Failure Analysis in Semiconductor Package Assembly

Dr. Tom Dory

This PDC provides details on current failure analysis methods and reliability testing in package assembly.

PDC participants will receive a detailed review of failure analysis methods and reliability testing in assembly. Quickly finding and eliminating package defects and failures due to assembly issues is critical. Package reliability directly affects manufacturing yield, time to market, product performance, customer satisfaction and cost. Many process steps and controls are needed for a high yield and reliable assembly process. A thorough understanding of product and technology reliability principles and mechanisms of failure is essential. Knowledge of defects and failure mechanisms enables a high yielding successful assembly process through material choices, package design, process optimization, and thermo-mechanical considerations. Fault isolation, failure analysis, and materials analysis play a major role in the improvement of yield and reliability. Coordination of engineers from many disciplines is needed in order to achieve high yield and reliability. Each engineer needs to understand the impact of their choices and methods on the final product. This PDC will discuss, using examples, mechanical and thermal failure mechanisms in assembly and detection methods. 

The objective is to provide the participants with an overview of the technologies, materials, and processes involved in the latest assembly failure analysis methods.

Main Topics:

  1. Why do failure analysis? 
  2. FA in Assembly how is it different from board level or system level 
  3. Is reliability testing important or part of FA?
  4. The Reliability Bath Tub Curve, its origin and implications
  5. Incoming wafer FA
  6. Assembly failure mechanisms
    1. Substrate design, warpage and cracks
    2. Underfill process control
    3. Wire bond failures
    4. Flip chip failures
    5. Substrate bake out
  7. Mechanical causes of assembly failures
  8. Thermal causes of assembly failures
  9. Accelerated Testing and Estimation of Useful Operating Life
    1. Burn-in as failure analysis
    2. Temperature cycling methods
    3. Drop testing (to find weak areas in design or assembly)
    4. Shock/vibration tests
  10. Methods to detect failures (destructive and non-destructive)
    1. FTIR
    2. Thermal cycling (TCA, TCB, etc.)
    3. SEM, scanning electron micrograph
    4. Interference pattern testing for package stress
    5. Thermal imaging
    6. Physical inspection, visual imaging, microscope
    7. De-capping methods
  11. FA used to predict mean time to failure, MTTF
  12. Summary and review

This workshop is designed for:

  • Manufacturing engineers and technicians, 
  • Manufacturing supervisors
  • Production and quality control engineers
  • Front of the line packaging engineers and technicians