In temperature changing environments, solder joints often experience fatigue failure due to cyclic mechanical stresses and strains induced by mismatches in the coefficients of thermal expansion. These stresses and strains lead to damage accumulation and contribute to the crack initiation, crack propagation, and eventually to failure. In this study, we have investigated the cyclic stress-strain behavior of SAC305 and SAC_Q reflowed lead free solders that occur at various testing temperatures and with various prior aging conditions. Lead free solder uniaxial test specimens with circular cross-section have been prepared using vacuum suction method and then were aged for 0 to 20 days at 125 °C. The samples were then subjected to cyclic stress-strain loading using a Micro-mechanical tester at different testing temperatures from T = 25 C to T = 100 C. The evolution of hysteresis loops with duration of prior aging was characterized by measuring the strain energy density dissipated per cycle (loop area), peak stress, and plastic strain range. It was observed that aging degrades the mechanical fatigue properties due to microstructural coarsening. At elevated temperatures, a drop in the loop area and peak stress and an increase in the plastic strain range for both lead free reflowed solder materials were obtained. In addition, SAC_Q samples had a higher loop area and peak stress compared to SAC305.

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