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Reliability Criteria for Thick Bonding Wire.

Turker Dagdelen1, Eihab Abdel-Rahman2, Mustafa Yavuz3

  • 1Mechanical and Mechatronics Engineering, University of Waterloo, 200 University Ave W, Waterloo, ON N2L 3G1, Canada. tdagdele@uwaterloo.ca.

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Summary
This summary is machine-generated.

This study found that aspect ratio, not flexure, reliably predicts thick bonding wire fatigue life. Aluminum coated copper wires show better performance and longevity than aluminum wires.

Keywords:
electronic packagingheel stresspower modulesreliabilitywire bonding

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Area of Science:

  • Materials Science
  • Electrical Engineering
  • Reliability Engineering

Background:

  • Thick bonding wires are crucial for high-power applications like power modules.
  • Traditional reliability criteria for thin wires may not apply to thick wires.
  • Understanding thick wire reliability is essential for advanced electronics.

Purpose of the Study:

  • To evaluate the applicability of thin wire reliability criteria (flexure, aspect ratio) to thick bonding wires.
  • To determine the correlation between wire properties and fatigue life in thick wires.
  • To compare the fatigue life of aluminum (Al) and aluminum coated copper (CucorAl) thick wires.

Main Methods:

  • Experimental testing of eleven 300 μm diameter Al and CucorAl wire samples.
  • Utilizing a novel non-contact method for measuring wire response.
  • Developing and validating high-fidelity Finite Element Method (FEM) models.

Main Results:

  • Wire flexure was found to be uncorrelated with stress state or fatigue life.
  • Aspect ratio emerged as a consistent predictor of thick wire fatigue life.
  • Increasing aspect ratio decreased critical stress and extended fatigue life.
  • CucorAl wire demonstrated superior performance and longer fatigue life compared to Al wire.

Conclusions:

  • Aspect ratio is a valid and critical criterion for assessing the fatigue life of thick bonding wires.
  • Wire flexure is not a reliable indicator of thick wire reliability.
  • Aluminum coated copper offers a more durable and reliable alternative to pure aluminum for thick bonding wire applications.