Microstructure evolution and interfacial bonding mechanisms of ultrasonically soldered sapphire/Al dissimilar joints using Sn-based solders

Sapphire and 5A06 Al were ultrasonically soldered with Sn9Zn, SAC305 alloy solders and NiCu alloy foam added Sn-based composite solders, respectively. The microstructure and mechanical properties of joints were investigated and the interfacial bonding mechanism was analyzed. Cracks were observed at the sapphire/Sn matrix interface in joints soldered with alloy solders, which were disappeared in the joints soldered with composite solders. In the joint using NiCu–Sn9Zn composite solder, the solder seam was uneven and Al3Ni intermetallic compound (IMC) layer was formed on the surface of NiCu alloy skeletons. While in the joint using NiCu-SAC305 composite solder, fine particles of (Ni,Zn)3Sn4 were largely formed and homogeneously distributed in the solder seam. An amorphous Al2O3 transition layer was formed at the sapphire/Sn matrix interface, and Zn enrichment was found at the Sn matrix/amorphous Al2O3 interface. The action mechanism of Zn was analyzed by first-principles calculation. The joints soldered with NiCu-SAC305 composite solder exhibited the highest shear strength of 74.42 MPa, the shearing failure mainly happened in the soldering seam.