New Sn-0.7Cu-based solder alloys with minor alloying additions of Pd, Cr and Ca

The exemption clause for Pb-containing automobile parts in the RoHS (Restriction of Hazardous Substances) legislation will expire in a few years. Therefore, there is an urgent need to develop new Pb-free solder alloys that are suitable for automobiles. To improve the properties of the Pb-free solders used in automobiles that are consistently exposed to high temperatures and vibrations, we investigated the effects of minor alloying additions of chromium, calcium and palladium and examined the various properties of the resulting Sn-0.7Cu solders. We then investigated the new intermetallic compounds observed after the addition of chromium. In addition, we conducted thermal analysis to confirm the stability of the alloys at temperatures of approximately 230 °C. The wettability and interfacial reactions between the solder alloys and the Cu under bump metallurgy are discussed. Furthermore, to evaluate the mechanical properties of the developed solder alloys, tensile tests were conducted. We confirmed that our minor alloying strategy enhances the strength and hardness of solder alloys without decreasing their melting temperatures.