Part ? II Assembly Guidelines 0.4mm Package-On … – II Assembly Guidelines for 0.4-mm...

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001 Application Report SWPA156 – February 2009 Part – II Assembly Guidelines for 0.4-mm Package-On-Package Packages Steven Kummerl ...................................................................................................................... OMAP ABSTRACT After the bottom circuit board is designed, the assembly guidelines for Package-On-Package (PoP) versions of the OMAP3 processor and the memory device must be considered. PoP package assembly involves multiple variables, including the following factors, which have a major effect on the quality and reliability of final assembly: Circuit board design Solder paste characteristics Solder paste deposition Reflow profile Fluxing or solder paste deposition onto the PoP memory before assembly There are two major techniques for mounting the PoP memory: one-pass and two-pass. Although this document describes both techniques , TI recommends the one-pass process because it is more economical and provides about the same assembly yields as the two-pass technique. The BeagleBoard, discussed in the companion document, Part-I, 0.4mm PCB Design Guidelines, provides a basis for understanding 0.4-mm assembly guidelines and process parameters. This document, which is Part II, describes trial runs performed with daisy chain units. However, this is only one of many possible variations of the assembly process. To optimize PoP assembly, TI strongly recommends performing trial runs and studies with the assembly house. Figure 1 shows POP after reflow. Figure 1. POP After Reflow Contents 1 Introduction .......................................................................................... 3 2 Focus of Part II ...................................................................................... 4 3 A Team Sport ....................................................................................... 5 4 OMAP3 and BeagleBoard ......................................................................... 6 4.1 Assembly Options ......................................................................... 7 SWPA156 – February 2009 Part – II Assembly Guidelines for 0.4-mm Package-On-Package Packages 1 Submit Documentation Feedback

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001

Application ReportSWPA156–February 2009

Part – II Assembly Guidelines for 0.4-mmPackage-On-Package Packages

Steven Kummerl...................................................................................................................... OMAP

ABSTRACTAfter the bottom circuit board is designed, the assembly guidelines forPackage-On-Package (PoP) versions of the OMAP3 processor and the memory devicemust be considered.

PoP package assembly involves multiple variables, including the following factors,which have a major effect on the quality and reliability of final assembly:• Circuit board design• Solder paste characteristics• Solder paste deposition• Reflow profile• Fluxing or solder paste deposition onto the PoP memory before assembly

There are two major techniques for mounting the PoP memory: one-pass andtwo-pass. Although this document describes both techniques , TI recommends theone-pass process because it is more economical and provides about the sameassembly yields as the two-pass technique.

The BeagleBoard, discussed in the companion document, Part-I, 0.4mm PCB DesignGuidelines, provides a basis for understanding 0.4-mm assembly guidelines andprocess parameters. This document, which is Part II, describes trial runs performedwith daisy chain units. However, this is only one of many possible variations of theassembly process. To optimize PoP assembly, TI strongly recommends performing trialruns and studies with the assembly house.

Figure 1 shows POP after reflow.

Figure 1. POP After Reflow

Contents1 Introduction .......................................................................................... 32 Focus of Part II...................................................................................... 43 A Team Sport ....................................................................................... 54 OMAP3 and BeagleBoard ......................................................................... 6

4.1 Assembly Options ......................................................................... 7

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4.2 Handling of Parts .......................................................................... 84.3 Solder Paste Stencil Design ............................................................ 104.4 BeagleBoard Solder Stencil and Case Study ........................................ 124.5 Memory Attachment Options ........................................................... 134.6 Solder Paste .............................................................................. 144.7 Screen Printing ........................................................................... 154.8 Reflow Atmosphere ...................................................................... 164.9 Reflow ..................................................................................... 17

5 Thermal Warpage ................................................................................. 196 Troubleshooting ................................................................................... 197 Acknowledgements ............................................................................... 21

7.1 Articles, Papers, Presentations......................................................... 217.2 Product References...................................................................... 22

8 Trademarks and Disclaimers .................................................................... 22

List of Figures

1 POP After Reflow................................................................................... 12 Overview of OMAP3 PoP Assembly Guidelines................................................ 33 Post-Solder Paste Dip Image of Memory and OMAP3 Processor ........................... 44 PoP Assembly Team............................................................................... 55 Mechanical Drawing and Beagle Board Layout ................................................ 66 PoP Package-to-Memory Package SMO Configuration....................................... 67 One-Pass Assembly Process ..................................................................... 78 Two-Pass Assembly Process ..................................................................... 89 Chipout From Impact Damage.................................................................... 810 Corner Chipout From Impact Damage........................................................... 811 Use the Substrate Edges to Manipulate the Device ........................................... 912 No Metal Tweezers................................................................................. 913 Passive Component Profile for Robust Handling and Assembly ........................... 1014 Post Reflow Solder Height Versus Stencil Design............................................ 1215 Sample Dimension A Measurement of Post-Reflow Solder Height ........................ 1316 Factors and Techniques in Generating an Optimal Flux/paste Dip Process ............. 1417 DEK 248 Screen Printer.......................................................................... 1518 DEK 248 Camera System and Fixture ......................................................... 1619 Reflow in Nitrogen and Air with SnAgCu Solder .............................................. 1720 General Reflow Profile for Reference .......................................................... 1821 Causes of Stress on BGA Packages and Solder Joints ..................................... 2022 Factors in Assembly Yield ....................................................................... 2023 Cross Section of PoP Assembly ................................................................ 21

List of Tables

1 Area Ratio Values................................................................................. 11

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1 Introduction

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Memory

0.5mm pitch

0.4mm pitch

OMAP Processor

PCB

Focus forPart 2

Focus for Part – 2OMAP3 Pop Assembly Guidelines

www.ti.com Introduction

This document is the second of two parts. Part I, Part-I, 0.4mm PCB Design Guidelines, describes generalPCB design guidelines. The design of the bottom board to which the OMAP processor is mounteddominates the PoP failure mechanisms. Be sure to read and apply the guidelines in Part I beforebeginning PoP assembly.

This document, which is Part II, describes the guidelines for assembly of printed circuit boards that use thePoP package. Included are assembly options and suggestions for qualifying and working with assemblysites. Figure 2 is an overview of the OMAP3 PoP assembly guidelines.

Figure 2. Overview of OMAP3 PoP Assembly Guidelines

Figure 3 shows a post-solder paste dip stack of the of the OMAP3 processor and memory.

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Memory

Processor

Circuit board

003

2 Focus of Part II

Focus of Part II www.ti.com

Figure 3. Post-Solder Paste Dip Image of Memory and OMAP3 Processor

The focus of this document is the assembly of the OMAP3 BGA package with its companion memorymounted on top – hence the package-on-package name. These guidelines do not cover all aspects ofautomated assembly nor is this a study of the reliability of the PoP package.

Assembly of PoP devices and circuit boards for fine-pitch BGA packages at 0.4mm and smaller is still verynew for most assembly shops. It is more of an art than a science. Thus, the material in this document willage and go out of date quickly.

Because this is a rapidly evolving technology, do as much research as possible on all aspects of fine-pitchboard design. Spend time with the assembly house. Find out what they know, what experience they have,and how they document fine-pitch package assembly. Time spent pre-planning and discussing is time wellspent.

Fine-pitch BGA assembly, especially PoP assembly, is considered a differentiator among assemblyhouses. Some assembly shops do not handle fine-pitch packages, and many do not have the appropriateequipment.

If the assembly house has never done PoP, allow time for several learning cycles before committing tovolume production. The use of the OMAP3 BeagleBoard gerbers is a big help. Use this as a starting pointto help the assembly shop develop its process. The processes and materials discussed will helpdetermine the capability of the assembly site.

Assembly success comes from experienced companies willing to work together. The most commonpairing is an assembly shop and a PCB board fabricator. Such companies openly share ideas and providefeedback to all parties involved in board design, fabrication, and assembly.

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3 A Team Sport

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www.ti.com A Team Sport

TI has explored several companies that have worked together and found many common points ofagreement on assembly guidelines as well a few minor points of disagreement. The suggestions andrecommendations, plus some precautions, in this document, originated with these companies. Always takeadvantage of any recommended changes from a vendor’s DFM studies. And be flexible enough to changea board layout to fit the suggestions of the assembly house.

As a final word of advice, have lots of patience.

Successful design and assembly of complex, fine-pitch circuit boards is a team sport. The days of tossingcircuit diagrams over the cubicle wall to the board designer who then tosses them to the assembly shopare gone. Today’s board design requires a team approach and the entire process, from componentselection to assembly, requires careful coordination.

The typical team is composed of four members, each representing one of the four major steps in productfabrication: the device supplier (chips, passives, mechanical), the PCB designer, the PCB fabricationshop, and the PCB assembly shop (see Figure 4).

Figure 4. PoP Assembly Team

Each team member brings experience and design guidelines to bear on the task. As a result, it is notuncommon to find conflicting guidelines. These conflicts must be resolved before the start of work. Toachieve the optimal yield, the philosophy of partnering in manufacture must be fostered. Constant andopen communication is the key to resolving conflicts, and everyone must be in the loop.

Get to know the team members and be sure to have frequent meetings as the project proceeds fromdesign through production. It will be money and time well spent.

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4 OMAP3 and BeagleBoard

005

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A = solder mask opening on PoPB = solder mask opening on Memory packageRatio A/B should be ~ 1.0

BMemory Package

PoP Package

A

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The BeagleBoard, a design based on the Texas Instruments OMAP3, was used to validate the assemblyguidelines described in this document. Figure 5 is the mechanical drawing and Beagle board layout.

Figure 5. Mechanical Drawing and Beagle Board Layout

Figure 6 shows the PoP package-to-memory package solder mask opening (SMO) configuration.

Figure 6. PoP Package-to-Memory Package SMO Configuration

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4.1 Assembly Options

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Memory

0.5mm pitch

0.4mm pitch

OMAP Processor

PCB

Focus forPart 2

Focus for Part - 2OMAP3 Pop Assembly Guidelines

www.ti.com OMAP3 and BeagleBoard

There are two options for building PoP assemblies, a one-pass option and a two-pass option.

In a one-pass assembly (see Figure 7), the OMAP processor is first mounted to the board, the memory ismounted to the processor, and the finished board is then run through the reflow oven in a single pass. TIhas used this process successfully with several assembly shops and the yields have been good.

Figure 7. One-Pass Assembly Process

The two-pass assembly (see Figure 8) has an intermediate step in which the memory is first mounted ontothe OMAP processor. Then these two parts are placed in a carrier tray and reflowed. These joined devicesare then mounted on the circuit board and the finished board is reflowed a second time.

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Memory

0.5mm pitch

0.4mm pitch

OMAP Processor

PCB

Assembly Options – 2 Pass

Fixture/Carrier

1st pass:Mount Memoryto OMAP

2nd pass:Mount Unitto PCB

4.2 Handling of Parts

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OMAP3 and BeagleBoard www.ti.com

Figure 8. Two-Pass Assembly Process

TI generally recommends the one-pass process because it is more economical and provides about thesame assembly yields as the two-pass technique.

Because of the exposed silicon of the OMAP3,care must be taken to avoid metal contactwhen handling bare parts. Impact to the siliconsurface can cause damage. If the memory isnot stacked on the OMAP device, the silicon isexposed to contact. In this situation, workareas must be examined for contact surfacesthat can impact the edges of the OMAPdevice. For instance, if the PCB is draggedacross the work surface, there should be nometal features that can affect the edges of theexposed silicon (see Figure 9 and Figure 10).

Figure 10. Corner Chipout From Impact Damage

Figure 9. Chipout From Impact Damage

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010

011

www.ti.com OMAP3 and BeagleBoard

Use the substrate edges, rather than the OMAP silicon, to manipulate the device as necessary (seeFigure 11).

Figure 11. Use the Substrate Edges toManipulate the Device

Another best practice is to prevent metal tweezers from contacting the silicon, to prevent potentialchipouts (see Figure 12

Figure 12. No Metal Tweezers

An additional strategy if memory is not stacked on the OMAP3 is to use higher profile components aroundthe OMAP to act as standoffs. Placing higher profile components strategically around the OMAP3 reducesthe risk of silicon damage caused by the impact of a work surface, as shown in Figure 13.

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012

4.3 Solder Paste Stencil Design

4.3.1 Area Ratio

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Figure 13. Passive Component Profile for Robust Handling and Assembly

Several aspects of stencil design critically affect solder paste deposition. The recommendations hereapply only to round, solder-mask-defined pads for fine-pitch BGA packages with 0.4-mm spacing. Theserecommendations, which assume a lead-free process, are a starting point for building design rules that fitspecific manufacturing requirements and capabilities. In all cases, you must carefully monitor assemblystartup to ensure that desired results are achieved.

The area ratio (AR) is the relationship between the surface of the aperture and the inside surface of theaperture walls in the stencil. For fine-pitch BGA pads, a round aperture is recommended. The AR is moresuitable than the aspect ratio for this shape.

The AR of ≥ 0.6 aperture opening to stencil wall surface area provides the best transfer efficiency andrepeatability of the deposited paste. Values from 0.6 to 0.8 ensure a good paste release from the stencil.

The greatest impact on AR is stencil thickness. The equation is

AR = Ap/Aw = πr2/2πrt

Where:

Ap is the aperture opening area.

Aw is the wall area.

r is the aperture opening radius.

t is the stencil thickness.

Table 1 lists the area ratio values for different aperture openings and stencil thicknesses.

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4.3.2 Aperture Size and Overprinting

4.3.3 Stencil Aperture Shape

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Table 1. Area Ratio ValuesAperture Stencil AR

Diameter (um) Radius (um) Thickness (um)230 115 80 0.72240 120 80 0.75250 125 80 0.78260 130 80 0.81270 135 80 0.84280 140 80 0.88290 145 80 0.91300 150 80 0.94230 115 90 0.64240 120 90 0.67250 125 90 0.69260 130 90 0.72270 135 90 0.75280 140 90 0.78290 145 90 0.81300 150 90 0.83230 115 100 0.58240 120 100 0.60250 125 100 0.63260 130 100 0.65270 135 100 0.68280 140 100 0.70290 145 100 0.73300 150 100 0.75230 115 110 0.52240 120 110 0.55250 125 110 0.57260 130 110 0.59270 135 110 0.61280 140 110 0.64290 145 110 0.66300 150 110 0.68

Some assembly houses specify a slightly larger than normal opening to overprint the paste. However, forthe BeagleBoard, because the pads are soldermask-defined, there is no overprinting. Overprinting isdescribed in detail in the OMAP25xx PCB Design Guidelines document, where non-solder-mask definedpads are suggested.

A round aperture is recommended for BGA pads. This allows for an equal, uniform amount of pasteddeposition on the round pad. Square corners should be avoided because they can cause unequalamounts of paste to be deposited.

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4.3.4 Stencil Material and Finishing

4.4 BeagleBoard Solder Stencil and Case Study

Each stencil mask

Paste height

53.4

71.375.9

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

Stencil type

Paste

heig

ht

(um

)

Max

Avg

Max 73.0 88.9 86.4

Avg 53.4 71.3 75.9

Min 41.5 60.2 66.0

80umt / 230um 85 80umt / 250um(100%) 100umt / 250um(125%)

156-013

OMAP3 and BeagleBoard www.ti.com

The solder stencil must be made from stainless steel, chromium, or cobalt nickel. The apertures must belaser cut. The finish must be electro-polished to provide mirror smooth walls, which ensure good pasterelease.

During assembly, the wider side of the aperture must be against the circuit board.

For the BeagleBoard, the solder stencil has the following parameters:

Material Stainless steelThickness 4 mils (~100um)Fabrication Laser CutAperture Shape RoundAperture Dimension 10 mils (~254µm)

From a subsequent evaluation, cross sections were used to characterize the solder print quality based onvolumetric metal deposited. The optimal dimensions are 100um stencil thickness and 250um aperturesize, as shown in Figure 14.

Figure 14. Post Reflow Solder Height Versus Stencil Design

Figure 15 shows a cross section and measurement taken post reflow of dimension A to generate theinformation in Figure 14.

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014

A

B

C

D

4.5 Memory Attachment Options

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Figure 15. Sample Dimension A Measurement of Post-Reflow Solder Height

Memory attachment to the top of the processor is often considered one of the critical and mosttroublesome tasks in PoP assembly. Fortunately, this is not true. In fact, memory mounting has proven tobe the least troublesome task.

The primary concern is creating a strong solder joint between the memory ball and the processor pad.Simple screening of paste cannot be used, because the die is in the way. Two processes, pastedeposition and flux dipping, have been developed and used in volume production. For very high-volumeproduction, flux dipping is preferred because of its simplicity and speed.

For the relatively low-volume BeagleBoard, a brushed-on tacky paste flux from Amtech, called LF4300Tacky Solder Flux, was used. This material has the consistency of a gel and is simply brushed onto theOMAP3 memory pads. The BeagleBoard OMAP3 to memory attachment yield was excellent. For the datasheet for this product, see Section 7.2, Product References.

For high-volume automated assembly, flux and a third option, solder paste dipping for the memory device,were evaluated. Using a height gauge, various dip depths were evaluated, as shown in Figure 16, withoptimal results at 66% for flux dip and 50% dip depth for solder paste. Senju 529D-1 was used for flux dip,while Senju M705-TVA was used for solder paste dipping.

Note: Insufficient/excessive deposition of flux or solder paste can sometimes be resolved with thepick and place equipment camera system.

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High Level of contrast indicatesabsence of solder paste or flux as

observed from the vision camera.

Regions of excessive flux orsolder paste will show bridgingas observed from the vision

camera.

015

4.6 Solder Paste

OMAP3 and BeagleBoard www.ti.com

Figure 16. Factors and Techniques in Generating an Optimal Flux/paste Dip Process

The most critical issues related to mounting the OMAP3 processor to the circuit board are the fluxing ofthe attachment surfaces and the creation of metallurgical bonds during the SMT reflow process.

From a process perspective, the following solder paste characteristics are important:• Solder powder particle size• Metallurgy• Slump• Sensitivity to temperature and humidity• Solder content• Type of flux residue• Viscosity• Propensity for solder balling

In mobile terminal PCB assembly, no-clean eutectic solder pastes with high metal content are widelyused.

The choice of the particle size used in the solder powder for area array depends on the device pitch. Asthe device pitch decreases, the aperture size shrinks, and a smaller particle size solder paste may berequired.

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4.7 Screen Printing

016

www.ti.com OMAP3 and BeagleBoard

For the BeagleBoard, AMTECH LF4300 paste was used to attach the OMAP3 to the circuit board. It offersexcellent reflow and profiling capabilities, and it is a no-clean paste that is water-soluble and lead-free. It iscomposed of the same alloy as the LF4300 Tacky Solder Flux, so they share the same reflow profile.

For the datasheet for LF4300 solder paste, see Section 7.2, Product References.

Screen printing plays a key role in the assembly yield equation. The key parameters that were used forthe high-yielding BeagleBoard can be used as a starting point for the screen printing process. Knowing thecorrect parameters allows for the solder paste to be applied in a controlled manner to preventinconsistencies and defects.

In solder paste printing, the printer is crucial for achieving desired print quality. Screen printers availabletoday fall into two main categories: laboratory and production. Each category has further subdivisionsbecause companies expect different performance levels from laboratory and production printers. Forexample, a laboratory application that is R&D for one company can be prototype or production for another.Moreover, production requirements can vary widely depending on volume. Because a clear-cut equipmentclassification is not possible, the best thing to do is discuss the volume requirements with the assemblyshop and ensure that the available machines match the desired application. Figure 17 shows a DEK 248screen printer.

Figure 17. DEK 248 Screen Printer

Critical parameters for high-quality solder paste printing include print speed, print pressure, separationspeed/distance (or the speed/distance at which the PCB and the stencil are separated), and printeralignment. Excellent operator training is also imperative, because solder printing is a sensitive and delicateprocess.

Squeegees are generally used to physically deposit and distribute solder paste evenly across the stencil.By rolling the squeegee evenly over the stencil, the solder paste passes through the stencil apertures andgets deposited on designated areas on the PCB. The stencil is then lifted, leaving behind the intendedsolder paste pattern on the PCB.

During solder paste printing, the PCB must be held by its support in a locked position perfectly parallel tothe stencil. The squeegee angle is usually between 45 and 60 degrees. A vision system, as shown inFigure 18, is also necessary to ensure accurate printing of solder paste on the solder lands of the PCB.Modern printing equipment offers many options: computer control, vision or laser print control,environment control, automatic PCB support setup, and even stencil cleaning.

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017

4.8 Reflow Atmosphere

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Figure 18. DEK 248 Camera System and Fixture

The BeagleBoard used the following screen printing parameters:

Material DEK 248Clamping method ParallelPrint speed 40 mm/s/1.575 in/sPrint pressure 5.5 lbsSeparation speed 40%PCB removal mode AutoPrint mode Two-pass

The environment in which solder paste printing occurs is also important. Defects such as solder bridgingand poor wetting can be caused by dust particles or microscopic fibers in the air that end up on the PCBor the stencil. Quick drying of the solder paste can be caused by high ambient temperature or thepresence of air draft that accelerates solvent evaporation. The viscosity of the solder paste can also bedifficult to control in an environment with fluctuating ambient temperature and humidity

Nitrogen used in reflow soldering decreases wetting time, provides better wetting (appearance), andallows fewer voids (inclusion of gas) in the solder joint. With SnAgCu paste, the nitrogen atmospheredecreases the wetting to about half the time needed for wetting in air. TI has repeated these tests andconfirms that a nitrogen atmosphere provides the widest process window.

This means that the duration of temperatures over the melting point can be shortened by the use ofnitrogen. Figure 19 shows the differences between reflow in nitrogen (left image) and air (right image) withSnAgCu solder. The number of voids is much less and the size of the voids is smaller when nitrogen isused in reflow soldering.

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018

4.9 Reflow

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Figure 19. Reflow in Nitrogen and Air with SnAgCu Solder

For the BeagleBoard, no special atmosphere was used.

The most popular method of reflowing solder is forced convection and/or IR radiation. other methods ofsolder reflow are vapor phase, laser, and hot bar. Mesh belt and edge conveyors are commonly used inreflow ovens. The following critical parameters must be controlled in the reflow profile:• Peak reflow temperature• Oxygen level• Dwell time above melting temperature (liquid)• Soak time• Ramp rate• Cooling rate• Conveyor speed• Temperature difference across the assembly (ΔT)

The ramp rate in the preheat zone must be within a reasonable range. If the rate is too low, the assemblymay not reach the required soak temperature fast enough. On the other hand, if the rate is too high,components can be thermally shocked, which causes failure.

Correct soak temperature and soak times are required to evaporate solvents and to activate flux in thepaste. The soak time has a significant influence on the temperature difference among components. Thelonger the small components are kept at a fixed temperature level, the better the chance that the largecomponents can reach the same temperature level.

For the N2 and Air reflow development, the profile shown in Figure 20 was used, which overlaps thesolder paste vendor recommendations.

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019

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Figure 20. General Reflow Profile for Reference

CircuitCo Reflow Profile:Number of zones in oven 12Pre-heat temperature 165°C to 185°CPre-heat dwell 60 to 120 secTime above melting temperature 30 to 60 sec(liquid state)Duration peak over 245C 1 to 10 secPeak reflow temperature 250°CCool down 8°C/secSpeed 50 cm/s

For this assembly, the following paste and fluxes were used.Paste supplier and part number Senju M705-221Solder paste chemistry Sn96.5/Ag3.0/Cu.5Solder paste dip & flux paste M705-TVA03 (Sn96.5/Ag3.0/Cu.5) & Senju 529D-1 (Fluxrespectively (memory) only)

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5 Thermal Warpage

6 Troubleshooting

www.ti.com Thermal Warpage

With this profile and the listed materials, yields were very good. However, this was a relatively smallsample, so results can vary. Check with your solder paste supplier for recommendations.

A critical aspect of PoP assembly is the type and amount of warpage that can occur during reflow of theprocessor and the memory. BGA package warpage during reflow soldering can cause open solder jointfailure. With PoP, it is more critical at the top solder joints (memory to processor) than at the solder jointsbetween the processor and the circuit board. As discussed in Part I, correct circuit board design preventsmost common problems at that interface because with correct circuit board design, sufficient solder pasteand properly sized pads between the paste and the BGA are all that are required. However, in mostcases, only flux is applied to the memory device before it is reflowed. Thus, there is no additional pastevolume to help fill the void as the two packages separate during reflow.

Minimizing warpage is a trade-off among materials, temperature control, and time. The assembly shopshould have recommended profiles for a PoP assembly. Also, memory vendors have done extensivetesting and material selection to minimize warpage. However, warpage is always present, and it may notalways be repeatable from batch to batch. Be sure and talk to the memory suppliers and obtain theirpresentations and papers.

Locate and read the references provided in Section 7.1, Articles, Papers, Presentations, that discussthermal warpage issues and test findings. Incorporating these insights into the assembly process ensuresthat PoP assemblies yield as well as non-PoP fine-pitch BGA assemblies.

This section addresses some aspects of troubleshooting assembly. There are literally thousands ofvariables that affect the overall success of fine-pitch assembly. This is where close cooperation with theassembly house and a willingness to try different experiments pays off.

The best way to explain many of the variables and interactions that can cause yield issues is through theuse of an Ishikawa diagram, or fishbone diagram, which shows the causes of an event. Suchcause-and-effect diagrams can reveal key relationships among variables and possible causes and canprovide additional insight into the behavior of a process.

Typically, causes in the diagram are related to a certain category. For most assembly issues, the categoryis yield and the primary causes are Equipment, Process, People, Materials, Environment, andManagement.

Figure 21 is a high-level overview of major causes of stress on BGA packages and solder joints.

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Troubleshooting www.ti.com

Figure 21. Causes of Stress on BGA Packages and Solder Joints

Figure 22 is typical fishbone diagram that highlights causes and effects surrounding assembly yield. Sucha diagram, modified to suit specific requirements, is invaluable in creating a systematic process forevaluating problems related to fine-pitch assembly.

An excellent software package, XMID, helps build this type of diagram. XMID also has brainstorming toolsfor troubleshooting and trouble prevention. For the weblink, see Section 7.2, Product References.

Figure 22. Factors in Assembly Yield

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7 Acknowledgements

7.1 Articles, Papers, Presentations

www.ti.com Acknowledgements

Finally, do not be surprised that major assembly issues are tracked down to a seemingly benign source. Inother words, the cause of the problem is, in many cases, relatively simple (see Figure 23).

Figure 23. Cross Section of PoP Assembly

Jeff De Serrano, Inter-Circuit Solutions, Inc.; 400 Black Castle Drive, Lewisville, Texas 75056, Office:972.410.0067

Ron Weindorf, AMS (Austin Division), 9715 A Burnet Road, Suite 500, Austin, Texas 78758, (512)491-7411

Clint Cooley, CircuitCo, Richardson, TX 75081.

Franklin Troung, CircuitCo, Richardson, TX 75081

Ellen Damaso, South Central Region, Micron Technology, Inc. (972) 521-5373.

Kenji Masumoto (TIJ)

Hiroaki Ueno (TIJ)

Michael Chen (TITL)

PoP (Package-on-Package) Stacking Yield Loss Study, Kazuo Ishibashi, Nokia Japan Co.,Ltd., ARCOTower 4F, 1-8-1 Shimomeguro, Meguro-ku, Tokyo 153-0064, Japan. Published in the IEEE 2007Electronic Components and Technology Conference Proceedings, 1-4244-0985-3/07.

Influence Of PCB Parameters On Chip Scale Package Assembly And Reliability, Anthony A. Primavera,Surface Mount Technology Laboratory, Universal Instruments Corporation, Binghamton, N.Y.

ECO Solder Lineup, Senju Metal Industry Co, Ltd. (SMIC), Senju Hashido-cho 23, Adachi-ki, Tokyo120-8555, Japan.

Fan-Out Interposers Solve Fine-Pitch Micro BGA Dilemma, Mark Gilliam, Interconnect Systems, Inc. 759Flynn Road, Camarillo, CA 93012, USA, (805) 482-2870. wwwlisipkg.com

Package on Package (PoP) Stacking and Board Level Reliability in Printed Circuits Handbook - 6thEdition, Clyde Coombs, Jr., McGraw-Hill, January 2008. Results of Joint Industry Study, Dreiza, Smith,Dunn, Vijayaragavan, Werner.www.amkor.com/products/notes_papers/PoP_Stacking_IMAPS_0306.pdf

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7.2 Product References

8 Trademarks and Disclaimers

Trademarks and Disclaimers www.ti.com

XMIND – 2008, PC-based software for fishbone diagrams, mindmaps and brainstorming sessions,www.xmind.org/us

Lead-Free Solder Products: AMTECH: Advanced SMT Solder Products Systems, 75 School GroundRoad, Branford, CT 06405. Toll free: 800-435-0317, www.amtechsolder.com

DEK48 Screen Printer, DEK USA Inc., 2225 Ringwood Avenue, San Jose, CA. 95131, www.dek.com

Technology for Innovators, the black/red banner, DaVinci, CCStudio, C55x, C62x and C64x aretrademarks of Texas Instruments. DLP is a registered trademark of Texas Instruments. All othertrademarks are the property of their respective owners.

All referenced material has been obtained from public domain papers, websites and publications and isdescribed as part of the resource appendix.

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