Nano Ag sintering on Cu substrate assisted by self-assembled monolayers for high-temperature electronics packaging

Sintering of nano Ag paste on bare Cu has attracted more interests recently for high-temperature electronics packaging, which offers the advantages of high reliability, cost-effective and direct bonding process. However, the current bonding methods normally need a protective atmosphere or metallization on Cu substrate to avoid oxidation. In this study, self-assembled monolayers (SAMs) were deposited on Cu substrate to suppress oxidation prior to nano Ag sintering. Thermal-compression bonding process of Cu/nano Ag/Cu joints was conducted and analysed with and without SAMs treatment. The cross-sectional characterization and shear tests were conducted to evaluate the influence of SAMs treatment. When SAMs applied, shear strength of 12.72 MPa has been achieved in the ambient atmosphere, which is much higher than the value without SAMs treatment (3.77 MPa). It has been identified that the shear mode changed from the interfaces of sintered nano Ag/Cu to inside of sintered nano Ag due to the applied SAMs. This technological approach provides a tangible and cost-effective method for high temperature electronics packaging

Statistical effects of pore features on mechanical properties and fracture behaviors of heterogeneous random porous materials by phase-field modeling

Heterogeneous materials with randomly distributed pores are ubiquitous, such as sintered silver nanoparticles, concrete materials, 3D printed polymers, and natural bones. Recent experimental investigations have revealed that porosity and also pore-related geometries (size, number, shape, distribution and alignment) have significant impacts on the mechanical behavior of random porous materials. However, existing studies focus on the porosity effect while ignoring other pore features such as pore size and pore shape. Our research is dedicated to a computational framework for generating isotropic/anisotropic random porous materials using Gaussian random fields with stochastic pore size and shape factor and addressing the mechanical properties and behavior of brittle fractures using a fracture phase-field model with a preferred degradation function. Sintered silver nanoparticles with typical randomly distributed pores, as representative porous materials, are chosen for their promising applications in emerging fields such as power electronics and wearable devices. In order to emphasize the effect of pore size and shape, 420 random samples with a fixed porosity were generated to discuss the stress–strain response during fracture and to establish statistical relationships between pore feature distributions and mechanical properties such as Young's modulus, UTS, and average historical energy. Our findings suggest that the statical attributes of the pore sizes and shape factors significantly affect the material performance related to the mechanical properties and fracture behavior, which could give a better understanding of the random porous materials and guide reliability-based material design optimization

Thermo-elasto-plastic phase-field modelling of mechanical behaviours of sintered nano-silver with randomly distributed micro-pores

Nano-silver paste is an emerging lead-free bonding material in power electronics, and has excellent mechanical properties, thermal conductivity and long-term reliability. However, it is extremely challenging to model the mechanical and failure behaviours of sintered nano-silver paste due to its random micro-porous structures and the coupled thermomechanical loading conditions. In this study, a novel computational framework was proposed to generate the random micro-porous structures and simulate their effects on mechanical properties and fracture behaviour based on the one-cut gaussian random field model and the thermo-elasto-plastic phase-field model. The elastic modulus, ultimate tensile strength and strain to failure are computed statistically, showing good agreement with the experimental results. Further, the framework was applied to model the fracture of sintered nano-silver paste under thermal cyclic conditions, demonstrating the formation of distinctive crack patterns and complex crack networks. The cracking behaviours observed in the experiments and simulations are remarkably similar to each other. The framework was implemented within Abaqus via a combination of subroutines and Python scripts, automating the process of model generation and subsequent computation. This study provides an efficient and reliable approach to simulate the mechanical and failure behaviours of sintered nano-silver paste with random micro-porous structures

Coupling of phase field and viscoplasticity for modelling cyclic softening and crack growth under fatigue

A coupled phase field-viscoplasticity approach was developed to model the deformation and crack growth in a nickel-based superalloy under fatigue. The coupled model has an advantage in predicting the cyclic softening behavior of the alloy caused by fatigue damage, overcoming a major limitation of the original cyclic viscoplasticity model. The coupled approach is also highly effective in predicting fatigue crack propagation under varied dwell times at peak load, an important behavior for crack growth under dwell fatigue. By incorporating the stress state factor, the coupled model is further utilized to investigate the growth behavior of 3D cracks under fatigue. Both the geometrical feature of the 3D crack front and the overall crack growth rate are well captured, confirming the predicative capability of the coupled model.</div