage plane space lay up 100 uM. verification (IPC A-600H 3.1.7) See additional detail 2.9 Substrate IPC Coupons 32 Coupons total IPC A-600H Sections IPC A-600H, B Registration 4 per panel 3.1.7 Sections 3.1.7, 3.3.1 Check visual on panel corners 3.3.1 Class 2 * 4 panels per lot Minimum via wall to 2 lots voltage plane space 100 uM. (IPC A-600H 3.1.7) See additional detail 2.10 2X, 6X DIMM 6 substrates total IPC TM 650 Method IPC 6012C B,C Solder Float module  2 lots / 1 panel / 2.6.8 d – paragraph Table 3.9. substrates lot 5.4 – 288oC Inner layer separation  3 substrates / Repeat steps 5.5-5.6, only. Page 15 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528

Panel 6 times No more than 10%  Diagonal 30 of inner layers may PTHs, 60 show visible connections/ per separation. substrate 2.11 2X Solder DIMM 6 substrates total IPC TM 650 Method IPC 6012C B,C Float Module  2 lots 2.6.8 Table 3.9 substrates  3 substrates/lot Repeat steps 5.5-5.6, Class 2 *  diagonal 2 times. Laminate Integrity - substrates. paragraphs 3.6 and  30 PTHs, 60 2.6.2.4; connections/ Solder mask adhesion  substrate – IPC SM-840

* Inspection is to Class 2 requirement, with exceptions listed in 77P3021, “Additions, Exceptions, and Limitations to Industry Standards to be applied to IBM Custom DIMMs”.

11.3.3 DIMM Substrate Electrical Requirements Test Test Test Vehicle Sample Size Specification Specification (When Description Defining Test Defining Pass/Fail used) Requirements Criteria 3.1 Impedance Impedance 20 coupons total IBM outline drawing Outline drawing. Test B Coupons  2 lots - 10 and coupons with coupons each IBM ES 21H5140 impedance data to be  100 data points provided to IBM for minimum correlation. ES 21H5140 3.2 Hi pot* DIMM 24 panels total- all IPC TM 650 IPC TM 650, 2.5.7. B Module substrates 2.5.7,ramp to Leakage current < Substrates 2 lots, 4 panels each 550 V, 100V/sec 600 uA See from beginning, max, hold at max 10 additional detail middle and end of lot. sec. min.

* Test is non destructive, parts can be reused for other stress or production

11.3.4 Mechanical Test Requirements Test Test Test Vehicle Sample Size Specification Specification (When Description Defining Test Defining Pass/Fail used) Requirements Criteria 4.1, A DIMM Functional 2 DIMM modules, See Detail Visual inspection for Module DIMM 1/lot damage, functional torque test. 4.2, A Module Functional 2 DIMM modules, See Detail See Detail Impact DIMM 1/lot Shock 4.3, A Module Functional 2 DIMM modules, See Detail See Detail Vibration DIMM 1/lot 4.4, A, Solder joint BGA solder joint intermetallic interfaces are prone to brittle failure by various B, C interface mechanisms depending on construction. A number of standardized and customer specific integrity tests have been developed to control these mechanisms. Describe the tests you use to qualify DIMM assemblies against intermetallic interface failures, and provide data on the performance of your part in these tests.

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11.4 Additional Detail Test 1.1 - DIMM Module Substrate insulation resistance (IR) Testing

The stress setup shall impose bias during stress between the ground network and all power nets.

Stress may be 50, 65, or 85C +/-2C, and 85%RH +/-5% RH,

Bias shall be 2 times the DRAM device application voltage minimum. Pass/Fail shall be judged at 500 hours. Stress should be continued to 2 times Pass/fail point for information purposes. Readouts to be performed at 24, 48, 100, 150, 200, 300, and 600 hours minimum.. At readouts: Visually inspect for dendritic growth or electrolytic corrosion product. Report any observed issues as fails.

Test 1.2 - DIMM Module Insulation Resistance The stress setup shall impose bias during stress between the ground network and all power nets, and as best possible across risk sites, while keeping devices in a low power consumption state, where risk sites are defined as vias at minimum drill pitch. Stress readouts and duration as above, 1.1

Test 1.3 - DIMM Module Thermal Cycling For equivalent stresses, minimum dwells at extreme temperatures are 7 minutes. Cycle delta T must be of at least 100C in the range -30 to 125C. Stress duration is 1200 cycles at 0 to 100C. Other stresses shall give an equivalent field life using the Coffin mansion equation, equivalent cycles equals 1200 times (delta T (100C) over delta T (proposed)) squared.

Test 2.6 - DIMM Module Substrate Visual

For exceptions to IPC 6012 see 77P3021

Test 2.8 - Microsection Visual

For exceptions to IPC 6012 see 77P3021

Test 2.9 - DIMM Module Substrate Registration Check visual

Registration coupon designs are discussed in IPC-A-600, Section 3.3.1, “Annular Ring - Internal Layers”. The two coupon designs acceptable to IBM are the Coupon F and Coupon R designs discussed in IPC 2221. Coupon F is an x-ray coupon and must be modified to have drilled hole and land sizes representative of what is on the product. Coupon R, which is both an electrical and x-ray coupon, must be modified to have clearance holes in 2 mil increments versus the 20 mil increments shown by IPC.

Test 3.2 - HiPot This test shall be applied between electrically isolated lines, lands, plated through holes, and internal planes.

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Test 4.1 - Torque Shock

DIMMs shall be capable of being torqued 1.8o per inch length of the DIMM for 25 cycles. The maximum torque frequency is 0.5 Hertz.

All visible solder joints on the DIMM shall be inspected before and after the test. Any cracking shall be noted.

No fracture of the solder joints after test in excess of 25% of the fillet length is allowed when viewed at 10X magnification.

The DIMM should be verified to be electrically functional at 0oC, 25oC, and 70oC before and after the test.

Test 4.2 - Impact Shock

Mount the DIMM in a typical application socket attached rigidly to an Impact shock table.

Subject the assembly to impact shock 30 G, 25 ms, Trapezoidal pulse, 3 times in each of 3 orthogonal directions, parallel to the major axes of the DIMM module.

Visual, DIMM functional readout post stress.

Test 4.3 - Vibration

Mount DIMM in typical application socket attached rigidly to a vibration table. Scan Vibration over the frequency 20 to 200 Hertz. Identify assembly resonant frequencies in this range. Dwell 15 minutes vibration at each resonant frequency. Maximum Acceleration to be <0.5G. Visual, DIMM functional readout post stress

11.5 Failure Analysis

Any fails occurring during reliability stress testing shall be electrically and physically analyzed to root cause. A report detailing the failure analysis activity shall be provided to IBM, along with any corrective action.

11.6 Coupons

Two coupons are discussed in this qualification plan. These coupon types are: 1. Impedance 2. Registration

It is IBM’s intent to have the raw card supplier integrate these coupons into the functional panel design, rather than to build unique test vehicle panels. Coupons will therefore have the same cross-section as the functional part being qualified. The impedance and registration coupons are expected to be on the panel at all times, unless the supplier has an equivalent method to demonstrate:  conformance to the impedance specification  registration is within specification

Page 18 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528 Appendix A. Recommended Preconditioning Flows for PTH (Pin Through Hole) Components

1. Temperature Cycle, 5 cycles, -40 to 150C; or similar condition. (Optional)

2. Flux Application - 1, Initial Attach

A. Lonco 3355-11 or similar IBM approved highly active, water soluble flux may be used. If Lonco 3355-11 flux is used, it should be used at room ambient temperature and be maintained at a specific gravity of 0.930+/-0.01. The specific gravity may be adjusted by adding isopropyl alcohol.

Option 1 Apply flux to the leads by immersing the device in flux. The lead egress area of the package must be completely submerged in the flux. Option 2 If the simulation is to be performed on cards with non-plated through holes or similar vehicle, its thickness shall not exceed 0.065 inches. The components shall be secured to the card using bus-wire or in any other suitable fashion. The card shall be lowered into the flux such that the flux comes up through the holes to the top of the card and completely submerges the lead egress area. The card shall remain in the flux for 2 to 3 seconds.

B. Preheat Simulation: Activate flux by heating component to 100C for 30 - 40 seconds. Fixturing must be nonabsorbent and non-contaminating.

3. Wave Solder Simulation

Option 1 For preconditioning, immerse leads into solder type specified by IBM: a. SnPb solder at 260C +5/-0C for 5 - 10 seconds b. Pb-free solder at 270C +5/-0C for 7 – 9 seconds Extent of solder immersion should be from lead tip to component standoff.

Option 2 If devices are mounted on a printed circuit card, the extent of solder immersion should be to guarantee contact of solder to the bottom of the card. Solder type and temperature are the same as in Option 1.

FOR PLASTIC PACKAGES STEPS 2-4 SHOULD BE CARRIED OUT IN THE SHORTEST TIME POSSIBLE

4. Within 60 seconds, rinse components in agitated DI water, at 50C minimum, for a minimum of two minutes.

5. Allow devices to dry at room ambient conditions for 10 to 15 minutes.

6. Flux Application - 2, Rework

A. Kester 450 or similar IBM approved, activated, water soluble, glycol flux may be used.

B. The component shall be immersed in the flux such that the leads and the lead egress area of the package are completely covered with flux.

C. This flux must be activated at 120+/-0.5C for 40 - 60 seconds.

7. Repeat step 3

8. Within 60 seconds, rinse components in agitated DI water, at 50C minimum, for a minimum of two minutes.

9. Allow devices to dry at room ambient conditions for 10 to 15 minutes.

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Appendix B. Recommended Preconditioning Flows for Backside Wave Attach of SMT Components

1. Temperature Cycle, -65 to 150C, 5 Cycles (Optional)

2. Moisture Soak, 85C / 85% RH for 168 Hours

3. Flux application - 1, Initial Attach

B. The component shall be completely immersed in the flux.

C. Activate the flux by heating the component to 100C for 30 - 40 seconds before reflow simulation. Move component to reflow immediately.

4. Reflow Simulation - Submerse entire component in molten solder type as specified by IBM: a. SnPb solder at 260C +5/-0C for 5 seconds b. Pb-free solder at 270C +5/-0C for 5 seconds (Component may be wrapped in aluminum foil.)

5. Within 60 seconds, rinse components in agitated DI water, at 50C minimum, for a minimum of two minutes.

6. Flux Application - 2, Rework

A. Kester 450 or similar IBM approved, activated, water soluble, glycol flux may be used.

B. The component shall be immersed in the flux such that the leads and lead egress area of the package are completely covered with flux.

C. This flux must be activated at 120C +/-5C for 40 - 60 seconds.

7. Preheat / Reflow - Repeat step 4.

8. Within 60 seconds, rinse components in agitated DI water, at 50C minimum, for a minimum of two minutes.

Note: Preconditioning is now complete. Proceed to appropriate reliability tests.

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Appendix C. Drop Test

In lieu of an internal or industry standard drop test previously approved by IBM, please perform the following test to ensure the mechanical integrity of components packaged for shipment.

1. Perform automated lead inspection (coplanarity and skew) on all components prior to placement into the shipping media (tray, tape & reel, tube, etc.,). Components are to be serialized. Nonfunctional devices may be used for this test.

2. Package the shipping media into its standard shipping container, as typically loaded for sale to a customer.

3. Perform drop test to the following conditions: Drop Height: 130 cm Number of drops: 10 Orientation of drops: 6 total - On all 6 faces of the shipping box 1 total - On 1 corner 3 total - On each edge adjacent to the above corner

4. Perform visual inspection of shipping container and the shipping media for signs of damage that would inhibit their functional use.

5. Remove the components from the packaging and perform automated lead inspection on all of the components and compare results to initial scan and to package outline specifications.

6. Perform visual inspection on components for any evidence of lead/terminal/ball or package damage.

Page 21 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528 Appendix D. Airflow Susceptibility Test for Copper Wire Bonding

Procedure

1. Preparation

A. Fix air gun or equivalent airflow source in front of bonder – shown in Methods 1 and 2 B. Blow air to bonding head and adjust airflow velocity • Levels: 0, 0.5, 1.0, 1.5 and 2.0 m/s C. Measure airflow velocity at multiple points and confirm velocity tolerance of +/-10% throughout FAB forming area of bonding head D. Use hot-wire airflow meter or other equivalent meter to measure above airflow velocity.

2. Pre- test

A. Form at least 30 Free Air Balls (FABs) for each of the 5 airflow velocity levels and each of the 3 airflow directions, shown in Method 1/2 and 2/2, and inspect shape and oxidation of FABs.

3. Test

A. Bond and sample at least 30 wires from at least 5 units at each of 5 airflow velocity levels from each of 3 airflow directions, shown in Method 1 and 2 for each test B. Measure ball height, ball shear and wire pull strength with observation of destruction modes C. Observe any anomalies on first and second bonds.

Airflow Susceptibility Test – Method 1 of 2

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Airflow Susceptibility Test – Method 2 of 2

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Test Report

1. Pre-test result

A. Inspection results of FAB shape and oxidation for 5 airflow levels and 3 directions

2. Test result

A. Test results for 5 airflow levels and 3 directions for the following measurement and tests 1. Ball height 2. Ball shear strength 3. Wire pull strength B. Above test results to include the following data 1. Average, max and min, and standard deviation (n 30), or all raw data 2. Ppk and spec limits 3. % destruction modes for ball shear and wire pull 4. Any anomalies observed

Test Criteria

1. No oxidation or FAB distortion

2. No OOS, Ppk 1.67, no significant change, or no anomalies in A. Ball height B. Ball shear strength C. Wire pull strength

3. Deviations to above criteria need approval by IBM

Note: Process Performance (Ppk) and Process Capability (Cpk) are calculated with the following formula:

USL     LSL  Min ,   3 3  n 2 (xi  x) For Ppk,  is calculated (estimated) with i1 where individual x’s are used. n 1 R s For Cpk,  is calculated (estimated) within-subgroup variations; e.g., or in control charts. d 2 c4 Per JESD47H, use of Cpk should be limited to data on more than 30 lots.

Page 24 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528 Appendix E. Audit Checklist for Copper Wire Bonding

1.0 Bonding Equipment 1.1 State bonder manufacturer and model 1.2 State copper wire bonding kit manufacturer and model 1.3 State first bond type (ball or wedge) 1.4 State second bond type (stitch or wedge) 1.5 State bonding stage temperature 1.6 State transducer frequency 1.7 State ultrasonic power 1.8 State bonding force 1.9 State bonding time 1.10 State if bonder automatically stops on non-sticking bonds 1.11 State what procedure is followed once bonder has stopped 1.12 Will thermosonic bonders be converted to use copper wire at a later date (after initial qualification)? If yes, please answer the following 2 questions: 1.13 State procedure to qualify converted bonders, especially if different models of bonders are to be converted 1.14 How will customers be notified of conversions initiated after initial qual completed?

2.0 Bonding Capillary 2.1 State capillary material 2.2 State if capillary design is dedicated for copper wire bonding. If yes, state differences from one for gold wire bonding 2.3 State capillary replacement frequency 2.4 State if capillary can be reworked or cleaned

3.0 Forming Gas 3.1 State incoming gas(es) specs and their tolerances (e.g., N2, H2) 3.2 State gas(es) IQC items 3.3 State forming gas composition spec and tolerance 3.4 State forming gas monitoring items and their action limits at facility area 3.5 State forming gas monitoring items and their action limits at use point

4.0 Forming Gas System 4.1 State flow rate specs with tolerances 4.2 State flow rate action limits and action procedures 4.3 State if bonder automatically stops on out-of-spec flow rate 4.4 State if nozzle alignment spec, adjustment procedure and verification procedure are documented. If yes, attach the documents. 4.5 State if nozzle PM procedures are documented. If yes, attach the document. 4.6 Attach airflow susceptibility test report (refer to Appendix D)

5.0 Bonding Wire 5.1 State wire manufacturer and type 5.2 State wire metallurgy; (e.g., gold, copper, etc.) 5.3 State wire purity and any alloys/impurities, and if coated, state coating material (e.g., Pd coating over Cu wire) 5.4 State wire diameter

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5.5 State shelf life and storage conditions 5.6 State floor life and storage conditions 5.7 State how Cu wire spool is packed to prevent oxidation 5.8 State Cu wire spool IQC items 5.9 State how wire spool is stored in warehouses 5.10 State temperature/humidity specs of the warehouses 5.11 State shelf life extension period if allowed 5.12 State how wire spool is stored in manufacturing floors 5.13 State temperature/humidity specs of the manufacturing floor 5.14 State how wire spool is released to bonder 5.15 State floor life extension period if allowed

6.0 Die 6.1 State bond pad metallurgy 6.2 State if die is cleaned/processed prior to wire bonding. If yes, respond to the following: 6.3 State how to clean/process 6.4 State smallest pad-to-pad clearance

7.0 Leadframe/Substrate 7.1 State bond area metallurgy 7.2 State if leadframe/substrate is cleaned/processed prior to wire bonding. If yes, respond to the following: 7.3 State how to clean/processed

8.0 Wire Pull Test 8.1 State if wire pull test performed. If yes, respond to all the following: 8.2 State at which portion of the wire pull force is applied (e.g., 1/3 length from ball) 8.3 State sample size and frequency 8.4 List failure modes if monitored and recorded 8.5 State wire pull test spec limit 8.6 State if control chart is applied. If yes, respond to the following two questions: 8.7 State current control limits 8.8 State if bonder is shut down when pull strength below control limit 8.9 State if bonder is shut down for any failure modes even if the pull force is above spec/control limit. If yes, respond to the following question: 8.10 List the failure modes

9.0 Stitch/Wedge (second bond) Pull Test 9.1 State if stitch/wedge pull test performed. If yes, respond to all the following: 9.2 State how to perform stitch/wedge (second bond) pull test 9.3 State sample size and frequency 9.4 List failure modes if monitored and recorded 9.5 State wire pull test spec limit 9.6 State if control chart is applied. If yes, respond to the following two questions: 9.7 State current control limits 9.8 State if bonder is shut down when pull strength is below control limit 9.9 State if bonder is shut down for any failure modes even if the pull force is above spec/control limit. If yes, respond to the following questions: 9.10 List the failure modes Page 26 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528

10.0 Ball/Wedge (first bond) Shear Test 10.1 State if ball/wedge (first bond) shear test performed. If yes, respond to all the following: 10.2 State sample size and frequency 10.3 List failure modes if monitored and recorded 10.4 State bond shear force spec limit 10.5 State if control chart is applied. If yes, respond to the following two questions: 10.6 State current control limits for bond shear test 10.7 State if bonder is shut down when shear force below control limit 10.8 State if bonder is shut down for any failure modes even if the shear force is above spec/control limit. If yes, respond to following question: 10.9 List the failure modes 10.10 For wedge bond, state wedge remnant criteria; i.e., shape, % remaining on bond pad, etc.

11.0 Stitch/Wedge (second bond) Shear Test 11.1 State if stitch/wedge (second bond) shear test performed. If yes, respond to all the following: 11.2 State sample size and frequency 11.3 List failure modes if monitored and recorded 11.4 State wire shear test spec limit 11.5 State if control chart is applied. If yes, respond to the following two: 11.6 State current control limits 11.7 State if bonder is shut down when shear strength below control limit 11.8 State if bonder is shut down for any failure modes even if the shear force is above spec/control limit. If yes, respond to the following question: 11.9 List the failure modes 11.10 For wedge bond, state wedge remnant criteria; i.e., shape, % remaining on bond area, etc.

12.0 Cratering (chemical etch) Test 12.1 State if bond cratering (chemical etch) is monitored. If yes, respond to the following question: 12.2 State sample size and frequency

13.0 Other Process Control 13.1 State if wire bond rework allowed 13.2 List defects that operators look for at wire bonding station 13.3 State maximum % offset that ball/wedge bond may be off the bond pad 13.4 State if pad metal splash is monitored. If yes, respond to the next three questions: 13.5 State monitoring method for metal splash 13.6 State sample size and frequency for metal splash inspection 13.7 State splash specification 13.8 State if nondestructive wire pull performed. If yes, respond to the following question: 13.9 State pull force for nondestructive pull test 13.10 State if wire loop height is monitored. If yes, respond to the following three questions: 13.11 State monitoring method for wire loop height 13.12 State sample size and frequency for wire loop height inspection 13.13 State wire loop height specification

14.0 Optical Inspection 14.1 State where wire bond inspection (3rd Optical) is performed

Page 27 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc) IBM Engineering Specification: 57G9271 EC: N81528

14.2 State sample size and frequency 14.3 State defect level (that triggers 100% inspection) 14.4 State magnification 14.5 List defects that device is rejected for 14.6 State how leadframes or substrates are handled for inspection 14.7 State if number of defects are recorded on lot traveler 14.8 State how defective devices are identified and tracked

15.0 On-going Reliability Test 15.1 State if on-gong reliability test for wire bond is performed. If yes, respond to the following two questions: 15.2 State what tests are performed 15.3 State sample size and frequency

Page 28 of 28 This specification is property of IBM. Its use is authorized only for responding to a request for quotation or for the performance of work for IBM. All questions shall be referred to the IBM procurement department requesting a quotation or the performance of work. (57G9271 N81528.doc)