Novel Cu/Cr/Ge/Pd Ohmic Contacts on Highly Doped n-GaAs

The thermal stability of the Cu/Cr/Ge/Pd/n⁺-GaAs contact structure was evaluated. In this structure, a thin 40 nm layer of chromium was deposited as a diffusion barrier to block copper diffusion into GaAs. After thermal annealing at 350°C, the specific contact resistance of the copper-based ohmic contact Cu/Cr/Ge/Pd was measured to be (5.1 ± 0.6) × 10⁻⁷ Ω cm². Diffusion behaviors of these films at different annealing temperatures were characterized by metal sheet resistance, X-ray diffraction data, Auger electron spectroscopy, and transmission electron microscopy. The Cu/Cr/Ge/Pd contact structure was very stable after 350°C annealing. However, after 400°C annealing, the reaction of copper with the underlying layers started to occur and formed Cu₃Ga, Cu₃As, Cu₉Ga₄, and Ge₃Cu phases due to interfacial instability and copper diffusion.     

Ohmic contact formation in palladium-based metallizations to n-Type InP

Two Pd-based metallizations have been systematically studied, i.e., Au/Ge/Pd and Pd/Ge contacts to n-type InP, in an attempt to better understand the role of the metallization constituents in forming ohmic contacts. Ohmic contacts were obtained with minimum specific resistances of 2.5 × 10⁻⁶ Ω-cm² and 4.2 × 10⁻⁶ Ω-cm² for the Au/Ge/Pd and the Pd/Ge contacts, respectively. The annealing regime for ohmic contact formation is 300-375°C for the Au/Ge/Pd/InP system and 350-450°C for the Pd/GelnP system. Palladium, in both cases, reacts with InP to form an amorphous layer and then an epitaxial layer at low temperatures, providing good metallization adhesion to InP substrates and improved contact morphology. Ohmic contact formation in both contacts is attributed to Ge doping, based on the solid state reaction-driven decomposition of an epitaxial layer at the metallization/InP interface, producing a very thin, heavily doped InP layer. Gold appears to be responsible for the difference in contact resistance in the two systems. It is postulated that Au reacts strongly with In to form Au-In compounds, creating additional In site vacancies in the InP surface region (relative to the Au-free metallization), thereby enhancing Ge doping of the InP surface and lowering the contact resistance. Both contacts degrade and ultimately become Schottky barriers again if over annealed, due to consumption of additional InP, which destroys the heavily doped InP layer.     

Thermal Stability Study of Cu(MoN<Subscript><Emphasis Type="Italic">x</Emphasis></Subscript>) Seed Layer on Barrierless Si

This study reports the good thermal stability of a sputtered Cu(MoN _x ) seed layer on a barrierless Si substrate. A Cu film with a small amount of MoN _x was deposited by reactive co-sputtering of Cu and Mo in an Ar/N₂ gas mixture. After annealing at 560°C for 1 h, no copper silicide formation was observed at the interface of Cu and Si. Leakage current and resistivity evaluations reveal the good thermal reliability of Cu with a dilute amount of MoN _x at temperatures up to 560°C, suggesting its potential application in advanced barrierless metallization. The thermal performance of Cu(MoN _x ) as a seed layer was evaluated when pure Cu is deposited on top. X-ray diffraction, focused ion beam microscopy, and transmission electron microscopy results confirm the presence of an ∼10-nm-thick reaction layer formed at the seed layer/Si interface after annealing at 630°C for 1 h. Although the exact composition and structure of this reaction layer could not be unambiguously identified due to trace amounts of Mo and N, this reaction layer protects Cu from a detrimental reaction with Si. The Cu(MoN _x ) seed layer is thus considered to act as a diffusion buffer with stability up to 630°C for the barrierless Si scheme. An electrical resistivity of 2.5 μΩ cm was obtained for the Cu/Cu(MoN _x ) scheme after annealing at 630°C.     

Pd/Ge contacts to n-type GaAs

Sintered metal-semiconductor contacts, formed by thin, evaporated layers of Pd and Ge on n-type GaAs, were studied using Auger electron spectroscopy, X-ray diffraction, X-ray photoelectron spectroscopy, secondary ion mass spectroscopy, current-voltage measurements, and capacitance-voltage measurements. Prior to sintering, the as-deposited Pd/Ge/GaAs contacts were rectifying and exhibited a reproducible Schottky barrier energy φ_Bn of 0.67±0.02 eV. Auger analysis indicated the initial behavior of the contact structure, upon sintering, to be an interdiffusion and reaction of Pd and Ge on a non-reacting GaAs substrate. Two germanide phases, Pd₂Ge and PdGe, were identified using X-ray diffraction and Auger analysis. The intervening Ge layer prevented the reaction of Pd with the GaAs substrate at low temperatures. Because of the PdGe reaction, φ_Bn increased to approximately 0.85 eV. Sintering at higher temperatures (i.e. between 300 and 400°C) produced additional reactions between Pd and the GaAs substrate. The electrical properties of the contact remained rectifying and φ_Bn exhibited little change from the value of 0.85 eV with the interdiffusion of Pd, Ga, and As. Sintering above 400°C resulted in the formation of ohmic contacts. The diffusion of Ge to the GaAs interface was found to correlate with the onset of ohmic behavior. Current conduction in the contact was best described by thermionic-field emission theory, and a specific contact resistance of 3.5 × 10^?4Ω-cm² was obtained after sintering above 550°C, independent of the initial impurity concentration in the substrate. Over the entire range of sintering temperatures (i.e. at or below 600°C), the interaction between the thin-film layers appeared to be governed by diffusion-controlled, solid-phase processes with no evidence of the formation of a liquid phase. As a result, the surface of the contact structure remained smooth and uniform during sintering.     

Pd/Zn/Pd/Au ohmic contacts to ρ-Type InP

Low resistance ohmic contacts (ρ_c = 7 x 10^-5 Ω-cm ² ) have been fabricated to Zn-doped p-type InP using an annealed Pd/Zn/Pd/Au metallization. Palladium reacts with InP at low temperatures to form a Pd₂InP ternary phase, which is initially amorphous but crystallizes and grows epitaxially on InP. Zinc reacts with some of the overlying Pd to form PdZn (≅250° C), which decomposes at 400-425° C to form PdP₂, freeing up Zn to diffuse into Au as well as InP. The contact resistance reaches a minimum as the decomposition reaction takes place. The resultant ohmic contact is laterally uniform and consists of epitaxial Pd₂InP adjacent to InP, followed by a thin layer of PdP₂ and then the outer Au layer. Further annealing leads to a breakdown of the contact structure,i.e. decomposition of Pd₂InP, and an increase in contact resistance.     

Effect of Pd Surface Roughness on the Bonding Process and High Temperature Reliability of Au Ball Bonds

A 0.3-μm-thick electrolytic Pd layer was plated on 1 μm of electroless Ni on 1 mm-thick polished and roughened Cu substrates with roughness values (R _a) of 0.08 μm and 0.5 μm, respectively. The rough substrates were produced with sand-blasting. Au wire bonding on the Ni/Pd surface was optimized, and the electrical reliability was investigated under a high temperature storage test (HTST) during 800 h at 250°C by measuring the ball bond contact resistance, R _c. The average value of R _c of optimized ball bonds on the rough substrate was 1.96 mΩ which was about 40.0% higher than that on the smooth substrate. The initial bondability increased for the rougher surface, so that only half of the original ultrasonic level was required, but the reliability was not affected by surface roughness. For both substrate types, HTST caused bond healing, reducing the average R _c by about 21% and 27%, respectively. Au diffusion into the Pd layer was observed in scanning transmission electron microscopy/ energy dispersive spectroscopy (STEM–EDS) line-scan analysis after HTST. It is considered that diffusion of Au or interdiffusion between Au and Pd can provide chemically strong bonding during HTST. This is supported by the R _c decrease measured as the aging time increased. Cu migration was indicated in the STEM–EDS analysis, but its effect on reliability can be ignored. Au and Pd tend to form a complete solid solution at the interface and can provide reliable interconnection for high temperature (250°C) applications.     

Improved Thermal Stability Observed in Ni-Based Ohmic Contacts to <Emphasis Type="Italic">n</Emphasis>-Type SiC for High-Temperature Applications

The high-temperature stability of a Pt/TaSi₂/Ni/SiC ohmic contact metallization scheme was characterized using a combination of current–voltage measurements, Auger electron spectroscopy, and transmission electron microscopy imaging and associated analytical techniques. Increasing the thicknesses of the Pt and TaSi₂ layers promoted electrical stability of the contacts, which remained ohmic at 600°C in air for the extent of heat treatment; the specific contact resistance showed only a gradual increase from an initial value of 5.2 × 10⁻⁵ Ω cm². We observed a continuous silicon oxide layer in the thinner contact structures, which failed after 36 h of heating. Meanwhile, thicker contacts with enhanced stability contained a much lower oxygen concentration that was distributed across the contact layers, precluding the formation of an electrically insulating contact structure.     

Thermal Stability of Nitride-Based Diffusion Barriers for Ohmic Contacts to <Emphasis Type="Italic">n</Emphasis>-GaN

The use of TaN, TiN, and ZrN diffusion barriers for Ti/Al-based contacts on n-GaN (n ∼ 3 × 10¹⁷ cm⁻³) is reported. The annealing temperature (600–1,000°C) dependence of the Ohmic contact characteristics using a Ti/Al/X/Ti/Au metallization scheme, where X is TaN, TiN, or ZrN, deposited by sputtering was investigated by contact resistance measurements and Auger electron spectroscopy (AES). The as-deposited contacts were rectifying and transitioned to Ohmic behavior for annealing at ≥600°C. A minimum specific contact resistivity of ∼6 × 10⁻⁵ Ω-cm⁻² was obtained after annealing over a broad range of temperatures (600–900°C for 60 s), comparable to that achieved using a conventional Ti/Al/Pt/Au scheme on the same samples. The contact morphology became considerably rougher at the high end of the annealing range. The long-term reliability of the contacts at 350°C was examined; each contact structure showed an increase in contact resistance by a factor of three to four over 24 days at 350°C in air. AES profiling showed that the aging had little effect on the contact structure of the nitride stacks.     

Compositional Study of Copper-Germanium Ohmic Contact to <Emphasis Type="Italic">n-</Emphasis>GaN

400°C alloying of Ge/Cu/Ge films on modestly doped n-GaN results in linear current-voltage (I-V) behavior over a wide range of relative Ge compositions. X-ray diffraction (XRD) and Auger depth profiling data suggest that the lowest contact resistivity is due to film compositions near 25 at.% Ge, where the amount of interfacial nonreacted Ge is low. Ohmic contact is likely established by a heavily doped GaN interfacial region influenced by premetallization reactive ion etching (RIE) and later low-temperature alloying, which assists in the formation of donorlike complexes possibly involving Ge_Ga or Si_Ga. This contact shows exceptionally smooth surface morphology, as revealed by atomic force microscopy (AFM). [rl](Received ...; accepted ...)     

Simultaneous Formation of Ni/Al Ohmic Contacts to Both n- and p-Type 4H-SiC

The fabrication procedure for silicon carbide power metal oxide semiconductor field-effect transistors can be improved through simultaneous formation (i.e., using the same contact materials and a one-step annealing process) of ohmic contacts on both the n-source and p-well regions. We have succeeded in the simultaneous formation of Ni/Al ohmic contacts to n- and p-type SiC after annealing at 1000°C for 5 min in an ultrahigh vacuum. Ohmic contacts to n-type SiC were found when the Al-layer thickness was less than about 6 nm, while ohmic contacts to p-type SiC were observed for an Al-layer thickness greater than about 5 nm. Only the contacts with an Al-layer thickness in the range of 5 nm to 6 nm exhibited ohmic behavior to both n- and p-type SiC, with a specific contact resistance of 1.8 × 10⁻⁴ Ω cm² and 1.2 × 10⁻² Ω cm² for n- and p-type SiC, respectively. An about 100-nm-thick contact layer was uniformly formed on the SiC substrate, and polycrystalline δ-Ni₂Si(Al) grains were formed at the contact/SiC interface. In the samples that exhibited ohmic behavior to both n- and p-type SiC, the distribution of the Al/Ni ratios in the δ-Ni₂Si(Al) grains was larger than that observed for any of the samples that showed ohmic behavior to either n- or p-type SiC. Furthermore, the grain size of the δ-Ni₂Si(Al) grains in the samples showing ohmic behavior to both n- and p-type SiC was smaller than the grains in any of the samples that showed ohmic behavior to either n- or p-type SiC. Thus, the large distribution in the Al/Ni ratios and a fine microstructure were found to be characteristic of the ohmic contacts to both n- and p-type SiC. Grains with a low Al concentration correspond to ohmic contacts to n-type SiC, while grains with a high Al concentration correspond to ohmic contacts to p-type SiC.     

Investigation of Thermal Stability and Degradation Mechanisms in Ni-Based Ohmic Contacts to <Emphasis Type="Italic">n</Emphasis>-Type SiC for High-Temperature Gas Sensors

We investigated the thermal stability of Pt/TaSi _x /Ni/SiC ohmic contacts, which have been implemented in SiC-based gas sensors developed for applications in diesel engines and power plants. The contacts remained ohmic on lightly doped n-type (~1 × 10¹⁶ cm⁻³) 4H-SiC for over 1000 h in air at 300°C. Although a gradual increase in specific contact resistance from 3.4 × 10⁻⁴ Ω cm² to 2.80 × 10⁻³ Ω cm² was observed, the values appeared to stabilize after ~800 h of heating in air at 300°C. The contacts heated at 500°C and 600°C, however, showed larger increases in specific contact resistance followed by nonohmic behavior after 240 h and 36 h, respectively. Concentration profiles from Auger electron spectroscopy and electron energy-loss spectroscopy show that loss of ohmic behavior occurs when the entire tantalum silicide layer has oxidized.     

Lateral diffusion effects in AuGe based source-drain contacts to AllnAs/InGaAs/InP doped channel MODFETs

We have investigated the formation of source-drain AuGe/Au and Ni/AuGe/Ni/Au alloyed ohmic contacts to AlInAs/InGaAs/InP doped channel MODFETs, and observed lateral diffusion of the contact system after the standard annealing procedure at the temperature range of 185 to 400°C. Auger depth profiling of contacts annealed at 250°C, revealed that Au(Ge) diffused through the top InGaAs and AlInAs layers into the active InGaAs layer, but had reduced penetration into the AlInAs buffer layer. This reduction in diffusion along the depth axis at the AlInAs buffer layer boundary is believed to result in enhanced lateral diffusion and the observed lateral encroachment of the contacts. Both Au and Ni containing contact systems showed similar behavior in terms of lateral diffusion with encroachment extending between 0.25 and 0.5 μm at the periphery of the contacts for annealing temperatures between 300 and 400°C. A controlled ramp-to-peak temperature annealing procedure is developed to suppress such lateral diffusion effects. Low temperature annealing (250°C) using this procedure resulted in equally low contact resistance values (∼0.1Θ-mm) and no lateral diffusion. It is concluded that in thin multilayered structures the modified annealing procedure presented here, is necessary for optimal ohmic contact formation.     

Low resistance, thermally stable Au/Pt/Ti/WSiN ohmic contacts on n+-InGaAs/n-GaAs layer systems

The electrical properties of the ohmic contact systems Au/Pt/Ti/WSiN and Au/Pt/Ti to n⁺-InGaAs/GaAs layers grown by metalorganic vapor phase epitaxy were investigated and compared to each other. The thermal stability properties of these contact systems were characterized by accelerated stress tests at elevated temperatures and by complementary thin film x-ray diffraction analysis to evaluate the microstructural properties of degraded and nondegraded structures. The goal of these efforts was to develop stable, homogeneous emitter contacts for power heterojunction bipolar transistors. It was found that for both contact systems the best (specific) contact resistance R_c (ρ _c) is about 0.05 Ωmm (2 × 10⁻⁷ Ωcm²) in the as-deposited state. Au/Pt/Ti/WSiN contacts show no degradation after aging at 400°C for more than 20 h. This is in contrast to standard Au/Pt/Ti contacts which significantly degrade even after short time annealing at 400°C. The good long-time stability of the Au/Pt/Ti/WSiN system is related to the advantageous properties of the reactively sputtered WSiN barrier layer.     

Fabrication of Source/Drain Electrodes for a-Si:H Thin-Film Transistors Using a Single Cu Alloy Target

A Cu alloy/Cu alloy oxide bilayer structure was formed on an n ⁺-a-Si:H substrate using a single Cu alloy target. It was employed for the source/drain electrodes in the fabrication of a-Si:H thin-film transistors with good electrical performance, high thermal stability, and good adhesion. Transmission electron microscopy and electron energy-loss spectroscopy analyses revealed that the initial sputtering of the Cu alloy in O₂/Ar allowed for preferential oxidation of Si and the formation of a SiO _x /Cu-supersaturated a-Si:H bilayer at the copper oxide–a-Si:H interface. This bilayer turned into an SiO _x /Cu₃Si bilayer after annealing at 300°C. It provided a stable contact structure with low contact resistance.     

Ir Diffusion Barriers in Ni/Au Ohmic Contacts to <Emphasis Type="Italic">p</Emphasis>-Type CuCrO<Subscript>2</Subscript>

The use of Ir diffusion barriers in Ni/Au-based Ohmic contacts to p-type CuCrO₂ layers was investigated. A specific contact resistance of ~5 × 10⁻⁴ Ω cm² was achieved after annealing at 500°C for the Ir-containing contacts, and the contacts were rectifying for lower anneal temperatures. In this case, the contact resistance was basically independent of the measurement temperature, indicating that tunneling is the dominant transport mechanism in the contacts. The morphology for the Ir-containing contacts was still smooth at 500°C although Auger electron spectroscopy depth profiling showed that some of the nickel had diffused to the surface and had oxidized. Contacts annealed at 800°C showed that some copper and most of the nickel had diffused to the surface and oxidized. The presence of the Ir diffusion barrier does increase the thermal stability of the contacts by ∼200°C compared to conventional Ni/Au contacts. By contrast, the use of other materials such as TaN, ZrN, and W₂B₅ as the diffusion barrier led to poorer thermal stability, with the contact resistance increasing sharply above 400°C.     

A Study on the Thermal Reliability of Cu/SnAg Double-Bump Flip-Chip Assemblies on Organic Substrates

The Cu/SnAg double-bump structure is a promising candidate for fine-pitch flip-chip applications. In this study, the interfacial reactions of Cu (60 μm)/SnAg (20 μm) double-bump flip chip assemblies with a 100 μm pitch were investigated. Two types of thermal treatments, multiple reflows and thermal aging, were performed to evaluate the thermal reliability of Cu/SnAg flip-chip assemblies on organic printed circuit boards (PCBs). After these thermal treatments, the resulting intermetallic compounds (IMCs) were identified with scanning electron microscopy (SEM), and the contact resistance was measured using a daisy-chain and a four-point Kelvin structure. Several types of intermetallic compounds form at the Cu column/SnAg solder interface and the SnAg solder/Ni pad interface. In the case of flip-chip samples reflowed at 250°C and 280°C, Cu₆Sn₅ and (Cu, Ni)₆Sn₅ IMCs were found at the Cu/SnAg and SnAg/Ni interfaces, respectively. In addition, an abnormal Ag₃Sn phase was detected inside the SnAg solder. However, no changes were found in the electrical contact resistance in spite of severe IMC formation in the SnAg solder after five reflows. In thermally aged flip-chip samples, Cu₆Sn₅ and Cu₃Sn IMCs were found at the Cu/SnAg interface, and (Cu, Ni)₆Sn₅ IMCs were found at the SnAg/Ni interface. However, Ag₃Sn IMCs were not observed, even for longer aging times and higher temperatures. The growth of Cu₃Sn IMCs at the Cu/SnAg interface was found to lead to the formation of Kirkendall voids inside the Cu₃Sn IMCs and linked voids within the Cu₃Sn/Cu column interfaces. These voids became more evident when the aging time and temperature increased. The contact resistance was found to be nearly unchanged after 2000 h at 125°C, but increases slightly at 150°C, and a number of Cu/SnAg joints failed after 2000 h. This failure was caused by a reduction in the contact area due to the formation of Kirkendall and linked voids at the Cu column/Cu₃Sn IMC interface.     

Effect of Pd Thickness on the Interfacial Reaction and Shear Strength in Solder Joints Between Sn-3.0Ag-0.5Cu Solder and Electroless Nickel/Electroless Palladium/Immersion Gold (ENEPIG) Surface Finish

Intermetallic compound formation at the interface between Sn-3.0Ag-0.5Cu (SAC) solders and electroless nickel/electroless palladium/immersion gold (ENEPIG) surface finish and the mechanical strength of the solder joints were investigated at various Pd thicknesses (0 μm to 0.5 μm). The solder joints were fabricated on the ENEPIG surface finish with SAC solder via reflow soldering under various conditions. The (Cu,Ni)₆Sn₅ phase formed at the SAC/ENEPIG interface after reflow in all samples. When samples were reflowed at 260°C for 5 s, only (Cu,Ni)₆Sn₅ was observed at the solder interfaces in samples with Pd thicknesses of 0.05 μm or less. However, the (Pd,Ni)Sn₄ phase formed on (Cu,Ni)₆Sn₅ when the Pd thickness increased to 0.1 μm or greater. A thick and continuous (Pd,Ni)Sn₄ layer formed over the (Cu,Ni)₆Sn₅ layer, especially when the Pd thickness was 0.3 μm or greater. High-speed ball shear test results showed that the interfacial strengths of the SAC/ENEPIG solder joints decreased under high strain rate due to weak interfacial fracture between (Pd,Ni)Sn₄ and (Cu,Ni)₆Sn₅ interfaces when the Pd thickness was greater than 0.3 μm. In the samples reflowed at 260°C for 20 s, only (Cu,Ni)₆Sn₅ formed at the solder interfaces and the (Pd,Ni)Sn₄ phase was not observed in the solder interfaces, regardless of Pd thickness. The shear strength of the SAC/ENIG solder joints was the lowest of the joints, and the mechanical strength of the SAC/ENEPIG solder joints was enhanced as the Pd thickness increased to 0.1 μm and maintained a nearly constant value when the Pd thickness was greater than 0.1 μm. No adverse effect on the shear strength values was observed due to the interfacial fracture between (Pd,Ni)Sn₄ and (Cu,Ni)₆Sn₅ since the (Pd,Ni)Sn₄ phase was already separated from the (Cu,Ni)₆Sn₅ interface. These results indicate that the interfacial microstructures and mechanical strength of solder joints strongly depend on the Pd thickness and reflow conditions.     

Pd/Sb(Zn) and Pd/Ge(Zn) ohmic contacts on p-type indium gallium arsenide: The employment of the solid phase regrowth principle to achieve optimum electrical and metallurgical properties

The development of two metallizations based on the solid-phase regrowth principle is presented, namely Pd/Sb(Zn) and Pd/Ge(Zn) on moderately doped In_0.53Ga_0.47As (p=4×10¹⁸ cm⁻³). Contact resistivities of 2–3×10⁻⁷ and 6–7×10⁻⁷ Ωcm², respectively, have been achieved, where both systems exhibit an effective contact reaction depth of zero and a Zn diffusion depth below 50 nm. Exhibiting resistivities equivalent to the lowest values of Au-based systems in this doping range, especially Pd/Sb(Zn) contacts are superior to them concerning metallurgical stability and contact penetration. Both metallizations have been successfully applied for contacting the base layer of InP/In_0.53Ga_0.47As heterojunction bipolar transistors.     

Influence of Surface Treatment and Annealing Temperature on the Formation of Low-Resistance Au/Ni Ohmic Contacts to <Emphasis Type="Italic">p</Emphasis>-GaN

We have studied the influence of surface treatment and annealing temperature on the specific contact resistance of Au/Ni ohmic contacts to p-GaN with hole concentrations in the range of 10¹⁶ cm⁻³ to 10¹⁸ cm⁻³. The sample with a hole concentration of 1 × 10¹⁸ cm⁻³, treated with the surface treatment HCl:H₂O = 3:1 solution and annealed at 500°C in a 90% N₂ and 10% O₂ atmosphere, yielded the lowest specific contact resistance of ~4 × 10⁻⁵ Ω cm² and ~2 × 10⁻⁷ Ω cm² at room temperature and at 150°C, respectively. To investigate the roles of interdiffusion between layer interfaces and the formation of NiO and nickel gallides, we examined the metallization stacks before and after annealing using high-resolution x-ray diffraction. We conclude that the nickel-gallide formation and the deterioration of the NiO layer are together responsible for the large deviation in contact resistances observed for samples annealed at various temperatures.     

Influence of Pd Concentration on the Interfacial Reaction and Mechanical Reliability of the Ni/Sn-Ag-Cu-xPd System

The interfacial reaction between Ni and Sn-3Ag-0.5Cu-xPd alloys (x = 0 wt.% to 1 wt.%) at 250°C and the mechanical reliability of the solder joints were investigated in this study. The reaction and the resulting mechanical properties were both strongly dependent on the Pd concentration. When x was low (≤0.2 wt.%), the reaction product at the Ni/Sn-Ag-Cu-xPd interface was a layer of (Cu,Ni)₆Sn₅. An increase of x to 0.3 wt.% produced one additional (Pd,Ni)Sn₄ compound that was discontinuously scattered above the (Cu,Ni)₆Sn₅. When x was relatively high (0.5 wt.% to 1 wt.%), a dual layer of (Pd,Ni)Sn₄-(Cu,Ni)₆Sn₅ developed with the reaction time. The results of the high-speed ball shear (HSBS) test showed that the mechanical strength of the Ni/Sn-3Ag-0.5Cu-xPd joints degraded with increasing x, especially when x reached a high level of ≥0.3 wt.%. This degradation corresponded to the growth of (Pd,Ni)Sn₄ at the interface, and joints easily failed along the boundaries of solder/(Pd,Ni)Sn₄ and (Pd,Ni)Sn₄/(Cu,Ni)₆Sn₅ in the HSBS test. The (Pd,Ni)Sn₄-induced joint failure (Pd embrittlement) was alleviated by doping the solder with an appropriate amount of Cu. When the Cu concentration increased to 1 wt.% and the Pd concentration did not exceed 0.5 wt.%, the growth of (Pd,Ni)Sn₄ could be thoroughly inhibited, thereby avoiding the occurrence of Pd embrittlement in the solder joints.