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Despite a shift to Pb-free solders in the majority of electronic assemblies, Pb-containing solders are still used in a variety of applications. Recent research has revealed the complexities of the intermetallic Cu 6 Sn 5  in terms of its crystal structure and stability when present as the reaction product between Pb-free solders and common substrates. In light of these findings, the effect of multiple reflow cycles with different cooling conditions on the microstructure of the interfacial Cu 6 Sn 5  intermetallic compound (IMC) between Sn-Pb solders and Cu substrates was re- examined. For this purpose, the Sn-37Pb (in wt.%) solder was reflowed on a Cu substrate at a temperature of around 240 °C and cooled at a rate of around 30 °C/min under each of two conditions; (i) direct-cooling to room temperature, and (ii) interrupted-cooling with extended isothermal holding periods of 30 and 180 seconds at 140 °C. This second condition was chosen to encourage the polymorphic transformation that occurs in the Cu 6 Sn 5  (at an equilibrium temperature of 186 °C) at a temperature which minimises the stresses involved. Smaller cracks and a thinner interfacial IMC layer were observed in the solder joints that were reflowed repeatedly with the interrupted-cooling conditions. However, despite the higher number of cracks in the samples undergoing conventional reflow, the shear strength was not significantly affected.

Influence of cooling conditions on the interfacial Cu6Sn5 intermetallic compound in Sn-37Pb/Cu solder joints during reflow