Abstract: Raised electrical contacts, such as Pb-alloy solder bumps or balls utilized in semiconductor IC flip-chip devices, are selectively and readily removed from underlying contact pads by means of a chemical etching process, thereby facilitating metallurgical and/or microstructural inspection and/or analysis of the contact pads for failure analysis, void formation, electromigration, diffusion, loss of adhesion, etc., by a variety of optical and microscopic techniques.

Abstract: Metallographic samples are cross-sectioned to inspect internal features of the samples and to determine the cause of component failures. In order to reach an area of interest that is to be inspected, the cross-sections undergo grinding. Conventional grinding techniques require that a metallographic sample be removed from the grinding apparatus and visually inspected in order to determine whether the area of interest has been reached. An improved grinding apparatus and method of grinding, images the sample while it is being ground so that grinding does not have to be interrupted in order to determine how far grinding has progressed. Real-time monitoring of the grinding process allows precision control of grinding of metallographic samples.

Abstract: A method for performing inspection of raised electrical contacts, such as ball grid array (BGA) and “flip-chip” type contacts, and associated underlying vias, comprises steps of: providing an electrical or electronic device or component having a major surface including an array of closely spaced apart BGA or flip-chip type raised contacts with respective underlying vias; selecting an area-of-interest (AOI) including at least one BGA or flip-chip type contact/via structure; cutting through the device or component along parallel lines to form a narrow, elongated strip including the AOI; mounting the elongated strip on a transparent substrate; and performing X-ray radiographic analysis of the elongated strip to inspect the at a least one BGA or flip-chip type contact/via structure for the presence of misalignments, voids, and delaminations.

Abstract: A method for reliable, safe removal of an electrical or electronic component or device mounted on a fragile or brittle circuit board substrate having opposed planar upper and lower surfaces, e.g., for performing testing such as failure analysis, comprises sequential steps of cutting the substrate transversely through its thickness to separate therefrom a segment comprising a first portion including the component or device and a second, adjoining portion; cutting the separated segment longitudinally along a plane parallel to the upper surface, the cutting extending beneath the entirety of the first portion; and cutting the substrate of the separated segment transversely through its thickness to separate the first portion including the component or device from the second portion.