Fluxless tin soldering eliminates flux residues but introduces tin fog, which affects the reliability of electronic packaging. The influence of tin fog was first analyzed through the shear strength of the Al wires bonded on DBC substrates. After aging at 300 °C for 4 h, shear strength increased by 4.5 % on pure copper surfaces but decreased by 22.6 % on tin fog-covered surfaces. Further SEM revealed tin fog created interfacial porosity, reducing strength. Secondly, the impact of tin fog formation during the formic acid reflow process was studied under different formic acid concentrations and different vacuum frequencies during the reflow's preheating stage. Through SEM, EDS, Micro-IR, and XPS tests, the principal components of tin fog were identified as elemental tin, tin dioxide, and organic compounds such as amides and esters. It is found that tin fog forms through a process wherein tin formate produced during formic acid reflow adheres to the substrate surface, which is already adsorbed with organic substances such as esters and amides, and subsequently decomposes at high temperatures to generate derivative products creating the fog. Therefore, to mitigate tin fog formation, tin fog was effectively controlled under a tripled vacuum frequency, resulting in reduced organic residues on substrates. Under such a mitigation strategy, further reliability tests showed that the shear strength of Al wire bonding after aging at 300 °C was comparable to that on clean DBC substrates. This research provides a valuable reference for enhancing the reliability of fluxless soldering in electronic packaging.

The soldering process, essential for electrical and mechanical connections in the microelectronics industry, is crucial for IGBT die attachment as well. This paper investigates the impact of the vacuum reflow process on IGBT assembly using fluxless solder paste activated by formic acid. The paste demonstrates excellent print quality, formability, and consistent solder joint formation. Achieving satisfactory wetting, it compares favorably to traditional solder materials. Key optimized parameters include reflow temperature profiles, activation, and vacuum conditions, such as preheat time, time above liquid (TAL), peak temperature, formic acid concentration, and vacuum ratio. Crucially, formic acid's concentration and activation duration play significant roles in reducing void percentages, effectively decreasing voids from 7.5% to as low as 1%. Vacuum pressure also critically influences void behavior, with reductions in pressure resulting in increased void percentages from 1% to a high of 30%. This study underscores the potential of fluxless solder methodology as a sustainable and economic advancement in the power electronics industry.

Copper sintering has gained great attention as a die-attach technology for power electronics because of its potential cost effectiveness and high reliability under harsh working conditions. However, the mechanism of how the intrinsic pores within such sintered joints influence the thermal and electrical properties still needs further investigation. The evolution of pores within such sintered joints is difficult for in-situ observation during the sintering process and reliability tests, while the porosity level greatly affects the thermal and electrical properties. In this work, four two-dimensional (2D) models with various random pore structures were established based on the Quartet Structure Generation Set (QSGS) algorithm. Then, finite element method (FEM) simulations were conducted to simulate the heat and current conduction in the sintered materials. Subsequently, the distribution of temperature as well as the electric potential in the porous sintered materials were further discussed. Lastly, both the thermal and the electrical conductivities were calculated, followed by a concluded parabolic relationship of thermal and electrical conductivities with the porosity. These findings offer insights into optimizing and predicting copper sintered joint performance and accelerate the wide application of copper sintering.