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of Cu can dissolve from the knee of the PTH Nickel barrier plating minimizes this effect because Ni dissolves far more slowly in eutectic Sn-Pb solder than Cu does Use of Au plating can embrittle the eutectic Sn-Pb solder most commonly used in electronic assembly Gold plating of various thicknesses is used for a variety of reasons, including as a solderability preservative over nickel plating, for connector contacts, and to provide wirebondable pads Reliability problems can arise because Au has a high solubility in eutectic SnPb solders at reflow temperatures and dissolves extremely rapidly In most cases, the Au finish on a PCB or component termination will be completely dissolved into the solder In a wavesoldering process, the Au will be washed into the bath, requiring monitoring and bath changes to maintain the Au concentration at a low level that does not affect the process.

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However, in a reflow process, this Au remains in the finished solder joint To avoid embrittlement of the solder by the AuSn4 and AuSn2 intermetallics that can form, the Au concentration should be kept below a critical level that most authors set at 3 to 5 percent by weight35,36 For most components used today, a nominal 5- in (01-mm) thickness Au flash to preserve solderability is harmless However, if thicker Au plating (eg, for connector contacts or wire bonding) is used, if the component lead pitch is less than 05 mm, or if the component lead terminations are also Au-plated, care should be taken to ensure that the Au concentration remains below the 3 to 5 percent by weight limit.

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For some applications in which use of thick Au is unavoidable, 50In-50Pb solder, in which Au dissolves very slowly, has been used to get around this problem37 Selective thick Au plating is another option The Au concentration in the finished reflowed solder joint can be estimated using the following equation: Wt % Au = (Au volume) [(Au volume) + (solder volume)(rsolder/Au)].

where solder/Au is the ratio of the density of the solder to the density of Au (0.4552 for 63Sn37Pb solder). If the Au is less than 1 m thick, it is usually valid to assume that all of the Au on the joined surfaces has dissolved into the joint. The solder volume should include any solder plated on either the component or board termination as well as that applied by stencil printing. It is common to specify only a minimum Au plating thickness; it is important to use a representative value to calculate the expected Au content in the solder joint.

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Interconnect Material 57.5.2.1 Eutectic Sn-Pb Solder. Eutectic Sn-Pb solder, 63Sn-37Pb, and near-eutectic SnPb solders, including 60Sn-40Pb and 62Sn-36Pb-2Ag, are used in the overwhelming majority of soldered electronic assemblies. From a reliability perspective, the most important characteristics of these solders are their susceptibility to creep and fatigue because ambient temperatures are so close to the metal temperature of the solder, their ability to dissolve common termination metals rapidly and in large amounts, and their tendency to form thick intermetallic layers with termination metals. Although solder joint thermal fatigue is a major source of PCA field failures, the industry has used the same solder alloy for several decades. At present, there is no generally agreed-on alternative to eutectic Sn-Pb solder that has improved fatigue resistance as well as the favorable processing characteristics of eutectic Sn-Pb solder. However, there has been a tremendous surge in research into alternative solders, especially Pb-free solders, in the last decade and one can expect improved alloys in the future. There is some evidence that solders containing 2 percent Ag have improved properties in thermal cycling to high temperatures. Many common termination metals dissolve rapidly in eutectic Sn-Pb solder, including Ag, Au, and Cu.36 The dissolved metals can alter the properties of the solder. Reliability can also be impacted if the termination metal is dissolved entirely, the most notable case being Ag (or AgPd with less than 33 percent Pd) terminations on ceramic resistors and capacitors. If the entire

termination thickness is dissolved, the solder will dewet from the ceramic part, leaving an open joint if the entire termination is dissolved, or a substantially weakened one if it is dissolved only in some areas Use of 63Sn-36Pb-2Ag substantially reduces this problem, since the presence of Ag in the solder reduces the dissolution rate of the Ag forming the termination Finally, eutectic and near-eutectic Sn-Pb solders form intermetallics with the termination metals that influence the properties of the finished joints On the most common termination metals, Cu and Ni, continuous intermetallic layers form: Cu3Sn and Cu6Sn5 on copper, and Ni3Sn4, Ni3Sn2, and Ni3Sn on nickel These intermetallic layers are composed of compounds that are hard and brittle in comparison to both the solder and the termination metals.

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