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caused by the plastic deformation that occurs during each cycle, not by the cyclic stressing of the joint.) Hold time: As long as the stress on the solder joint remains nonzero, the thermal fatigue damage per cycle is increased if the hold time is lengthened, again because there is more time for creep to occur. Once the stress relaxation process has gone to completion, no further damage occurs and increasing the hold time further has no effect. Thermal shock: If the thermal cycle is extremely rapid, the components of the PCA may not be at the same temperature; consequently, the imposed strains may be larger or smaller than at slower rates.

Although the designer may be able to influence the peak temperature through cooling schemes, the thermal cycling profile and the frequency of thermal cycles in service are largely fixed by the application. Solder joint fatigue life may be increased by decreasing the strain e imposed on the solder joint by:

Choosing a package with a compliant attachment scheme. In this case, part of the strain is taken up by deflection of the lead, reducing the amount of strain in the solder. For these packages, the joint life can be further extended by decreasing the lead stiffness and increasing the joint area. Decreasing a, the difference in the package and substrate thermal expansion coefficients, by carefully selecting the CTE of the package and substrate (see Secs. 57.5.3.1 and 57.5.1.1, respectively). Decreasing the size of the package, decreasing l. Increasing the height h of the solder joint. Solder joint fatigue life may also be increased by:

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Decreasing the local CTE mismatch that occurs at the interfaces between the solder and the component lead and substrate metallization.While the substrate metallization is usually

Cu, which is moderately well matched to solder (17 vs. 25 ppm/ C), the leads may be made of a low-expansion metal such as Alloy 42 ( 5 ppm/ C) or Kovar, as well as of Cu. Decreasing the mean stress imposed on the solder joint (for example, due to residual stress after assembly). Increasing ef or decreasing the creep rate of the solder by controlling the solder joint microstructure or by selecting an alternative solder. (Finer microstructures, which may be achieved by faster reflow cooling rates, have significantly greater fatigue lives because they are resistant to fatigue crack initiation and propagation. Unfortunately, solder microstructures coarsen over time, even at room temperature. Some solders, such as Sn4Ag and 50In-50Pb, seem to have significantly improved fatigue lives over eutectic Sn-Pb; however, their higher reflow temperatures are not necessarily compatible with FR-4. See Sec. 57.5.2.2.)

Thermal Shock Thermal shocks (>30 C/s) cause failures because differential heating or cooling rates introduce large additional stresses into the assembly versus thermal cycling Under thermal cycling conditions, it is a good assumption that all components of the assembly are at approximately the same temperature (High-power components may be an exception) Under thermal shock conditions, different portions of the assembly are temporarily at different temperatures because their heating or cooling rates are not the same These temperature transients are caused by differences in thermal mass and thermal conductivity across the assembly; they are caused by component selection and placement decisions and by differences in the physical properties of the materials used in the assembly The temperature differences across the assembly and any resulting warpage can enhance the stresses normally imposed during temperature changes due to differences in CTE.

Thermal shocks can cause reliability problems, such as solder joint failures in overload and crazing in conformal coatings leading to corrosion failures, as well as a range of component failures Because of the differential thermal stresses that may be induced, thermal shock can cause failures that do not occur during slower thermal cycling between the same temperature extremes On the other hand, rapid thermal shock cycles actually cause less solder joint fatigue than slower thermal cycles; because little creep occurs, more cycles are needed to cause solder fatigue failure 57222 Mechanically Induced Failures PCAs can also fail in response to externally imposed mechanical stresses, for example, due to mechanical shock or vibration in shipping or in use These failures can be divided into two categories: overload failures and mechanical fatigue failures, which are caused by mechanical shocks and vibration, respectively.