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Microelectronics Reliability
journal homepage: www.elsevier.com/locate/microrel
a
China Electronic Product Reliability and Environmental Testing Research Institute, Guangzhou 510610, People's Republic of China
b
College of Electronic Engineering, South China Agricultural University, Guangzhou 510610, People's Republic of China
c
School of Electronic and Information Engineering, South China University of Technology, Guangzhou 510610, People's Republic of China
Keywords: The fatigue life prediction of solder joints under random vibration load is one of the most important aspect in
Frequency-domain design of packaging. A fatigue-life estimation in the frequency domain is proved to have advantages in com-
Fatigue life prediction parison to the time-domain estimation. This paper presents a comparison of the fatigue life prediction of solder
Solder joints joints under random vibration load by several popular frequency domain methods, including the narrow-band,
the Wirsching–Light, the single-moment, the Empirical α0.75, the Tovo–Benasciutti, the Zhao–Baker, and the
Dirlik methods. The comparison between these selected frequency domain methods and the traditional Steinberg
method was investigated with the help of the relative error. Results indicate that most spectral methods are
accurate than the Steinberg method, the Tovo–Benasciutti method is proved to be the best method for the life
estimation of solder joints suited not only to the BGA package but also to the PoP package.
1. Introduction vibration, in their studies, the respond stress power spectral density
(PSD) of the critical solder joints was calculated by finite element
With the development of wearable electronic devices, electronic analysis (FEA) and then was transformed into time-history data by
products are more often subjected to vibration loading in the process of using the inverse fast Fourier transform (IFFT) method. A unit sample of
production, transportation and use. The vibration-induced failure of 2 s time-history data was generated, and then rainflow cycle counting
electronic devices is one of the most important reliability issues and has [9] and Miner's rule [10] were applied to estimate cumulative damage
been widely studied by many researchers [1–3]. Since solder joints are to obtain the fatigue life.
the critical part for the packages under random vibration [4,5], the Alternatively, the frequency-domain method based on spectral
most challenging issue in the packaging industry is to estimate the fa- analysis provides a direct connection between the PSD and the cumu-
tigue life of the critical solder joints more rapidly and effectively during lative damage, and can make use of analytical formulae to correlate the
the design process [6,7]. fatigue cycle distribution and the fatigue damage by means of numer-
The fatigue-life prediction methods under random vibration loading ical simulation from the PSD data, so fatigue counting can be performed
can be broadly divided into two types: the time-domain method based in the frequency domain using empirical or semi-empirical formulae.
on the stress or strain time history and the frequency-domain method Compared to the time-domain method, the frequency-domain method is
based on the power spectral density function (PSD) of stress or strain simpler and faster. Several efforts [11–13] were made to estimate the
process. In the time domain many stress time histories obtained by fatigue life of solder joints in practice PCB system by the frequency-
experimental measurements or numerical simulations have been ana- domain method, and most approaches are based on Steinberg's three-
lyzed, and the cumulative fatigue damage is obtained by combining band technology [14] which is a semi-empirical formula through many
cycle-counting methods and linear damage accumulation models. This years of practical experience. Dave S. Steinberg assumes that the
makes the time domain approaches, even if easy from a theoretical random vibration loading follows Gaussian distribution and the re-
point of view, clearly costly and time-consuming. Only a few people use sponse stresses or strains of 1σ, 2σ and 3σ will occur at 68.31%, 27.1%
the time-domain method to predict the fatigue life of solder joints under and 4.33% of the time, respectively. By combining the Miner's rule and
random vibration. Da. Yu et al. [8] investigated the high cycle fatigue the S-N curve of the solder joints, the cumulative damage index can be
reliability of Pb-free BGA with different Ag content under random written as follows:
⁎
Corresponding author.
E-mail address: phgyli@scut.edu.cn (G. Li).
https://doi.org/10.1016/j.microrel.2019.02.008
Received 26 April 2018; Received in revised form 28 January 2019; Accepted 21 February 2019
0026-2714/ © 2019 Elsevier Ltd. All rights reserved.
J. Xia, et al. Microelectronics Reliability 95 (2019) 58–64
3 mi
ni 1 b i =
CDI = = (0.683 + 0.27 2b + 0.0433 3b) fn t 1 m 0 m2i (5)
i=1
Ni C (1)
The αi bandwidth parameters are dimensionless numbers, and it
where Niσib = C is the Basquin's relationship [15], σi is the i-σ level takes range value from 0 to 1. For a narrow-band process, αi tends to 1,
stress and Ni is the failure cycles at σi, b is fatigue strength exponent, C is and for a wide-band process it approaches 0. The most commonly used
a constant, fn is the natural frequency and t is the applied time of parameters [25,26] are:
random vibration.
m1 m2 m 0.75
Actually, in other fields subjected to random loading, such as 1 = , 2 = , 0.75 =
bridges, vehicles and aircraft, several methods based on frequency
m 0 m2 m 0 m4 m 0 m1.5 (6)
domain analysis, such as the narrow-band approximation method or According to the Palmgren-Miner's rule, the accumulated damage
Dirlik's approximate formula, have been proposed to predict fatigue life per unit of time under the random variable stress amplitude loading is
under random vibration loading. These methods are the same in essence defined as:
– but only adopt different empirical or semi-empirical formulas that
directly relate the statistics of the fatigue cycles to the PSD. However, n (S ) VP p (S )
D = dS = dS
no body uses these formulas in the field of microelectronics packaging, 0
N (S ) 0
N (S ) (7)
and the best frequency-domain method based on empirical or semi-
here Vp is given by Eq. (4), S is the stress amplitude, n(S) is the actual
empirical formulas is not certain for the fatigue prediction of solder
number of cycles at S, N(S) is the fatigue number of cycles at S, and p(S)
joints under random vibration.
is the stress cycle amplitude probability density function (PDF) at S. The
In this paper, a brief review of the theoretical background of fre-
function p(S) is unknown and it is a key factor considered by the fre-
quency-domain method is firstly given, and several popular spectral
quency domain methods for fatigue analyses. As the S-N curve equation
methods for the fatigue analysis, including the narrow-band approx-
can be written as the following form:
imation method (NB) [16], the Wirsching–Light correction formula
(WL) [17], the single-moment method (SM) [18], the Empirical α0.75 N (S ) = CS k (8)
method (EM) [19], the Tovo–Benasciutti's method (TB) [20], the
where C and k are both material constants determined by fatigue test or
Zhao–Baker's model method (ZB) [21], and Dirlik's approximate for-
the manual, the accumulated damage per unit of time can be simplified
mula (DK) [22] are selected and reviewed. Then, the first attempt to
by plugging Eq. (8) into Eq. (7):
predict the fatigue life of solder joints under random vibration is exe-
cuted by these selected spectral methods and the Steinberg method (ST)
D = C 1VP S kp (S ) dS
[14]. A theoretical and experimental comparison study between these (9)
0
selected spectral methods and the Steinberg's three-band technology
method is presented to optimize the fatigue life prediction method of and the fatigue life estimation T obtained from the damage intensity per
solder joints under random vibration load. Some of those methods are unit of time D can be expressed as:
for the first time compared side-by-side. The aim of this paper is to find 1 C
T= =
the most accurate method for the fatigue life prediction of solder joints D
VP S kp (S ) dS
by using these frequency domain methods and the Steinberg method to (10)
0
deal with two typical package structures (ball grid array (BGA) and
Package-on-Package (PoP)) under random vibration.
2.2. Frequency-domain methods
2. Theoretical background
The fatigue life estimation can be performed in the frequency do-
main by using empirical or semi-empirical methods to describe p(S)
2.1. Random processes and spectral density
according to Eq. (10). Typical frequency-domain methods for the fa-
tigue prediction to deal with Gaussian random loadings are presented in
In the frequency domain the one-sided stress PSD G(f) is customa-
this section. These are the narrow-band method, the Wirsching–Light
rily used to describe the random stress loading, with f denoting the
method, the single-moment method, the Empirical α0.75 method, the
frequency. Most of statistical properties of a random stress process can
Tovo–Benasciutti method, the Zhao–Baker method, and the Dirlik
be depicted by the spectral moment mi of the PSD. Note that index i can
method.
take also non-integer values. The ith spectral moment mi has the general
form:
(1) Narrow-band approximation [16]. In the case of narrow band
processes peaks and valleys are almost symmetrically placed with
mi = f i G (f ) df respect to the mean level of the process, it is reasonable to assume
0 (2) that the p(S) tends to Rayleigh distribution:
For example, the variance σs2 of the random stress process is given S S2
by [23]: p (S ) = 2
exp
s 2 s2 (11)
2
s = m0 = G (f ) df here σs2
is determined by Eq. (3). Combining Eqs. (9) and (11), the
0 (3) narrow-band accumulated damage expression per unit of time can be
expressed as:
For a fatigue analysis, the spectral moment m2 and m4 are often used
in the analysis process, the expected peak occurrence frequency VP and
the expected positive zero-crossing frequency V0 are defined with [24]:
DNB = Vp C 1 ( 2m 0 ) k (1 + k 2 ) (12)
m4 m2 where m0 is 0th spectral moment determined by Eq. (2), Γ(⋅) is the well-
VP = V0 = known Euler gamma function, and VP is very close to the peak intensity
m2 m0 (4)
V0 for a narrow-band process. Notice that the narrow-band approx-
The spectral width of the process is described by bandwidth para- imation is appropriate for narrow-band processes, the fatigue life will
meters, where the ith parameter is defined as [25]: get a conservative value if the narrow-band approximation method is
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J. Xia, et al. Microelectronics Reliability 95 (2019) 58–64
carried out in wide-band processes. from only two spectral properties [21]:
Z2
(2) Wirsching–Light method [17]. In order to improve the reliability PZB (Z ) = w ZB Z 1e Z + (1 w ) Ze 2 (24)
and accuracy of the narrow-band approximation method for the
where αZB and β are the Weibull parameters:
wide-band processes, Wirsching and Light developed the empirical
correction factor λWL to correct the narrow-band approximation 1.1; 2 < 0.9
ZB =8 7 2, =
method: 1.1 + 9( 2 0.9); 2 0.9 (25)
WL = a (k ) + [1 a (k )](1 ) b (k ) (13) and Z is the normalized amplitude defined by:
where the spectral width parameter ε is defined as: S
Z=
2
m0 (26)
= 1 2 (14)
The weighting factor w is given as:
and the fitting parameters a(k) and b(k) are dependent on the S-N slope
k: 1 2
w= 1
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J. Xia, et al. Microelectronics Reliability 95 (2019) 58–64
Table 1
The dimension parameters of the PoP.
Components Top package (mm) Bottom package (mm)
Fig. 3. The package architecture for the PoP: (a) the top package; (b) the bottom package.
61
J. Xia, et al. Microelectronics Reliability 95 (2019) 58–64
method, the Dirlik method and the Steinberg method were selected for Table 2
a detailed analysis to each group of the samples. Material parameters of solder joints with different packaging structures.
Package structures C (Mpa) k Packaging formats
4. Discussion 12
BGA 3.58 × 10 6.93 2-D packaging
PoP 5.53 × 1013 8.62 3-D packaging
A reasonable fatigue life prediction method would give result that
are equal or close to the real fatigue-life obtained from the real ex-
periment approach, and preferably be conservative when not accurate. groups of loads) were experimentally compared. They found that the
Table 3 shows the relative error of the selected methods compared to Tovo–Benasciutti is found to be the best method, followed by the im-
the real fatigue-life for the BGA. From Table 3 it can be seen that most proved Zhao–Baker and Dirlik methods.
selected spectral methods are more accurate than the Steinberg method The trend of the relative errors for the PoP are similar to the BGA,
except for one case of the narrow-band method. Only two methods (the and most spectral methods are also more accurate than the Steinberg
Tovo–Benasciutti method and the Zhao–Baker method) exhibit less than method, as shown in Table 4. Overall, the average absolute value of
10% absolute error, which indicates that the Tovo–Benasciutti method relative errors for the PoP are less than the BGA, both the Dirlik and
and the Zhao–Baker method give the relatively accurate prediction for Tovo–Benasciutti methods exhibit less than 10% absolute error, which
the general case of wide-band random processes. This conclusion is are more accurate than others. The Tovo–Benasciutti method exhibits
consistent with Matjaž Mršnik's research [30]. In Matjaž Mršnik's re- less error again.
search, the frequency-based methods are compared to the time-domain Fig. 6 shows the relative errors of the selected methods for the
rainflow method, and twenty-eight different fatigue loads (five different
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J. Xia, et al. Microelectronics Reliability 95 (2019) 58–64
Table 3 Table 5
Relative error of the selected methods compared to the real fatigue-life for the The average absolute values and standard deviations of the relative error for the
BGA (k = 6.93). selected methods.
Methods Ttes (min) Tpre (min) Terr Methods The average absolute values The standard deviations
Table 4
Relative error of the selected methods compared to the real fatigue-life for the
PoP (k = 8.62).
Methods Ttes (min) Tpre (min) Terr
5. Conclusion
The vibration-fatigue life estimation of the solder joints for the ty-
Fig. 6. Relative errors of the selected methods for the solder joints with BGA pical BGA and PoP packaging structures under random vibration
and PoP packaging format. loading was performed and optimized by different life predication
methods, including the traditional Steinberg method and seven selected
spectral methods (the narrow-band approximation method, the
solder joints with BGA and PoP packaging formats. It is evident that Wirsching–Light correction formula, the single-moment method, the
most methods are conservative except for the Tovo–Benasciutti method Empirical α0.75 method, the Tovo–Benasciutti method, the Zhao–Baker's
and the Dirlik method. The Tovo–Benasciutti and the Dirlik method method (ZB), and Dirlik's approximate formula), these methods were
63
J. Xia, et al. Microelectronics Reliability 95 (2019) 58–64
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