New technology for heterogeneously integrated devices allows for underfilling of complex geometries using driven fluids 

From left to right, they are a heterogeneously integrated device with voids; a HI device with no voids, and right, a computed image or vorticity vector orbits.
(Left) Without a magnetic field, there are voids in the HI devices. (Middle) Using the phase-modulated 1+dc:2:3 magnetic field, the HI device is void-free, completely gap filled, with no filler particle segregation. (Right) A set of vorticity vector orbits computed for a phase-modulated 1+dc:2:3 field.

Underfilling is a widely used manufacturing process that helps stabilize and reinforce solder joints in electronic parts. However, heterogeneously integrated (HI) devices are challenging to underfill using standard capillary flow methods, due to large areas with narrow gaps—trenches that act as strong flow barriers, and high bump density that cause filler particle segregation. Through this LDRD project, the team developed a magnetic underfill that can be driven with multiaxial magnetic fields having key symmetries to create vorticity in the fluid, enabling it to fill narrow gaps, cross barriers in any orientation, and uniformly disperse the filler particles. This approach was demonstrated using driven fluids consisting of epoxy and magnetic nanoparticles. A new Sandia capability was developed to create vorticity vector orbits with low frequency triaxial magnetic fields. It was discovered that significant torque density can be generated in viscous particle suspensions, enabling driven underfilling of complex geometries—a viable new technology for HI devices. Discoveries during this two-year project led to new concepts for low moisture permeation coatings now under study and generated one Technical Advance. 

Sandia researchers linked to work

  • Lauren Shea Rohwer
  • Thomas Friedmann

Sponsored by

Image of LDRD_Icon-01

Associated Publications

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  • Anderson, E., Campbell, D., Briscoe, J., Coon, W., Alford, C., Wood, M., Klem, J.F., Gamache, P., Gunter, M., Olesberg, J., Hawkins, S.D., Rohwer, L.E.S., Stephenson, C., Peters, D., Goldflam, M., & Goldflam, M. (2021). Full-Resolution Two-Color Infrared Detector [Conference Presenation]. https://doi.org/10.2172/1878277 Publication ID: 79419
  • Hackett, L., Miller, M., Storey, M., Dominguez, D., Brimigion, F., DiGregorio, S., Peake, G., Tauke-Pedretti, A., Arterburn, S., Friedmann, T.A., Weinstein, D., Eichenfield, M., & Eichenfield, M. (2021). Active Nonreciprocal and Nonlinear Surface Acoustic Wave Devices in a Heterogeneously Integrated InGaAs on Lithium Niobate Material Platform [Conference Presenation]. https://doi.org/10.2172/1872181 Publication ID: 78753
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  • Mudrick, J., Sierra Suarez, J.A., Jordan, M., Friedmann, T.A., Jarecki, R., Henry, M., & Henry, M. (2019). Sub-10um Pitch Hybrid Direct Bond Interconnect Development for Die-to-Die Hybridization [Conference Poster]. https://www.osti.gov/biblio/1640140 Publication ID: 68735
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  • Branch, D., Christopher, D., Eichenfield, M., Douglas, J., Siddiqui, A., Friedmann, T.A., & Friedmann, T.A. (2018). Investigation of a Solid-State Tuning Behavior in Lithium Niobate [Conference Poster]. https://doi.org/10.1109/IMWS-AMP.2018.8457130 Publication ID: 63914
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  • Sava Gallis, D., Rohwer, L.E.S., Butler, K.S., Luk, T.S., & Luk, T.S. (2018). Biocompatible near-infrared MOF fluorophores for bio-imaging applications [Conference Poster]. https://www.osti.gov/biblio/1508454 Publication ID: 61207
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  • Grine, A., Siddiqui, A., Keeler, G.A., Shaw, M.J., Eichenfield, M., Friedmann, T.A., Douglas, E.A., Wood, M.G., Dagel, D.J., Hains, C., Koch, L.F., Nordquist, C.D., Serkland, D.K., & Serkland, D.K. (2017). Optomechanical spring effect readout in resonant micro-optical Sagnac gyroscopes design and scaling analysis [Conference Poster]. International Conference on Optical MEMS and Nanophotonics. https://www.scopus.com/inward/record.uri?partnerID=HzOxMe3b&scp=85035051957&origin=inward Publication ID: 56452
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  • Beechem, T., Biedermann, L., Friedmann, T.A., McCarty, K., Ohta, T., Pan, W., Ross III, A., Washburn, C.M., & Washburn, C.M. (2011). Enabling Graphene Nanoelectronics [Conference]. https://www.osti.gov/biblio/1120848 Publication ID: 21344
  • Howell, S., Beechem, T., Biedermann, L., Gutierrez, C., Friedmann, T.A., McCarty, K., Ohta, T., Pan, W., Ross III, A., & Ross III, A. (2011). Characterization and Comparison of Devices Fabricated From Epitaxial Graphene on SiC and Electrostatically Transferred Graphene [Conference]. https://www.osti.gov/biblio/1120859 Publication ID: 21404
  • Rohwer, L.E.S., Chu, D., Martin, J.E., & Martin, J.E. (2010). Chemical strategies for die/wafer submicron alignment and bonding. https://doi.org/10.2172/1008133 Publication ID: 19957
  • Rohwer, L.E.S. (2010). Impenetrable polymer composites for tin whisker mitigation [Conference]. https://www.osti.gov/biblio/1021568 Publication ID: 19312
  • Pan, W., Howell, S., Ohta, T., Friedmann, T.A., & Friedmann, T.A. (2010). Observation of the Integer Quantum Hall Effect in Record High-Mobility Uniform Wafer-Scale Epitaxial Graphene Films Grown on the Si-Face of 6H-SiC(0001). Applied Physics Letters. https://www.osti.gov/biblio/1141938 Publication ID: 17535
  • Rohwer, L.E.S. (2010). Tin Whisker Mitigation [Presentation]. https://www.osti.gov/biblio/1673496 Publication ID: 17643
  • Friedmann, T.A., Piekos, E.S., Sullivan, J., Peebles, D., & Peebles, D. (2010). Phonon engineering for nanostructures. https://doi.org/10.2172/984139 Publication ID: 17160
  • Lambert, T., Hernandez-Sanchez, B.A., Lu, P., Ambrosini, A., Friedmann, T.A., Boyle, T., & Boyle, T. (2009). Synthesis and Characterization of Titania-Graphene Nanocomposites [Conference]. https://doi.org/10.1021/jp905456f Publication ID: 16985
  • Rohwer, L.E.S., Wavrik, R., Witham, J., & Witham, J. (2009). Tin Whisker mitigation methods [Conference]. https://www.osti.gov/biblio/1278777 Publication ID: 16758
  • Friedmann, T.A. (2009). Growth and characterization of tetrahedral amorphous-carbon films (ta-C) by pulsed laser deposition [Conference]. https://www.osti.gov/biblio/1142039 Publication ID: 16817
  • Hernandez-Sanchez, B.A., Lu, P., Ambrosini, A., Friedmann, T.A., Boyle, T., & Boyle, T. (2009). Synthesis and Characterization of Titania-Graphene Nanocomposites. Journal of Physical Chemistry, C., 113(46). https://doi.org/10.1021/jp905456f Publication ID: 16455
  • Crawford, M., Rohwer, L.E.S., Koleske, D., Tsao, J., Armstrong, A., Wang, G., Fischer, A., Wierer, J., Coltrin, M.E., & Coltrin, M.E. (2009). Roadblocks to high efficiency solid-state lighting : [Conference]. https://www.osti.gov/biblio/1274740 Publication ID: 16242
  • Rodriguez, M.A., Nyman, M., Rohwer, L.E.S., & Rohwer, L.E.S. (2009). NEW LANTANUM TANTALATE PHASES INVESTIGATED BY HIGH TEMPERATURE XRD AND HIGH RESOLUTION POWDER DIFFRACTION [Conference]. https://www.osti.gov/biblio/1142431 Publication ID: 15894
  • Marchiondo, J., Rohwer, L.E.S., & Rohwer, L.E.S. (2008). Long Term Dormant Storage Experiment of COTS Components Under Field Conditions [Conference]. https://www.osti.gov/biblio/1142543 Publication ID: 15545
  • Dempsey, J., Rohwer, L.E.S., & Rohwer, L.E.S. (2008). Design Fabrication and Characterization of Embedded Resistor Heaters for Die Attach on a Multilayer Low Temperature Cofired Ceramic Package [Conference]. https://www.osti.gov/biblio/1145711 Publication ID: 13103
  • Friedmann, T.A., Sullivan, J., & Sullivan, J. (2008). Measuring stress gradients by etch-back in annealed diamond-like tetrahedral amorphous-carbon thin films. Proposed for publication in Thin Solid Films.. https://www.osti.gov/biblio/943951 Publication ID: 12423
  • Rohwer, L.E.S., Martin, J.E., & Martin, J.E. (2007). Rohwer and Martin Response to Comment on %22Measuring the absolute quantum efficiency of luminescent materials%22. Journal of Luminescence. https://www.osti.gov/biblio/1147177 Publication ID: 10903
  • Sullivan, J., Czaplewski, D., Friedmann, T.A., Modine, N., Wendt, J., & Wendt, J. (2007). Defect-related internal dissipation in mechanical resonators and the study of coupled mechanical systems. https://doi.org/10.2172/900851 Publication ID: 8622
  • Friedmann, T.A., Sullivan, J., & Sullivan, J. (2005). Measuring stress gradients by etch-back in annealed (ta-C) thin films [Conference]. https://www.osti.gov/biblio/886656 Publication ID: 6490
  • Espinosa, H.D., Peng, B., Moldovan, N., Friedmann, T.A., Xiao, X., Mancini, D.C., Auciello, O., Carlisle, J., Zorman, C.A., & Zorman, C.A. (2005). A comparison of mechanical properties of three MEMS materials – Silicon carbide, ultrananocrystalline diamond, and hydrogen-free tetrahedral amorphous carbon (Ta-C) [Conference]. 11th International Conference on Fracture 2005, ICF11. https://www.scopus.com/inward/record.uri?partnerID=HzOxMe3b&scp=84869810921&origin=inward Publication ID: 3224
  • Boyce, B., Buchheit, T., Friedmann, T.A., & Friedmann, T.A. (2005). Fracture Toughness Measurements of Amorphous Diamond Thin Films using Acoustic Emission-Sensing Nanoindentation [Conference]. https://www.osti.gov/biblio/1465841 Publication ID: 6297
  • Boyce, B., Buchheit, T., Friedmann, T.A., & Friedmann, T.A. (2005). Fracture Toughness Measurements of Amorphous Diamond Thin Films using Acoustic Emission-Sensing Nanoindentation [Conference]. https://www.osti.gov/biblio/1122176 Publication ID: 5572
  • Rohwer, L.E.S., Anderson, R.A., & Anderson, R.A. (2005). Strong intrinsic magnetic mixing in triaxial fields. Proposed for publication in Nature Materials.. https://www.osti.gov/biblio/972144 Publication ID: 5600
  • Sullivan, J., Friedmann, T.A., Wendt, J., & Wendt, J. (2005). Mechanical dissipation at elevated temperatures in tetrahedral amorphous carbon. Proposed for publication in Diamond and Related Materials. https://www.osti.gov/biblio/971811 Publication ID: 5114
  • Griffiths, S., Lu, W.-Y., Hekmaty, M.A., McLean, D., Yang, C., Friedmann, T.A., Losey, M., Hachman, J., Skala, D.M., Hunter, L., Yang, N., Boehme, D., Korellis, J., Aigeldinger, G., & Aigeldinger, G. (2005). An aluminum resist substrate for microfabrication by LIGA. https://doi.org/10.2172/923166 Publication ID: 5008
  • Friedmann, T.A., Boyce, B., Czaplewski, D., Dyck, C., Webster, J., Carton, A., Carr, D., Keeler, B., Wendt, J., Tallant, D., & Tallant, D. (2004). Nano-electromechanical oscillators (NEMOs) for RF technologies. https://doi.org/10.2172/920822 Publication ID: 4155
  • Boyce, B., Buchheit, T., Friedmann, T.A., & Friedmann, T.A. (2004). Fracture of amorphous diamond thin films using acoustic emission-sensing nanoindentation [Conference]. https://www.osti.gov/biblio/965484 Publication ID: 3914
  • Simmons, J., Fischer, A., Crawford, M., Abrams, B.L., Biefeld, R., Koleske, D., Allerman, A., Figiel, J., Creighton, J., Coltrin, M.E., Tsao, J., Mitchell, C., Kerley, T., Wang, G., Bogart, K., Seager, C., Campbell, J., Follstaedt, D., Norman, A., … Waldrip, K. (2004). Final report on grand challenge LDRD project : a revolution in lighting : building the science and technology base for ultra-efficient solid-state lighting. https://doi.org/10.2172/919202 Publication ID: 2982
  • Carr, D., Keeler, B., Sullivan, J., Friedmann, T.A., Wendt, J., & Wendt, J. (2003). Optical NEMS grating transducers [Conference]. https://www.osti.gov/biblio/1003894 Publication ID: 2516
  • Carr, D., Sullivan, J., Friedmann, T.A., & Friedmann, T.A. (2003). Laterally deformable nanomechanical zero order gratings : anomalous diffraction studied by rigorous coupled wave analysis. Proposed for publication in Optics Letters.. https://doi.org/10.1103/PhysRevLett.91.133902 Publication ID: 1876
  • Friedmann, T.A., Friedmann, T.A., Sullivan, J., & Sullivan, J. (2003). Amorphous Diamond In Vivo and In Vitro Evaluation. https://doi.org/10.2172/809621 Publication ID: 1890
  • Mitchell, R., Rohwer, L.E.S., Robinson, M., Kilgo, R., Mulhall, J., Fischer, T., & Fischer, T. (2002). New microsystem packaging capabilities at Sandia National Laboratories [Conference]. https://www.osti.gov/biblio/913214 Publication ID: 1649
  • Sullivan, J., Friedmann, T.A., Ashby, C., De Boer, M., Schubert, W., Shul, R., Hohlfelder, R.J., & Hohlfelder, R.J. (2002). Amorphous Diamond MEMS and Sensors. https://doi.org/10.2172/800990 Publication ID: 1496
  • Cox, T., Sasaki, D., Hunter, J., Jones, G.D., Sinclair, M.B., Rohwer, L.E.S., Pohl, P., Andrzejewski, W., Sasaki, D., & Sasaki, D. (2001). Autonomous Optical Sensor System for the Monitoring of Nitrogen Dioxide from Aging Rocket Propellant. https://doi.org/10.2172/787637 Publication ID: 1312
  • Rohwer, L.E.S. (2000). Cathodoluminescent display phosphors [Conference]. https://www.osti.gov/biblio/750228 Publication ID: 74
  • Rohwer, L.E.S., Rohwer, L.E.S., & Rohwer, L.E.S. (2000). Combustion synthesis and effects of processing parameters on physical properties of {alpha}-alumina. https://www.osti.gov/biblio/750186 Publication ID: 75
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June 7, 2023