Dissertation (Ph.D.)--Auburn University, 2005. / Abstract. Vita. Includes bibliographic references.

Das Cu-Cu-Bonden ist eine vielversprechende lötfreie Fine-Pitch-Verbindungstechnologie für die 2,5D- und 3D-Systemintegration. Diese Bondtechnologie wurde in den letzten Jahren intensiv untersucht und wird derzeit für miniaturisierte mikroelektronische Produkte eingesetzt. Allerdings, stellt das Cu‑Cu-Bonden zum einen sehr hohe Anforderungen an die Oberflächenplanarität und -reinheit, und zum anderen sollten die Bondpartner frei von Oxiden sein. Oxidiertes Cu erfordert erhöhte Bondparameter, um die Oxidschicht zu durchbrechen und zuverlässige Cu-Cu-Verbindungen zu erzielen. Diese Bondbedingungen sind für viele sensible Bauelemente nicht geeignet. Aus diesem Grund sollten alternative Technologien mit einer einfachen Technik zum Schutz von Cu vor Oxidation gefunden werden. In dieser Arbeit werden selbstorganisierte Monolagen (SAMs) für den Cu-Oxidationsschutz und die Verbesserung der Cu-Cu-Thermokompression- (TC) und Ultraschall- (US) Flip-Chip-Bondtechnologien untersucht. Die Experimente werden an Si-Chips mit galvanisch aufgebrachten Cu-Microbumps und Cu-Schichten durchgeführt. Die Arbeit beinhaltet die umfassende Charakterisierung der SAM für den Cu-Schutz, die Bewertung der technologischen Parameter für das TC- und US-Flip-Chip-Bonden sowie die Charakterisierung der Cu-Cu-Bondqualität (Scherfestigkeitstests, Bruchflächen- und Mikrostrukturanalysen). Eine Lagerung bei tiefen Temperaturen (bei ‑18 °C und ‑40 °C) bestätigte die langanhaltende Schutzwirkung der kurzkettigen SAMs für das galvanisch abgeschiedene Cu ohne chemisch-mechanische Politur. Der Einfluss der Tieftemperaturlagerung an Luft und der thermischen SAM-Desorption in einer Inertgasatmosphäre auf die TC-Verbindungsqualität wird im Detail analysiert. Die Idee, mit Hilfe der US-Leistung SAM mechanisch zu entfernen und gleichzeitig das US-Flip-Chip-Bonden zu starten, wurde in der Literatur bisher nicht systematisch untersucht. Die Methode ermöglicht kurze Bondzeiten, niedrige Bondtemperaturen und das Bonden an Umgebungsluft. Sowohl beim TC- als auch beim US-Flip-Chip-Bonden zeigt es sich, dass die Scherfestigkeit bei den Proben mit SAM-Passivierung um ca. 30 % höher ist als bei unbeschichteten Proben. Das Vorhandensein von Si- und Ti-Bruchflächen nach den Scherfestigkeitstests ist für die Proben mit der SAM-Passivierung typisch, was auf eine höhere Festigkeit solcher Verbindungen im Vergleich zu ungeschützten Proben schließen lässt. Die Transmissionselektronenmikroskopie (TEM) zeigt keine SAM-Spuren im zentralen Bereich der Cu-Cu-Grenzfläche nach dem US-Flip-Chip-Bonden. Die Ergebnisse dieser Arbeit zeigen die Verbesserung der Bondqualität durch den Einsatz von SAM zum Schutz des Cu vor Oxidation im Vergleich zum üblicherweise angewandten Cu-Vorätzen. Das gefundene technologische Prozessfenster für das US-Flip-Chip-Bonden an Luft bietet eine hohe Bondqualität bei 90 °C und 150 °C, bei 180 MPa, bei einer Bonddauer von 1 s an. Die in dieser Arbeit gewonnenen Erkenntnisse sind ein wichtiger Beitrag zum Verständnis des SAM-Einflusses auf Chips mit galvanischen Cu-Microbumps, bzw. Cu-Schichten, und zur weiteren Anwendung der Cu-Cu-Fine-Pitch-Bondtechnologie in der Mikroelektronik. / Cu-Cu bonding is one of the most promising fine-pitch interconnect technologies with solder elimination for 2.5D and 3D system integration. This bonding technology has been intensively investigated in the last years and is currently in application for miniaturized microelectronics products. However, Cu-Cu bonding has very high demands on the sur-face planarity and purity, and the bonding partners should be oxide-free. Oxidized Cu requires elevated bonding parameters in order to break through the oxide layer and achieve reliable Cu-Cu interconnects. Those bonding conditions are undesirable for many devices (e.g. due to the temperature/pressure sensitivity). Therefore, alternative technologies with a simple technique for Cu protection from oxidation are required. Self-assembled monolayers (SAMs) are proposed for the Cu protection and the improvement of the Cu-Cu thermocompression (TC) and ultrasonic (US) flip-chip bonding technologies in this thesis. The experiments were carried out on Si dies with electroplated Cu microbumps and Cu layers. The thesis comprises the comprehensive characterization of the SAM for Cu protection, evaluation of technological parameters for TC and US flip-chip bonding as well as characterization of the Cu-Cu bonding quality (shear strength tests, fracture surface and microstructure analyses). The storage at low temperatures (at ‑18 °C and ‑40 °C) confirmed the prolonged protective effect of the short-chain SAMs for the electroplated Cu without chemical-mechanical polishing. The influence of the low-temperature storage in air and the thermal SAM desorption in an inert gas atmosphere on the TC bonding quality was analyzed in detail. The approach of using US power to mechanically remove SAM and simultaneously start the US flip-chip bonding has not been systematically investigated before. The method provides the benefit of short bonding time, low bonding temperature and bonding in ambient air. Both the TC and US flip-chip bonding results featured the shear strength that is approximately 30 % higher for the samples with SAM passivation in comparison to the uncoated samples. The presence of Si and Ti fracture surfaces after the shear strength tests is typical for the samples with the SAM passivation, which suggests a higher strength of such interconnects in comparison to the uncoated samples. The transmission electron microscopy (TEM) indicated no SAM traces at the central region of the Cu-Cu bonding interface after the US flip-chip bonding. The results of this thesis show the improvement of the bonding quality caused by the application of SAM for Cu protection from oxidation in comparison to the commonly applied Cu pre-treatments. The found technological process window for the US flip-chip bonding in air offers high bonding quality at 90 °C and 150 °C, at 180 MPa, for the bonding duration of 1 s. The knowledge gained in this thesis is an important contribution to the understanding of the SAM performance on chips with electroplated Cu microbumps/layers and further application of the Cu-Cu fine-pitch bonding technology for microelectronic devices.

With increasing miniaturization in microelectronics the wirebonds used in IC packages are witnessing a thrust towards fine pitch wirebonding. To have a precise control over loop height of the wirebond for fine pitch wirebonding, it is imperative to do mechanical characterization of the wirebond. The present work studies the mechanical properties of gold wire and wirebond using nanoindentation. The wirebond specimen surface was planarized using mechanical polishing. The loop height of the gold wirebond is directly proportional to the length of the heat affected zone (HAZ) above the ball of gold wirebond. Metallographic preparation of gold wirebond cross section reveals the presence of undesirable coarse grain structure in HAZ due to recrystallization and grain growth in the gold wire adjacent to the ball. The recrystallization temperature of our gold wire was found using D.S.C. to be 340.66°C. The doping elements present in the gold wire used, were identified using TOF-SIMS. Nanoindentation of the gold wire was done at different maximum loads to observe the hardness variation with load. The nanoindentation of gold wirebond has confirmed a v-shaped hardness profile in the HAZ. The hardness minima for the particular gold wire used with a ball size ratio of 2.4 was observed at distance of 160-170 µm from the neck of the ball. The elastic modulus was found to vary randomly and to be independent of the microstructure in the wirebond. A yield stress profile based on empirical hardness-yield strength correlation has been predicted for the gold wirebond. / Singapore-MIT Alliance (SMA)

With the semiconductor industry racing toward a historic transition, nano chips with less than 45 nm features demand I/Os in excess of 20,000 with multi-core processors aggregately providing highest bandwidth at lowest power. On the other hand, emerging mixed signal systems are driving the need for 3D packaging with embedded active components and ultra-short interconnections. Being able to provide several fold increase in the chip-to-package vertical interconnect density is essential for garnering the true benefits of nanotechnology that will utilize nano-scale devices. Electrical interconnections are multi-functional materials that must also be able to withstand complex, sustained and cyclic thermo-mechanical loads. Device- to- system board interconnections are typically accomplished today with either wire bonding or solders. Both of these are incremental and run into either electrical or mechanical barriers as they are extended to higher interconnections densities. Downscaling traditional solder bump interconnect will not satisfy the thermo-mechanical reliability requirements at very fine pitches. Other approaches such as compliant interconnects require lengthy connections and are limited in terms of electrical properties. A novel chip-package interconnection technology is developed to address the IC packaging requirements and to introduce innovative design and fabrication concepts that will further advance the performance of the chip, the package, and the system board. The nano-structured interconnect technology simultaneously packages all the ICs intact in wafer form with quantum jump in the number of interconnections with the lowest electrical parasitics. The intrinsic properties of nano materials also enable several orders of magnitude higher interconnect densities with the best mechanical properties for the highest reliability and yet provide higher current and heat transfer densities. This thesis investigates the electrical and mechanical performance of nano-structured interconnections through modeling and test vehicle fabrication. Test vehicles with nano-interconnections were fabricated using low cost electro-deposition techniques and assembled with various bonding interfaces. Interconnections were fabricated at 200 micron pitch to compare with the existing solder joints and at 50 micron pitch to demonstrate fabrication processes at fine pitches. Experimental and modeling results show that the proposed nano-interconnections could enhance the reliability and potentially meet all the system performance requirements for the emerging micro/nano-systems.

Thesis--Auburn University, 2009. / Abstract. Includes bibliographical references (p. 170-177).

This research reports for the first time conductive anodic filament reliability of copper plated-through-vias with spacing of 75 – 200 µm in thin glass fiber reinforced organic packaging substrates with advanced epoxy-based and cyclo-olefin polymer resin systems. Reliability studies were conducted in halogenated and halogen-free substrates with improved test structure designs including different conductor spacing and geometry. Accelerated test condition (temperature, humidity and DC bias voltage) was used to investigate the effect of conductor spacing and substrate material influence on insulation reliability behavior. Characterization studies included gravimetric measurement of moisture sorption, extractable ion content analysis, electrical resistance measurement, impedance spectroscopy measurement, optical microscopy and scanning electron microscopy analysis and elemental characterization using energy dispersive x-ray spectroscopy. The accelerated test results and characterization studies indicated a strong dependence of insulation failures on substrate material system, conductor spacing and geometry. This study presents advancements in the understanding of failure processes and chemical nature of failures in fine-pitch copper plated-through-vias in newly developed organic substrates and demonstrates potential methods to mitigate failures for high density organic packages.

Ever growing demands for portability and functionality have always governed the electronic technology innovations. IC downscaling with Moore s law at IC level and system miniaturization with System-On-Package (SOP) paradigm at system level, have resulted and will continue to result in ultraminiaturized systems with unprecedented functionality at reduced cost. However, system miniaturization poses several electrical and thermal challenges that demand innovative solutions including advanced materials, bonding and assembly techniques. Heterogeneous material and device integration for thermal structures and IC assembly are limited by the bonding technology and the electrical and thermal impedance of the bonding interfaces. Solder - based bonding technology that is prevalent today is a major limitation to future systems. The trend towards miniaturized systems is expected to drive downscaling of IC I/O pad pitches from 40µm to 1- 5µm in future. Solder technology imposes several pitch, processability and cost restrictions at such fine pitches. Furthermore, according to International Technology Roadmap for Semiconductors (ITRS-2006), the supply current in high performance microprocessors is expected to increase to 220 A by 2012. At such supply current, the current density will exceed the maximum allowable current density of solders. The intrinsic delay and electromigration in solders are other daunting issues that become critical at nanometer sized technology nodes. In addition, formation of intermetallics is also a bottleneck that poses significant mechanical issues. Similarly, thermal power dissipation is growing to unprecedented high with a projected power of 198 W by 2008 (ITRS 2006). Present thermal interfaces are not adequate for such high heat dissipation. Recently, copper based thin film bonding has become a promising approach to address the abovementioned challenges. However, copper-copper direct bonding without using solders has not been studied thoroughly. Typically, bonding is carried out at 400oC for 30 min followed by annealing for 30 min. High thermal budget in such process makes it less attractive for integrated systems because of the associated process incompatibilities. Hence, there is a need to develop a novel low temperature copper to copper bonding process. In the present study, nanomaterials - based copper-to-copper bonding is explored and developed as an alternative to solder-based bonding. To demonstrate fine pitch bonding, the patterning of these nanoparticles is crucial. Therefore, two novel self-patterning techniques based on: 1.) Selective wetting and 2.) Selective nanoparticle deposition, are developed to address this challenge. Nanoparticle active layer facilitates diffusion and, thus, a reliable bond can be achieved using less thermal budget. Quantitative characterization of the bonding revealed good metallurgical bonding with very high bond strength. This has been confirmed by several morphological and structural characterizations. A 30-micron pitch IC assembly test vehicle is used to demonstrate fine pitch patternability and bonding. In conclusion, novel nanoparticle synthesis and patterning techniques were developed and demonstrated for low-impedance and low-cost electrical and thermal interfaces.

Ever growing demands for portability and functionality have always governed the electronic technology innovations. IC downscaling with Moore s law and system miniaturization with System-On-Package (SOP) paradigm has resulted and will continue to result in ultraminiaturized systems with unprecedented functionality at reduced cost. The trend towards 3D silicon system integration is expected to downscale IC I/O pad pitches from 40µm to 1- 5 µm in future. Device- to- system board interconnections are typically accomplished today with either wire bonding or solders. Both of these are incremental and run into either electrical or mechanical barriers as they are extended to higher density of interconnections. Alternate interconnection approaches such as compliant interconnects typically require lengthy connections and are therefore limited in terms of electrical properties, although expected to meet the mechanical requirements. As supply currents will increase upto 220 A by 2012, the current density will exceed the maximum allowable current density of solders. The intrinsic delay and electromigration in solders are other daunting issues that become critical at nanometer size technology nodes. In addition, formation of intermetallics is also a bottleneck that poses significant mechanical issues. Recently, many research groups have investigated various techniques for copper-copper direct bonding. Typically, bonding is carried out at 400oC for 30 min followed by annealing for 30 min. High thermal budget in such process makes it less attractive for integrated systems because of the associated process incompatibilities. In the present study, copper-copper bonding at ultra fine-pitch using advanced nano-conductive and non-conductive adhesives is evaluated. The proposed copper-copper based interconnects using advanced conductive and non-conductive adhesives will be a new fundamental and comprehensive paradigm to solve all the four barriers: 1) I/O pitch 2) Electrical performance 3) Reliability and 4) Cost. This thesis investigates the mechanical integrity and reliability of copper-copper bonding using advanced adhesives through test vehicle fabrication and reliability testing. Test vehicles were fabricated using low cost electro-deposition techniques and assembled onto glass carrier. Experimental results show that proposed copper-copper bonding using advanced adhesives could potentially meet all the system performance requirements for the emerging micro/nano-systems.

Small form-factor packages with high integration density are driving the innovations in chip-to-package interconnections. Metallurgical interconnections have evolved from the conventional eutectic and lead-free solders to fine pitch copper pillars with lead-free solder cap. However, scaling down the bump pitch below 50-80µm and increasing the interconnect density with this approach creates a challenge in terms of accurate solder mask lithography and joint reliability with low stand-off heights. Going beyond the state of the art flip-chip interconnection technology to achieve ultra-fine bump pitch and high reliability requires a fundamentally- different approach towards highly functional and integrated systems. This research demonstrates a low-profile copper-to-copper interconnect material and process approach with less than 20µm total height using adhesive bonding at lower temperature than other state-of-the-art methods. The research focuses on: (1) exploring a novel solution for ultra-fine pitch (< 30µm) interconnections, (2) advanced materials and assembly process for copper-to-copper interconnections, and (3) design, fabrication and characterization of test vehicles for reliability and failure analysis of the interconnection. This research represents the first demonstration of ultra-fine pitch Cu-to-Cu interconnection below 200°C using non-conductive film (NCF) as an adhesive to achieve bonding between silicon die and organic substrate. The fabrication process optimization and characterization of copper bumps, NCF and build-up substrate was performed as a part of the study. The test vehicles were studied for mechanical reliability performance under unbiased highly accelerated stress test (U-HAST), high temperature storage (HTS) and thermal shock test (TST). This robust interconnect scheme was also shown to perform well with different die sizes, die thicknesses and with embedded dies. A simple and reliable, low-cost and low-temperature direct Cu-Cu bonding was demonstrated offering a potential solution for future flip chip packages as well as with chip-last embedded active devices in organic substrates.

Multi-chip integration with emerging technologies such as a 3D IC stack or 2.5D interposer is primarily enabled by the off-chip interconnections. The I/O density, speed and bandwidth requirements for emerging mobile and high-performance systems are projected to drive the interconnection pitch to less than 20 microns by 2015. A new class of low-temperature, low-pressure, high-throughput, cost-effective and maufacturable technologies are needed to enable such fine-pitch interconnections. A range of interconnection technologies are being pursued to achieve these fine-pitch interconnections, most notably direct Cu-Cu interconnections and copper pillars with solder caps. Direct Cu-Cu bonding has been a target in the semiconductor industry due to the high electrical and thermal conductivity of copper, its high current-carrying capability and compatibility with CMOS BEOL processes. However, stringent coplanarity requirements and high temperature and high pressure bonding needed for assembly have been the major barriers for this technology. Copper-solder interconnection technology has therefore become the main workhouse for off-chip interconnections, and has recently been demonstrated at pitches as low as 40 microns. However, the current interconnection approaches using copper-solder structures are not scalable to finer feature sizes due to electromigration, and reliability issues arising with decreased solder content. Solid Liquid Inter-Diffusion (SLID) bonding is a promising solution to achieve ultra-fine-pitch and ultra-short interconnections with a copper-solder system, as it relies on the conversion of the entire solder volume into thermally-stable and highly electromigration-resistant intermetallics with no residual solder. Such a complete conversion of solders to stable intermetallics, however, relies on a long assembly time or a subsequent post-annealing process. To achieve pitches lower than 30 micron pitch, this research aims to study two ultra-short copper-solder interconnection approaches: (i) copper pillar and solder cap technology, and (ii) a novel technology which will enable interconnections with improved electrical performance by fast and complete conversion of solders to stable intermetallics (IMCs) using Solid Liquid Diffusion (SLID) bonding approach. SLID bonding, being a liquid state diffusion process, combined with a novel, alternate layered copper-solder bump structure, leads to higher diffusion rates and a much faster conversion of solder to IMCs. Moreover this assembly bonding is done at a much lower temperature and pressure as compared to that used for Cu-Cu interconnections. FEM was used to study the effect of various assembly and bump-design characteristics on the post-assembly stress distribution in the ultra-short copper-solder joints, and design guidelines were evolved based on these results. Test vehicles, based on these guidelines, were designed and fabricated at 50 and 100 micron pitch for experimental analysis. The bumping process was optimized, and the effect of current density on the solder composition, bump-height non-uniformity and surface morphology of the deposited solder were studied. Ultra-short interconnections formed using the copper pillar and solder cap technology were characterized. A novel multi-layered copper-solder stack was designed based on diffusion modeling to optimize the bump stack configuration for high-throughput conversion to stable Cu3Sn intermetallic. Following this modeling, a novel bumping process with alternating copper and tin plating layers to predesigned thicknesses was then developed to fabricate the interconnection structure. Alternate layers of copper and tin were electroplated on a blanket wafer, as a first demonstration of this stack-technology. Dies with copper-solder test structures were bonded using SLID bonding to validate the formation of stable intermetallics.