A prognostic method for the embedded failure monitoring of solder interconnections with 1149.4 test bus architecture

This paper describes the feasibility of accurate low frequency measurements in predicting the breakdown of modern lead free ball grid array (BGA) interconnections. In these measurements, performed partly with 1149.4 analogue boundary scan, ceramic BGA modules measuring 15×15 mm in width, with 9×9 ball matrixes, were attached on an FR-4 printed wiring board (PWB) and thermally cycled over a temperature range of −40 to +125 °C. The condition of corner interconnections was monitored using the developed measurement methods and construction. In-situ measurements were performed with a datalogger during temperature cycling, accompanied with 1149.4 mixed-signal test bus measurements of corner interconnections performed between cycling intervals. In addition, the measurements were complemented by scanning acoustic microscopy and, X-ray. Monitoring corner interconnections by a simple, low-frequency voltage measurement method with embedded test constructions gives an early warning indication well before the electrical interconnection failures. Of two studied interconnection compositions, the ones with plastic core solder balls (PCSB) proved to be more reliable than the ones with 90/10 PbSn balls.