Grain-Scale Study of SAC305 Oligocrystalline Solder Joints: Anisotropic Elasto-Plastic Constitutive Properties of Single Crystals

This paper focuses on anisotropic elastic-plastic constitutive modeling of SAC (SnAgCu) solder grains because of their importance in modeling the behavior of oligocrystalline (few-grained) micron-scale solder joints that are increasingly common in heterogeneous integration. Such grain-scale anisotropic modeling approach provides more accurate assessment of the mechanical response of solder interconnects in terms of predicting different failure modes, failure sites, and variability in time-to-failure. Anisotropic plasticity is represented using Hill–Ramberg–Osgood (RO) continuum plasticity model, which utilizes Hill's anisotropic plastic potential along with a RO power-law plastic hardening flow rule. Mechanistically motivated empirical scaling factors are proposed to extrapolate the stress–strain response for different grain sizes/shapes and for different coarseness of microstructures within each grain (generated with different cooling rates). This scaling factor can therefore also capture the effects of microstructural coarsening due to isothermal aging. This goal is achieved by first conducting monotonic tensile and shear tests on monocrystalline and oligocrystalline SAC305 solder joints containing grains of various geometries and also intragranular microscale (dendritic and eutectic) structures of various coarseness. The grain structures are characterized for each tested specimen using electron backscattered diffraction (EBSD). The Hill–RO model constants and the empirical scaling factors are then estimated by matching grain-scale anisotropic elastic-plastic finite element models of each tested specimen to the measured stress–strain behavior, using an inverse-iteration process. Grain shape is seen to influence the sensitivity of the effective stress–strain curves to the applied stress state (i.e., to the orientation of the principal stress directions) relative to (i) the material principal directions and (ii) the geometric principal directions of grains with high aspect ratio. Limitations of the current results and opportunities for future improvements are discussed.