<p>To fulfill the requirements for dependable low-temperature soldering of high-temperature lead-free materials and to inhibit the transformation of Cu<sub>6</sub>Sn<sub>5</sub> to Cu<sub>3</sub>Sn during transient liquid phase diffusion bonding (TLPB) and aging processes, along with minimizing joint porosity, Cu particles were initially coated with a Ni layer through electroless plating, followed by Sn layer deposition via stannous sulfamate electroplating to achieve Cu@Ni@Sn core-shell structured powder. The study explored the oxidation resistance of Cu@Ni@Sn powder and examined the formation rate and activation energy of Cu<sub>3</sub>Sn in both Cu@Sn and Cu@Ni@Sn TLPB joints, clarifying the Ni coating’s role in restricting element migration and phase transformation. The Cu@Ni@Sn TLPB joint displayed a three-dimensional network of intermetallic compounds enveloping Cu particles. This joint demonstrated thermal endurance of at least 400&#xa0;°C, room temperature shear strength exceeding 80&#xa0;MPa, and shear strength of no less than 28&#xa0;MPa after aging at 250&#xa0;°C for 336&#xa0;h, representing a 20% improvement compared to the Cu@Sn system. Joint porosity was lowered from 10% in the Cu@Sn system to 5% in the Cu@Ni@Sn system, surpassing both high-lead and nano-sintered Ag systems. The findings illustrate that the introduction of a Ni coating successfully restricted Cu diffusion, suppressed Cu<sub>6</sub>Sn<sub>5</sub> phase transformation, decreased void formation, and improved the high-temperature oxidation resistance of Cu@Ni@Sn powder. After undergoing reflow at 250&#xa0;°C, the Cu@Ni@Sn joint exhibited thermal conductivity of 156 W/m·K and electrical resistivity of 4.2 μΩ·cm, surpassing those observed in the Cu@Sn system, Cu<sub>6</sub>Sn<sub>5</sub>, and Cu<sub>3</sub>Sn. These results imply that Cu@Ni@Sn TLPB joints fulfill the criteria for high-performance interconnections, presenting a viable replacement for high-lead and sintered nano-Ag soldering materials, making them a favorable candidate for high-temperature, high-reliability interconnect applications in power modules.</p>

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Preparation and performance study of high-temperature resistant joints using Cu@Ni@Sn transient liquid phase diffusion bonding materials

  • Honghui Zhang,
  • Hongyan Xu,
  • Erika Hodúlová

摘要

To fulfill the requirements for dependable low-temperature soldering of high-temperature lead-free materials and to inhibit the transformation of Cu6Sn5 to Cu3Sn during transient liquid phase diffusion bonding (TLPB) and aging processes, along with minimizing joint porosity, Cu particles were initially coated with a Ni layer through electroless plating, followed by Sn layer deposition via stannous sulfamate electroplating to achieve Cu@Ni@Sn core-shell structured powder. The study explored the oxidation resistance of Cu@Ni@Sn powder and examined the formation rate and activation energy of Cu3Sn in both Cu@Sn and Cu@Ni@Sn TLPB joints, clarifying the Ni coating’s role in restricting element migration and phase transformation. The Cu@Ni@Sn TLPB joint displayed a three-dimensional network of intermetallic compounds enveloping Cu particles. This joint demonstrated thermal endurance of at least 400 °C, room temperature shear strength exceeding 80 MPa, and shear strength of no less than 28 MPa after aging at 250 °C for 336 h, representing a 20% improvement compared to the Cu@Sn system. Joint porosity was lowered from 10% in the Cu@Sn system to 5% in the Cu@Ni@Sn system, surpassing both high-lead and nano-sintered Ag systems. The findings illustrate that the introduction of a Ni coating successfully restricted Cu diffusion, suppressed Cu6Sn5 phase transformation, decreased void formation, and improved the high-temperature oxidation resistance of Cu@Ni@Sn powder. After undergoing reflow at 250 °C, the Cu@Ni@Sn joint exhibited thermal conductivity of 156 W/m·K and electrical resistivity of 4.2 μΩ·cm, surpassing those observed in the Cu@Sn system, Cu6Sn5, and Cu3Sn. These results imply that Cu@Ni@Sn TLPB joints fulfill the criteria for high-performance interconnections, presenting a viable replacement for high-lead and sintered nano-Ag soldering materials, making them a favorable candidate for high-temperature, high-reliability interconnect applications in power modules.