Xinlei Wei, Guoqing Cai, Shaoyang Zhu, Guoqing Mei
Abstract: To reveal the microstructure formation mechanism of Cu-Sn alloy and the synergistic effect law of composite energy fields in the ultrasonic-assisted laser soldering process, this study employed a combination of experimental and numerical simulation methods to systematically investigate the effects of laser power (5-20W) and ultrasonic frequency (0-40kHz) on the temperature field, flow field, growth of interfacial intermetallic compounds (IMC), and reliability of solder joints. The experiment utilized a semiconductor laser system and an ultrasonic auxiliary device, and combined with COMSOL multiphysics simulation to construct a laser-ultrasonic composite energy field model, focusing on analyzing molten pool convection, temperature distribution, creep strain, and failure cycle characteristics. The results show that laser power dominates heat input and determines the energy accumulation state of the molten pool; ultrasonic frequency regulates molten pool flow through acoustic streaming effect, with around 30kHz achieving optimal momentum transfer, significantly improving temperature uniformity and refining the IMC layer; the synergy of high power (15-20W) and ultrasound (30-40kHz) can enhance the wettability and spreadability of solder joints, but excessively high ultrasonic frequency (40kHz) easily causes solder splashing. Accelerated life test simulations indicate that the interfacial region experiences creep strain concentration due to thermal mismatch, which is the weak link of fatigue failure, and ultrasonic assistance can extend the service life of solder joints by reducing the energy dissipation rate. This study clarifies the matching mechanism of laser-ultrasonic parameters, providing a theoretical basis for optimizing high-reliability soldering processes in electronic packaging.
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