A Hybrid 3D Thermo-Elastic in Nite Element Modeling For Area-Array Package Solder Joints
A Hybrid 3D Thermo-Elastic in Nite Element Modeling For Area-Array Package Solder Joints
A Hybrid 3D Thermo-Elastic in Nite Element Modeling For Area-Array Package Solder Joints
www.elsevier.com/locate/nel
A hybrid 3D thermo-elastic innite element modeling for
area-array package solder joints
D.S. Liu
i=1
[
i
(, p, )x
I
i
, (2)
I
II
x
y
O
( , , )
I I I
i i i
x y z
( , , )
II II II
i i i
x y z
1
2
3
4
5
6
7
8
z
Fig. 1. Schematic diagram of similar 3D isoparametric elements.
D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727 1707
,
I
=
m
i=1
[
i
(, p, ),
I
i
, (3)
:
I
=
m
i=1
[
i
(, p, ):
I
i
. (4)
Multiplying both sides by z, and in view of Eq. (1), we have
x
II
= zx
I
=
m
i=1
[
i
(, p, )x
II
i
, (5)
,
II
= z,
I
=
m
i=1
[
i
(, p, ),
II
i
, (6)
:
II
= z:
I
=
m
i=1
[
i
(, p, ):
II
i
. (7)
From Eqs. (5)(7), both hexahedral elements II and I can be mapped using the same cubic-shaped
master element, which is dened in natural coordinates. In other words, if one isoparametric element
has nodal coordinate values similar to the values of other elements, they are designated as similar
elements.
When the physical coordinates are mapped to the natural coordinates, the associated element
stiness matrix [ k] and the nodal temperature load [f
th
] (the superscript th represents thermal
eect) for a 3D isoparametric element are then calculated using
[k]
3m3m
=
1
1
1
1
1
1
[B]
T
3m6
[D]
66
[B]
63m
det[J] d dp d, (8)
[f
th
]
3m1
=
1
1
1
1
1
1
[B]
T
3m6
[D]
66
[]
61
1 det[J] d dp d, (9)
where
[B] =
9[
i
9x
0 0
0
9[
i
9,
0
0 0
9[
i
9:
9[
i
9,
9[
i
9x
0
0
9[
i
9:
9[
i
9,
9[
i
9:
0
9[
i
9x
, (10)
1708 D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727
[D] =
E
(1 + v)(1 2v)
(1 v) v v 0 0 0
v (1 v) v 0 0 0
v v (1 v) 0 0 0
0 0 0
(1 2v)
2
0 0
0 0 0 0
(1 2v)
2
0
0 0 0 0 0
(1 2v)
2
, (11)
[J] =
9x
9
9,
9
9:
9
9x
9p
9,
9p
9:
9p
9x
9
9,
9
9:
9
9[
i
9
9[
i
9p
9[
i
9
x
i
,
i
:
i
, (12)
where E is the Youngs modulus, v is the Poissons ratio, [] is the coecient matrix of thermal
expansion and 1 is the temperature dierence.
Recalling Eq. (1), and from Eqs. (10) and (12), we have
[B]
II
=
1
z
[B]
I
, (13)
det[J]
II
= z
3
det[J]
I
. (14)
When Eqs. (10)(12) are substituted into Eqs. (8) and (9), it is obvious that
[k]
II
= z[k]
I
, (15)
[f
th
]
II
= z
2
[f
th
]
I
. (16)
Eqs. (15) and (16) indicate that the stiness and thermal load terms for similar 3D isoparametric
elements are directly in dimensional dependence on the ratios z and z
2
, respectively.
2.2. 3D thermo-elastic innite element method formulation
The detailed IEM formulation with thermal eects for illustrating 3D thermo-elastic problems
is presented in this section. The pyramid-like body shown in Fig. 2 is used as an example to
illustrate the above-mentioned partition concept. The meshing steps are described as follows: rst,
the primary domain boundary surface, I
0
, is properly distributed over a total number of n master
nodes and discretized into virtual four-node quadrilateral elements. Second, when the global origin O
is chosen as the similar partition center, and a constant z is used, surfaces I
1
, I
2
, . . . , I
S
, . . . similar
D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727 1709
0
1 s
O
layer 1
layer 2
layer s
Fig. 2. Schematic diagram of 3D innite element mesh.
to I
0
are constructed with the center O and proportionality constants z
1
, z
2
, . . . , z
S
, . . . , respectively.
The region bounded between I
i1
and I
i
is called the ith element-layer (i = 1, 2, . . . , s), where s is
number of chosen element-layers. Third, straight lines are drawn from the origin to the master nodes
and each individual I
i
is regularly discretized in a manner similar to I
0
. The nodal number and
coordinates of nodes on each individual I
i
can be determined from the master node coordinates that
have geometrically similar conditions. Fourth, every element-layer is auto-meshed into eight-node
hexahedral elements that are similar to one another in a radial direction.
When the outermost element-layer (layer 1) is considered, the element stiness matrix of each
hexahedral element can be calculated and assembled into an element-layer stiness matrix using
the conventional nite element formulation. The stiness matrix of the rst element-layer can be
expressed as
K
a
A
T
A K
b
6n6n
, (17)
where K
a
, K
b
, and A are the sub-matrices of the stiness matrix and have the identical dimension
3n 3n. A
T
is the transpose of A. Since the global layer stiness is symmetrical and banded, both
K
a
and K
b
are symmetrical and banded. The nodal displacement vector
i
of nodes on I
i
is dened
as
i
[ u
i
1
t
i
1
w
i
1
u
i
n
t
i
n
w
i
n
]
T
. (18)
The nodal force vector [
i
of nodes on I
i
is dened as
f
i
[ [
i
1x
[
i
1,
[
i
1:
[
i
nx
[
i
n,
[
i
n:
]
T
. (19)
1710 D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727
The nodal temperature load vector f
th
i
of nodes on I
i
is dened as
f
th
i
[ [
i(th)
1x
[
i(th)
1,
[
i(th)
1:
[
i(th)
nx
[
i(th)
n,
[
i(th)
n:
]
T
. (20)
The ith element-layer stiness matrix represents the nodal force and displacement vector relation-
ships of I
i1
and I
i
. Recalling Eq. (17) and treating the rst element-layer as an example, we
have
K
a
A
T
A K
b
f
0
+f
th
0
f
1
+f
th
1
. (21)
Two algebraic equations are extracted from Eq. (21) as follows:
K
a
0
A
T
1
=f
0
+f
th
0
, (22)
A
0
+K
b
1
=f
1
+f
th
1
, (23)
where
0
, f
0
, and f
th
0
denote the nodal displacements, traction, and thermal load on I
0
, respectively.
According to the foregoing similarity principle (Eqs. (15) and (16)), it is obvious that the stiness
and thermal load matrices of all of the element-layers are in dimensional dependence on the ratios
z and z
2
, respectively. Hence, we can express the stiness matrix of the s element-layers (from the
1st element-layer to the sth element-layer) as a set of algebraic equations, namely,
K
a
A
T
A K
b
f
0
+f
th
0
f
1
+f
th
1
K
a
A
T
A K
b
f
1
+ z
2
f
th
0
f
2
+ z
2
f
th
1
K
a
A
T
A K
b
f
2
+ z
4
f
th
0
f
3
+ z
4
f
th
1
K
a
A
T
A K
b
s1
f
s1
+ z
2(s1)
f
th
0
f
s
+ z
2(s1)
f
th
1
s
=M
1
s
A
s1
+
F
s
z
s1
. (26)
By substituting Eq. (26) into Eq. (25-5), we get
z
s2
A
s2
+ (z
s2
P z
s1
A
T
K
1
b
A)
s1
=A
T
K
1
b
( f
s
+ z
2(s1)
f
th
1
) + z
2(s2)
( f
th
1
+ z
2
f
th
0
). (27)
When Eq. (25-6) is compared with Eq. (27), two iteration formulas can be inferred
M
i
=P z A
T
M
1
i+1
A, (28)
F
i
=A
T
M
1
i+1
F
i+1
+ z
2(i1)
( f
th
1
+ z
2
f
th
0
), (29)
where i = 1, 2, 3, . . . , s 1.
By substituting the above two iteration formulas into Eq. (27), we get
z
s2
A
s2
+ z
s2
M
s1
s1
=F
s1
. (30)
Rearranging Eq. (30) and another iteration formula can be inferred as
)
= z
( )1)
M
1
)
(z
)1
A
)1
+F
)
), (31)
where ) = 1, 2, . . . , s.
Since M
s
and F
s
are known, then M
s1
, M
s2
, . . . , M
1
; F
s1
, F
s2
, . . . , F
1
can be iterated out using
Eqs. (28) and (29), respectively. From Eq. (31), we have
1
=M
1
1
(A
0
+F
1
). Substituting
1
into Eq. (25-1), we obtain the most important formula for 3D IEM, that is,
(K
a
A
T
M
1
1
A)
0
= (A
T
M
1
1
F
1
+ ( f
0
+f
th
0
)). (32)
Eq. (32) can be expressed in the concise form
K
Z
0
=F
Z
. (33)
1712 D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727
0
1 s
O
layer 1
layer 2
layer s
0
Infinite
Element
Fig. 3. Schematic diagram of 3D innite element formation.
where K
Z
and F
Z
denote the equivalent combined element stiness matrix and associated combined
loading vector, respectively. F
Z
contains both the eects from the outer surface traction and the
thermal loading. Once F
Z
is determined,
0
can be obtained from Eq. (32). Then
1
,
2
, . . . , and
s
can be obtained sequentially from Eq. (31).
When the numerical procedures from Eq. (25-1) to Eq. (25-6) are used, and when layers are
added layer by layer, all of the inner layer elements are condensed and transformed into only one
combined element with master nodes along the domain boundary I
0
only. This is called the IE,
as schematically shown in Fig. 3. It can be viewed as a process of element elimination. The inner
elements and nodes are imaginary and virtual, but they in fact exist and work in IEM manipulations.
Generally, the IE renement strategy can be achieved by increasing the number of master nodes
and element-layers. From a physical point of view, K
Z
can be treated as the equivalent stiness
matrix of this IE with a dimension of 3n 3n. Although the total degree of freedom of K
Z
is
largely reduced, the mesh renement eect of large amounts of innitesimal elements around the
reference point O is maintained and does not increase any corresponding round-o errors because of
its specic matrix condensation process. Moreover, to compute K
Z
, only the calculation of the rst
element-layer stiness matrix with the chosen proportionality constant z and element-layer number
s is required.
2.3. IEFE coupling method
FEM can model problems with complicated shape domains (e.g. concave shapes) and boundary
conditions but cannot manage local rened areas with large numbers of d.o.f.s well. On the other
hand, IEM is favorable for modeling local rened areas with fewer d.o.f.s, but it is applicable only
to relatively simpler shaped domains. A better modeling strategy involves combining both methods
to deal with all kinds of problems.
Therefore, an IEFE coupling scheme is proposed using the IEs to sub-divide critical parts in the
entire domain. Outside the IE sub-domains, the solutions are obtained using the conventional FEM
in the FE sub-domains. The master nodes on the outer boundary surface of each IE are converted
D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727 1713
D
FEM
domain
IEM
domain
D
IEM
domain
FEM
domain
+
conventional
finite
elements
coupling
interface
common
nodes
Infinite
Element
0
K
couple
K
T
c[
K
c[
K
fem
fem
F
0fem
F
fem
, (35)
where
0
and
fem
denote the vectors of the IEFE interface and non-interface nodal displacements,
respectively. F
0fem
and F
fem
are the associated loading vectors, respectively. From Eq. (35), two
equations can be extracted
K
couple
0
+K
T
c[
fem
=F
0fem
, (36)
K
c[
0
+K
fem
fem
=F
fem
. (37)
Conversely, the IE sub-domain produces the following algebraic equation using the IEM described
in detail in Section 2.2
K
IEM
0
=F
0iem
, (38)
where K
IEM
=K
Z
=(K
a
A
T
M
1
1
A) denotes the combined stiness matrix K
Z
of the IE sub-domain.
0
and F
0iem
denote the interface nodal displacements and the associated load vectors, respectively.
1714 D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727
Along the IEFE interface, the displacement compatibility and force equilibrium must be satised.
Thus, we combine Eqs. (36) and (38), resulting in the following:
(K
couple
+K
IEM
)
0
+K
T
c[
fem
=F
0iem
+F
0fem
= 0. (39)
Eqs. (37) and (39) are combined to give the nal IEFE coupled element equation in the form:
K
couple
+K
IEM
K
T
c[
K
c[
K
fem
fem
0
F
fem
. (40)
When boundary conditions are applied to the global matrix and vector, the displacements
fem
in
the FE sub-domain can be obtained using Eq. (40). Once we obtain the interface nodal displacements
0
for the IE sub-domain, the traction along IEFE interface F
0iem
can be found using Eq. (38).
Furthermore, a sequence of the nodal displacement
)
within the IE sub-domain can be obtained
using Eq. (31). The static stressstrain analysis can be performed using the stressstrain relationship
and element straindisplacement relationship.
2.4. Integration of IEFE coupling method with commercial FEM software
The implementation of the IEFE coupling method used in this study was carried out using
the commercial nite element software ABAQUS/Standard. All related IEM numerical procedures
were programmed and executed in the MATLAB v.5.3 language [20]. After the IEM mathematical
manipulations, the special elements, called innite elements (IEs), were generated (see Section 2.2).
The IEs were treated as regular nite elements, and their element properties were obtained from the
pre-determined IE stiness matrices K
Z
. The IE denition is not included in the ABAQUS element
library; therefore, the IE is designated as a user-dened element that represents a geometric part
of the model. In the ABAQUS codes, the user-dened elements are introduced using the *USER
ELEMENT option. In the simplest case, a linear user-dened element can be dened as a stiness
matrix. This matrix (K
Z
) can be distilled from the Matlab results and dened by using the *MATRIX
option. The properties of linear user-dened elements are dened using the *UEL PROPERTY option
and, optionally, the *MATRIX option. For further details on this implementation, please refer to the
ABAQUS users manual [21].
3. Verication of the IEFE coupling methodology
A MCM BGA assembly, developed by ChipMos INC. for the 128 Mb SDRAM, was investigated
in this study. The assembly employed dual 64 Mb SDRAM chips on a single-sided wiring organic
substrate, using the proven wire boding and transfer molding technologies. The external connection
terminals are an area-array structure using solder joints with a pitch of 0.8 mm and a joint diameter
of 0.35 mm. Fig. 5 shows the schematic diagram of this package. Cross-sectional views along the
length and width of the package are shown in Fig. 6.
A 3D IEFE model of the MCM BGA assembly was established using the commercial software
ABAQUS/Standard for thermo-mechanical analysis. A full model of this package was created in this
D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727 1715
Silicon Die Molding Compound
BT Substrate
Adhesive
FR-4 PWB
Eutectic Solder Joint
Fig. 5. Schematic diagram of a novel MCM BGA assembly.
(b) Lengthwise view
(a) Widthwise view
Fig. 6. Two cross-sectional views of a MCM BGA assembly.
Table 1
Brief geometric dimensions of the MCM BGA package
Die size 9.2 mm 5.1 mm 0.25 mm
Die pitch 1.1 mm
Adhesive size 9.2 mm 1.35 mm 0.2 mm
BT substrate size 21 mm 3.13 mm 0.5 mm
FR-4 PWB size 21 mm 8.6 mm 1.6 mm
Solder joint diameter 0.35 mm
Solder joint stand-o 0.3 mm
Solder joint pitch 0.8 mm
Solder joint number 15 (row) 4 (column)
study. The IEFE model, with lengthwise, widthwise and vertical cross-sectional views, is shown in
Fig. 7. Table 1 lists the geometric dimensions of the package. The material properties used for the
package are given in Table 2. These properties were obtained from the providers (ChipMos Inc.)
database system and the literature [22]. The properties of all component materials were assumed to
be linear elastic, isotropic, and independent of temperature variation. The FE modeling components
1716 D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727
Fig. 7. Three cross-sectional views of a 3D IEFE model.
contained the silicon dies, BT substrate, epoxy molding compound, adhesive, and FR-4 PWB. The FE
model was composed of 118 416 elements and 142 505 nodes. The IE modeling component contained
60 eutectic solder joints. Based on the similarity property of 3D isoparametric elements, all of the
60 IEs possessed identical stiness matrices. Only one solder joint with its IE stiness matrix was
required to be calculated once, and the matrix was also valid for the other solder joints. The IE
model for each solder joint was composed of 162 master nodes and 1 innite element (IE), which
is equivalent to 9600 rened hexahedral elements and 9882 nodes. The full IEFE model, therefore,
consisted of 152 387 nodes, 118 416 hexahedral elements, and 60 innite elements, equivalent to a
D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727 1717
Table 2
Material properties of the MCM BGA package
Component Youngs modulus Poissons ratio CTE Yielding stress
E (GPa) v :(}
C) (MPa)
BT substrate 2.3 0.3 1.7 (E-5)
Die 163.1 0.3 3 (E-6)
Molding compound 14.0 0.25 1.6 (E-5)
Adhesive 2.65 0.3 4.43 (E-5)
Solder joint 20.6 0.4 2.96 (E-5) 25 [24]
FR-4 PWB 18.2 0.19 3 (E-5)
Table 3
IEFE modeling information of the MCM BGA package
Component Node Element Equivalent node Equivalent element
BT substrate 60 612 48 720 60 612 48 720
Silicon die 16 212 10 416 16 212 10 416
Molding compound 33 081 23 796 33 081 23 796
Adhesive 9408 4380 9408 4380
FR-4 PWB 42 292 31 104 42 292 31 104
Solder joint (IEM) 9882 60 592 920 576 000
Total 152 387 118 476 735 425 694 416
total of 694 416 rened hexahedral elements and 735 425 nodes. Table 3 lists the number of nodes
and elements and the corresponding equivalent rened nodes and elements for individual package
components. When IE modeling is used instead of regular FE modeling of the solder joints, large
numbers of degrees of freedom were signicantly reduced. This also greatly reduced the required
computational cost and eort.
3.1. Modeling validation
To precisely validate the IEFE model of the package, a proven displacement measurement
method, microscopic Moir e interferometry, was employed in this research [23]. Moir e interferometry
is an optical technique that measures thermally induced in-plane displacement elds with high sensi-
tivity. Fig. 8 shows the Moir e interferometry instrument (Portable Engineering Moir e Interferometer,
PEMI), which was designed by IBM and was set up in our laboratory.
After the package was sectioned and polished to the cross-section of interest, a thin cross-lined
diraction grating was applied to the widthwise cross-section at 85
C (room temper-
ature) from 85
C. The detailed principles and experimental procedures using Moir e can be found
1718 D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727
Fig. 8. A picture of the Moir e interferometry instrument.
in the literature [24]. The PEMI, together with the phase-shifting technique, was applied to capture
the digital images of the fringe pattern and the corresponding phase diagram which represents the
continuous displacement eld. The displacement elds U (x-direction) and J (,-direction) were
then extracted based on the following relationships:
U =
1
[
N
x
, J =
1
[
N
,
, (41)
where N
x
and N
,
are the fringe numbers in the U and J eld patterns, respectively, and [ is the
frequency of the virtual reference grating.
The horizontal (U) and vertical (J) displacement elds obtained using experimental measure-
ments and computer simulations are shown in Figs. 9 and 10. Because user-dened element plotting
is not supported in ABAQUS/Post, the IEs representing solder joints cannot be displayed. Moir e
fringes were found to distort more seriously at the solder joint/BT interface than at the solder
joint/PWB interface, chiey due to the larger CTE mismatch between the solder joint and BT mate-
rials. Corresponding to Figs. 9 and 10, the numerical analysis results matched the experimental data
in magnitude as well as in overall deformation trend. The maximum dierence in the number of
fringes was not more than about ve fringe orders (2.085 m deformation). The deformation trends
for the calculated thermo-mechanical behaviors of the package based on the Moir e interferometry
experiment and IEFE analyses were reasonably identical. The proposed IEFE model was therefore
deemed to be acceptable for conducting the following analyses.
4. Case study
With a broad variety of wiring layout technology and practical engineering applications, mis-
cellaneous electronic packaging structural designs can be roughly classied into symmetrical and
non-symmetrical structures. Non-symmetrical structures are the most commonly encountered struc-
ture. In this section, a full 3D IEFE model is used to study a MCM BGA assembly with symmetrical
D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727 1719
Fig. 9. A plot of the measured fringe pattern versus the simulated displacement contour as temperature changes from
85
C to 25
C (U eld).
Fig. 10. A plot of the measured fringe pattern versus the simulated displacement contour as temperature changes from
85
C to 25
C (J eld).
and non-symmetrical area-array type solder joints that are subjected to a temperature gradient.
This study focused on the use of IE to simulate a large number of solder joints. The board-level
thermal deformation and thermal stress distribution within the relatively susceptible solder joints are
discussed.
1720 D.S. Liu et al. / Finite Elements in Analysis and Design 40 (2004) 17031727
Fig. 11. On-board warpage of the package (unit: mil.).
4.1. A MCM BGA assembly with symmetrical type solder joints (60-I/Os)
Consider a MCM BGA assembly with symmetrical type solder joints subjected to a temperature
gradient from 25
C to 175
C (1 = +150
C to ambi-
ence were compared. The comparison results showed reasonable agreement in both approaches. Two
cases involving assemblies carrying symmetrical and non-symmetrical area-array type solder joints
subjected to +150
C temperature gradients were considered. In the symmetrical case, the point with
the largest warpage value was the point farthest from the center, located in the four diagonal corner
areas. The maximum von Mises stress value within the four corner joints was found to be higher
than that within other solder joints and exceeded the yielding stress of the solder material. This nd-
ing was also consistent with the warpage observations. In the non-symmetrical case, similar results
showed that the corner joints were also subjected to higher von Mises stress than any other solder
joint, even with some of the joints randomly removed.
The proposed method was able to identify the solder joints most susceptible to failure in the
assembly. The identied susceptible solder joints can be replaced by regular 3D nite element
models for a complete thermal elasticplastic re-analysis. This innovative idea not only enhances
the modeling capabilities but also provides online engineers another useful and ecient numerical
tool for examining a large number of warpage-aected solder joints in electronic packages.
Acknowledgements
The authors would like to express their thanks to the National Science Council, Taiwan, R.O.C.,
for nancially supporting this research under Grant NSC90-2212-E-194-032. They would also like
to thank Dr. Shen at ChipMos, Ltd. Co. for his assistance in providing MCM BGA assemblies and
shadow Moir e measurements.
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