Is Fully Automatic Bond Testing Possible? » Automatic failure mode analysis

Automatic failure mode analysis / Autograding

With the ability to differentiate between different features the two type of illumination are equally useful for either manual or automatic failure mode analysis. Example of the same sample taken with the two different types of illumination are shown in Fig 18 of a 250µm solder ball and Fig 19 of 50µm pitch Gold ball shear.

Fig 18. 250 µm solder ball
Fig 18. 250 µm solder ball
Fig 19. 50 µm pitch Gold ball shear
Fig 19. 50 µm pitch Gold ball shear

For the example in the 250µm solder ball application, coaxial illumination was combined with a bond tester pattern recognition system enabling automatic grading of percentage Ductile vs Brittle fracture (Fig 20).

Fig 20. Automatic failure mode analysis of 250 µm solder balls
Fig 20. Automatic failure mode analysis of 250 µm solder balls

The capability of automatic grading has limitations but continuous development increases this capability every year. Where current technology limits what can be done automatically, operator intervention needs to be applied but in a manner that least affects what would otherwise be a fully automatic system. The example automatic analysis of the 250µm solder balls (Fig 20) shows a dialogue box with 6 failure modes. In practice the failure modes of tests can be tiled in a programmable matrix size (Fig 21).

Fig 21a. Failure mode matrix
Fig 21a. Failure mode matrix
Fig 21b. Zoomed in portion of Fig 21a showing grading analysis and automatic grading decision by red or green squares
Fig 21b. Zoomed in portion of Fig 21a showing grading analysis and automatic grading decision by red or green squares

At the end of a fully automatic run, the bond tests system can display a screen, or screens, of failure modes for an operator to make a quick assessment. In many cases there is a significant similarity in the failure mode types, so together with the automated analysis, the operator can quickly accept or edit what is automatically presented. This manual assessment can be done live on the system or remotely and at any time. In this way, one operator can run several systems.

Continue to read:

  1. Introduction
  2. What is Required for Automation?
  3. What is Possible with Modern Automation?
  4. Non-Destruct Testing
  5. Conclusion

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