In this paper modeling and simulation of board-level four-point bend fatigue and impact tests were investigated for 7mm×7mm VQFN(48I/O) assembly and 15mm×15mm FBGA(324I/O) assembly with Sn-Ag-Cu lead-free solder and OSP board surface finish. For cyclic bending fatigue, four-point bend cyclic loading at room temperature (25°C) and at high temperature (125°C) were investigated in order to develop bend fatigue model for Pb-free solder. The acceleration factor of failure at high temperature (125°C) to room temperature (25°C) will be presented. Test results show that the cycle to failure increases significantly when bending displacement ranges decrease for both bend tests at 25°C and 125°C. The acceleration factor of cycle to failure due to high temperature (125°C) effect is higher than that due to room temperature effect. The FBGA component has higher bending fatigue resistance compared to VQFN component. Accumulated energy density per cycle at 125°C is more than that at 25°C significantly, which indicates that higher temperature accelerates bending fatigue failure of solder. Energy-based bending fatigue models were developed for Sn-Ag-Cu lead free solder subjected to cyclic bending load at 25°C and 125°C based on FEA result and experimental data. Using the same FEA model the loading was changed to simulate a four-point bend impact test with the same corresponding magnitude of bending curvatures. Comparisons of solder joint deformation response between the slow cyclic bend test and impact drop bend test will be presented.
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