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Effects of Thermo-Mechanical Fatigue and Low Cycle Fatigue Interaction on Performance of Solder Joints

This paper demonstrates the feasibility of low cycle fatigue effects on the thermo-mechanical fatigue evolution in the solder joints of a power module. To achieve this goal, finite-element method (FEM) simulation and experimental studies have been carried out. One of the prepared samples was exposed to the sole thermal cycling while another one underwent frequent drop impacts, as an indicator of low cycle fatigue event, during the thermal cycling. The FEM results indicate that the thermal cycling leads to the accumulated creep strain in the solder joints. The amount of creep strain considerably increases when the drop impacts are coupled to the thermal cycling. This phenomenon is due to the additional peeling stress applied by drop impacts to the solder joints. It is also revealed that with an increase in the number of drop impacts, the rate of strain accumulation declines which may be due to the restriction of changes led by stress triaxiality. The fractography also validates that the sample exposed to both drop and thermal loadings shows an entire brittle fracture mode. Moreover, the EDS map shows that the elemental distribution heterogeneity and intermetallic growth were created under mutual effects of drop impacts and thermal cycle fatigue.