There have been serious debates about whether Pb should be removed from solder joints, in view of environmental problems. These debates have now developed to the extent that a remarkable movement to establish regulations for the removal of Pb has emerged, especially in European countries and Japan. Therefore, Many studies have been aggressively undertaken to develop technologies for replacing Sn-Pb solder with lead-free alternative. From the results obtained so far, it has been proven that the fatigue strength in lead-free solder joints is almost equivalent to the fatigue strength of Sn-Pb eutectic solder joints. However, a new problem is that voids are very easily formed in lead-free solder joints during the reflow process, and the effect of the voids on the fatigue strength of solder joints has attracted attention. In this study, the relationship between the voids and fatigue strength of solder joints was examined using mechanical shear fatigue test and FEM (finite element method) analysis. Using the mechanical shear fatigue test, the effect of the position and size of voids on fatigue crack initiation and crack propagation has been investigated. And quantitative evaluation of fatigue life of solder joints with the voids has been enabled by Manson-Coffin’s law and Miner’ rule.

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