Reflow profile has significant impact on solder joint performance because it influences wetting and microstructure of the solder joint. The purpose of this study is to investigate the effects of reflow profile and thermal shock on the shear performance of eutectic SnPb (SnPb) and Sn3.0Ag0.5Cu (SAC305) solder joints. Test boards were assembled with four different sized surface mount chip resistors (1206, 0805, 0603 and 0402). Nine reflow profiles for SAC 305 and nine reflow profiles for SnPb were developed with three levels of peak temperature (12ºC, 22ºC, and 32ºC above solder liquidus temperature, or 230ºC, 240ºC, and 250ºC for SAC 305; and 195ºC, 205ºC, and 215ºC for SnPb) and three levels of time above solder liquidus temperature (30 sec., 60 sec., and 90 sec.). Half of the test vehicles were then subjected to air-to-air thermal shock conditioning from -40 to 125°C. The shear force data were analyzed using the Analysis of Variance (ANOVA). The fracture surfaces were studied using a Scanning Electron Microscopy (SEM) with Energy Dispersive Spectroscopy (EDS). It was found that thermal shock degraded both SnPb and SnAgCu joints shear strength, and that the effect of thermal shock on solder joint shear strength is much more significant than that of reflow profile. The SnAgCu solder joints have weaker shear strength than the SnPb solders. SnAgCu solder joint after thermal shock retains more of its shear strength than that of SnPb for small components and vice versa for larger components.
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