Cost-effective lead-free solder alloy for electronic applications

Abstract

A lead-free silver-free solder alloy may comprise tin, copper, bismuth, cobalt, and antimony. Alternatively, the alloy may comprise gallium in lieu of cobalt. The alloy may further comprise nickel, germanium, or both. The copper may be present in an amount from about 0.5% to 0.9% by weight of the solder. The bismuth may be present in an amount from about 1.0% to about 3.5% by weight of the solder. The cobalt may be present in an amount from about 0.02% to about 0.08% by weight of the solder. Where gallium is used in lieu of cobalt, the gallium may be present in an amount from about 0.2% to about 0.8% by weight of the solder. The antimony may be present in an amount between about 0.0% to about 0.09% by weight of the solder. The balance of the solder is tin.

1 - 20 . (canceled) 
     
     
         21 . A lead-free, silver-free solder alloy consisting of:
 0.5 to 0.9 wt% copper;   1.0 to 3.5 wt% bismuth;   0.02 to 0.08 wt% cobalt;   0.02 to 0.09 wt% antimony;   0.01 to 0.2 wt% nickel;   optionally 0.001 to 0.01 wt% germanium; and   balance tin, together with any unavoidable impurities.   
     
     
         22 . The lead-free, silver-free solder alloy of  claim 21  consisting of:
 0.5 to 0.9 wt% copper; 
 1.0 to 3.5 wt% bismuth; 
 0.02 to 0.08 wt% cobalt; 
 0.02 to 0.09 wt% antimony; 
 0.01 to 0.2 wt% nickel; and 
 balance tin, together with any unavoidable impurities. 
 
     
     
         23 . The lead-free, silver-free solder alloy of  claim 21  consisting of:
 0.5 to 0.9 wt% copper; 
 1.0 to 3.5 wt% bismuth; 
 0.02 to 0.08 wt% cobalt; 
 0.02 to 0.09 wt% antimony; 
 0.001 to 0.01 wt% germanium; 
 0.01 to 0.2 wt% nickel; and 
 balance tin, together with any unavoidable impurities. 
 
     
     
         24 . The lead-free, silver-free alloy of  claim 21 , wherein:
 the copper is present at a concentration of about 0.7 wt%;   the bismuth is present at a concentration of about 1.5 wt%;   the cobalt is present at a concentration of about 0.04 wt% or about 0.05 wt%; or   the antimony is present at a concentration of about 0.05 wt%.   
     
     
         25 . The lead-free, silver-free alloy of  claim 21 , wherein:
 the copper is present at a concentration of about 0.7 wt%;   the bismuth is present at a concentration of about 1.5 wt%;   the cobalt is present at a concentration of about 0.04 wt% or about 0.05 wt%; and   the antimony is present at a concentration of about 0.05 wt%.   
     
     
         26 . The lead-free, silver-free alloy of  claim 21 , wherein germanium is present at a concentration of about 0.006 wt% and/or the nickel is present at a concentration of about 0.05 wt%.