Interactions at the planar Ag3Sn/liquid Sn interface under ultrasonic irradiation

The interactions at the interface between planar Ag3Sn and liquid Sn under ultrasonic irradiation were investigated. An intensive thermal grooving process occurred at Ag3Sn grain boundaries due to ultrasonic effects. Without ultrasonic application, planar shape of Ag3Sn layer gradually evolved into scalloped morphology after the solid-state Sn melting, due to a preferential dissolution of the intermetallic compounds from the regions at grain boundaries, which left behind the grooves embedding in the Ag3Sn layer. Under the effect of ultrasonic, stable grooves could be rapidly generated within an extremely short time (<10 s) that was far less than the traditional soldering process (>10 min). In addition, the deepened grooves leaded to the formation of necks at the roots of Ag3Sn grains, and further resulted in the strong detachment of intermetallic grains from the substrate. The intensive thermal grooving could promote the growth of Ag3Sn grains in the vertical direction but restrain their coarsening in the horizontal direction, consequently, an elongated morphology was presented. All these phenomena could be attributed to the acoustic cavitation and streaming effects of ultrasonic vibration.