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Abstract—Electrically conductive adhesives are of large poten- delamination have for instance been observed, although the extent
tial interest for the bonding of surface mount devices, especially of their contributions under various conditions still needs to be
in those cases where the use of soldering processes is restricted resolved. The danger of Ag migration seems to be low as long as
or impossible. Among the claimed benefits are mild processing no liquid water is present.
conditions, process simplicity, flexibility, high resolution potential, In summary, present results indicate that reliable connections
and lead omission. Most of the presently available knowledge with conductive adhesives even under harsh climate conditions
on the utility and reliability of conductive adhesives has been are possible with the right choice of adhesive and metallizations
gathered with silver filled isotropic conductive epoxy adhesives of components and boards.
(ICA’s). In addition, the use of gold or nickel filled anisotropic
conductive film or paste adhesives has been investigated quite Index Terms— Adhesive, anisotropic, climate tests, crack for-
intensively. Even conductive adhesive joints made with unfilled mation, electrically conductive adhesive, failure causes, isotropic,
nonconductive adhesives are being considered for flip chip ap- oxidation, reliability, review, surface mount technology.
plications.
To date, quite some work has been published demonstrating the
usefulness and limitations of isotropic adhesives to bond a variety
of IC (e.g., QFP) discrete (e.g., SOT) and passive components (R I. INTRODUCTION
and C) under different climate conditions using various circuit-
and component-metallizations. Most of the isotropic conduc-
tive adhesives require noble metallizations (e.g., Au or AgPd)
to survive harsh environmental conditions as for instance 85
D URING the last 15 years many new electronic products
have entered our homes, cars, and offices to an extent
never thought of. With a unprecedented speed, new develop-
C/85%RH and temperature cycling from 040 to +125 C. Most ments are entering our personal and work environments, and
of the adhesives give bad results on SnPb surfaces, a few special expand our data-handling capacity and communication possi-
types show better results in 85 C/85%RH. Deterioration of the bilities. Within a few years, most of us will have hand-held
electrical properties is due to an increase in the contact resistance.
The bulk resistance of the adhesive, although considerably higher phones, pagers, personal TV, car information control systems,
than that of solder, usually remains quite constant. On passivated home office systems, lap top computers, computer network
Cu substrates reasonable good results are obtained. connections for worldwide communication, electronic banking
With Au finished surfaces large components may give problems and information retrieval. We will have the possibilities to
in drop tests and temperature cycling due to insufficient bond
area, unfavorable bond geometries or failures due to thermal
contact virtually everyone in the civilized world. We will have
expansion differences. The use of a coating or glob top on the digital cameras, show our pictures to our friends from TV,
leads may overcome these problems. and be able to make direct print outs. We will have rewritable
With Au coated plastic spheres filled anisotropic conductive optical discs, flat TV’s, plastic liquid crystal displays and more.
adhesives [ACA(F)] results opposite to the ICA’s were obtained. To a large extent, these developments have become possible
For QFP80 (Au) joints with ACAF on FR-4 (Au) considerable
increase in R-value was found after Temperature Humidity (TH) by the enormous increase in package density of the electronic
testing at 85 C/85%RH and Temperature Cycling (TC,020/100 circuits, realized by an astonishing level of integration of
C), while with QFP80 (SnPb) R-values did not increase. This functions in the IC’s, which as a result have become more
was found to be due to the formation of microsolder bridges. and more complicated and with higher and higher lead counts
Microsolder joints can also be made with commercially available
SnBi filled ACA. and smaller pitches down to 0.3 mm. New package forms such
Some insight has been developed into the possible failure causes as BGA, micro BGA, flip chip, and chip size packaging are
with ICA’s. Surface oxidation of SnPb and interfacial cracks and being developed and are expected to contribute 5–10% to the
package volume by the year 2000.
New technologies are needed to make these components
Manuscript received October 1, 1997; revised April 22, 1998. This paper and to connect them on the circuit boards, to achieve the high
was presented at the First IEEE International Symposium on Polymeric
Electronics Packaging, Norrkoping, Sweden, October 26–30, 1997. This paper
resolution needed.
was recommended for publication by Editors J. Liu and J. E. Morris upon Also from an environmental point of view improvements
evaluation of the reviewers’ comments. are needed, i.e., lead free and environmentally sound bonding
The author is with Philips Centre for Manufacturing Technology, Eindhoven
5600, The Netherlands. processes. Among the possibilities are lead free soldering,
Publisher Item Identifier S 1070-9886(98)05008-2. thermocompression and conductive adhesives.
1070–9886/98$10.00 1998 IEEE
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216 IEEE TRANSACTIONS ON COMPONENTS, PACKAGING, AND MANUFACTURING TECHNOLOGY—PART A, VOL. 21, NO. 2, JUNE 1998
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JAGT: RELIABILITY OF ELECTRICALLY CONDUCTIVE ADHESIVE JOINTS FOR SURFACE MOUNT APPLICATIONS 217
Fig. 4. Several universities, institutes, suppliers, and users (or consortia with
users) performed extensive reliability investigations with isotropic conductive
adhesives.
TABLE I Fig. 6. Drift in joint resistance for R 1206 (AgPd) jumpers adhesively
SOME EXAMPLES OF RELIABILITY TESTS IN VARIOUS INDUSTRIAL SECTORS bonded to FR-4, with different contact pad material, after damp heat testing
(85 C/85%RH, 1000 h).
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218 IEEE TRANSACTIONS ON COMPONENTS, PACKAGING, AND MANUFACTURING TECHNOLOGY—PART A, VOL. 21, NO. 2, JUNE 1998
Fig. 9. Contact resistance values for QFP80s (0.5 mm) with different met-
allizations bonded to Au-plated FR4 boards, using ACA-7 (Au-coated plastic
spheres) before and after climate tests.
2
Fig. 11. SEM BSE micrographs (400 ) of R 1206 with SnPb90/10 termi-
Fig. 10. Contact resistance values for QFP80s (0.5 mm) bonded to nation bonded to NiAu finished contact pads on FR-4 with CA-6, showing
SnPb-plated FR4 with ACA-7 (Au-coated plastic spheres) before and after extensive crack formation after damp heat (85 C/85%RH).
climate tests.
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JAGT: RELIABILITY OF ELECTRICALLY CONDUCTIVE ADHESIVE JOINTS FOR SURFACE MOUNT APPLICATIONS 219
Fig. 12. SEM BSE and EPMA micrographs of R 1206 with SnPb 90/10 termination bonded to NiAu finished contact pads on FR-4 with CA-6, after
damp heat (85 C/85% RH), showing local oxidation (see also Fig. 16).
adhesives less sensitive to Ag migration than silver inks used to printed circuit boards [42], [43]. One of the limitations of the
in the hybrid industry. On the other hand in most of the ACA(F) adhesives is the need to cure under a contact pressure.
damp heat tests performed no water condensation takes place, In an investigation by Lijten et al. [43] it was found that
a prerequisite for fast Ag-migration. Ag-migration has been contrary to the observations for ICA’s, anisotropic joints (e.g.,
reported by other investigators to occur with conductive adhe- with Au coated plastic spheres) of QFP80s on FR-4 (Au)
sives in the presence of liquid water at the joint location [23]. (Fig. 9) showed significant increase in resistance values after
The mechanical shear strength of the adhesive joints gener- 85 C/85%RH testing and RCT ( 25 to 100 C). Surprisingly
ally decreases in the temperature/humidity and thermal cycling
with components finished with SnPb (Figs. 9 and 10), far
tests, but in general no direct correlation with the electrical
better results were obtained. It was shown that under the
properties is observed.
conditions used solder bridges were formed across the Au
particles in the ACA, which showed very low and stable
IV. RELIABILITY OF ANISOTROPIC CONDUCTIVE ADHESIVES resistance values.
Only a few studies have been reported about the reliability Recently SnBi filled anisotropic adhesives have become
of anisotropic conductive adhesive joints of SMD components commercially available, that can form micro-solder joints
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220 IEEE TRANSACTIONS ON COMPONENTS, PACKAGING, AND MANUFACTURING TECHNOLOGY—PART A, VOL. 21, NO. 2, JUNE 1998
Fig. 13. SEM EPMA micrographs of R 1206 with SnPb 90/10 termination bonded to NiAu finished FR-4 with CA-6, after damp heat (85 C/85%RH,
1000 h). Note the presence of Cl0 at the corroded location and crack formation along the component surface.
within the adhesive matrix, showing low and stable resistance a silver depleted surface layer in the adhesive, creep of
values. the adhesive, the formation of intermetallics, and processing
An example from the work of Kivilahti et al., i.e., bonding failures. In some cases (with water condensation), also silver
of flex to flex with Sn58Bi filled anisotropically conductive migration could be a failure cause.
adhesive is given in Table III. Results for the SnBi filled
adhesive after 60 C/95%RH are quite good in case of Cu
and Sn, but worse for Au/Ni due to gold dissolution and A. Oxidation and Corrosion (SnPb, Cu)
Ni corrosion [7], [8]. In TC ( 40 C/100 C) no significant Oxidation of the SnPb layer can be uniform or local.
resistance increase was observed. For flip chip similar results The formation of a 100 nm thick oxide layer has been
were reported (85 C/85%RH). reported [40], [41]. Local oxidation has also been observed
by several investigators [23], [40], [41]. In some cases, traces
of have been detected at the oxidized/corroded places
V. FAILURE CAUSES (see Fig. 13) It has been suggested that the mechanism of
Several failure causes have been suggested to explain the SnPb corrosion is by electrochemical cell formation [23].
resistance increases sometimes observed with conductive ad- Resistance increases appear to be more severe for Sn fin-
hesives, i.e., oxidation of SnPb and Cu, crack formation, ished products than for SnPb and even less for Pb. The
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JAGT: RELIABILITY OF ELECTRICALLY CONDUCTIVE ADHESIVE JOINTS FOR SURFACE MOUNT APPLICATIONS 221
Fig. 14. SEM micrograph of R1206 (SnPb 90/10) joint with CA-3 to passivated Cu board, after 1000 cycles 40 C/125 C. Although cracks are formed 0
along the SnPb/adhesive surface and electrical resistance increased dramatically, joint strength is still considerable (25 N versus 38 N initially).
Fig. 15. Resistance values of joints of R0603 (Ag/Pd) to Sn plated FR4 boards made with ICA-A after cyclic humidity testing (25–80 C, 98% RH, 8
h cycle). Note that some components suddenly fail probably due to crack formation [23].
oxidation is also stronger underneath the adhesives than on In addition, in the case of bare Cu substrates also oxidation
unprotected SnPb. of Cu has been observed and considered as a cause of
It is also claimed that combinations of noble/less-noble resistance increase [14]–[19], [20]–[22].
metallizations suffer more severely from oxidation/corrosion
than combinations of nonnoble metals only. This could be due
to the electrochemical cell formation. B. Crack Formation/Delamination
Oxidation of SnPb may be the direct cause of the sometimes The occurrence of cracks in electrically poor performing
huge resistance increases, or indirectly by inducing crack joints has been observed by many different investigators
formation. after constant temperature/humidity as well as cyclic temper-
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222 IEEE TRANSACTIONS ON COMPONENTS, PACKAGING, AND MANUFACTURING TECHNOLOGY—PART A, VOL. 21, NO. 2, JUNE 1998
Fig. 16. SEM BSE micrographs of R1206 (AgPd) bonded with CA-6 to PbSn finished FR-4 boards after damp heat (85 C/85%RH, 1000 h). No significant
crack formation is observed, and resistance value is still low (Fig. 7).
ature/humidity testing, and thermal cycling. Some examples at the component side after temperature/humidity testing, by
for R1206 (SnPb) are given in Figs. 11–13, for 85 C/85%RH Auger analysis in combination with Ar-ion sputtering. The
testing, and also in Fig. 14 after RCT testing. Despite crack observation was made after cleavage of the joint at the
formation, the shear strength of the joint may still be consid- component side. It is also possible that crack formation and
erable (Fig. 14). some creep of the adhesive occurred.
Fig. 15 (Botter [23]) shows that during humidity cycling,
sudden increases in resistance values may occur in some joints, D. Creep of the Adhesive
possibly due to crack formation, while in similar joints the Some authors suggested the possibility of adhesive creep
increase is rather smooth. leading to resistance increase during TC testing. This could be
With AgPd finished resistors, which did not show significant due to cyclic shear motion of the component and visco-plastic
resistance increase in the indicated tests, no cracks were deformation of the adhesive. The fact however that with a gold
observed (Fig. 16) [40], [41]. finish on component and board no large resistance increase is
observed, indicates that it is unlikely that creep is a main cause
C. Silver Depleted Layer of the R-increase with SnPb. It has also been observed by
In one case it has been reported [40], [41] that a thin several workers that the bulk resistance of the adhesive does
silver depleted layer ( 50 nm) was observed in the adhesive not increase significantly in climate tests. This observation,
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JAGT: RELIABILITY OF ELECTRICALLY CONDUCTIVE ADHESIVE JOINTS FOR SURFACE MOUNT APPLICATIONS 223
(a) (b)
(c)
Fig. 17. R0402 (AgPd) bonded with CA-7a (high yield value) to FR4. The figures show (a) bad fillet formation and very thin bond line, (b) magnification
2
160 , and (c) magnification 400 . 2
however does not exclude the creep explanation, because G. Processing Defects
the bulk resistance measurements are normally performed on Undercure [14]–[19], [20]–[22] of the adhesive may lead to
conductor structures, not forming a joint, and therefore not resistance increase during reliability testing. Also bad wetting,
subjected to a similar cyclic mechanical load on the adhesive voids in the adhesive, a very thin bondline, and misalignment
as in the case of bonded components. can lead to R-increase possibly by crack formation in the
adhesive joints (Fig. 17).
E. Formation of an Intermetallic Layer
Formation of Ag Sn intermediate layers of lower conduc- VI. IMPROVEMENT AREAS FOR CONDUCTIVE
tivity was suggested by Orthmann et al. [10]–[13] as the ADHESIVE BONDING WITH ICA’s
cause of R-increase during hot storage tests at 150 C. Other A survey of the factors that may lead to further improve-
investigators, however, have not observed Ag Sn during TC ments in conductive adhesive bonding, is given in Fig. 18.
and pressure cooker testing [24], [25]. Increase of drop resistance and improvement of RCT re-
sistance for larger components is wanted. This could be
attained either by improvement of the adhesive bond strength
F. Ag Migration (adhesion, impact resistance) or larger bond area and more
Several investigators have reported that they did not observe favorable lead geometries or the extra step of using a coating
signs of Ag migration during climate testing [14]–[19], [36], or glob top on the leads.
[37], [44]. It is clear however that silver migration can easily Further improvement of SnPb compatibility, and low mois-
occur if a liquid water film can be formed on the adhesive ture permeability in addition to increased adhesion and better
[44], [45], [46]. If any danger exists for water condensation it strength would increase the competitiveness with soldering.
is advisable to avoid the risk for silver migration by applying Better control of adhesive bondline thickness which is
a protective coating or glob top on the joints. usually quite thin, could possibly reduce failures in TC tests.
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224 IEEE TRANSACTIONS ON COMPONENTS, PACKAGING, AND MANUFACTURING TECHNOLOGY—PART A, VOL. 21, NO. 2, JUNE 1998
[8] K. Puhakka et al., “Bonding flexible circuits and flip chips with solder-
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