THICK-FILM RESISTORS WITH LOW AND HIGH TCRS ON LTCC SUBSTRATES Marko Hrovat\ Darko Belavič^, Jaroslaw Kita^, Janez Holc\ Jena Cilenšek^ Leszek Golonka^, Andrzej Dziedzic^ ^ Jožef Stefan Institute, Ljubljana, Slovenia ^HIPOT-R&D, d.o.o., Šentjernej, Slovenia ^Wroclaw University of Technology, Wroclaw, Poland Key words: thick-film, resistors, NTC, LTCC, interactions, electrical parameters Abstract: Low-Temperature Co-fired Ceramic (LTCC) materials, which are sintered at the low temperatures typically used for thick-film processing, i.e., around 850°C, are widely used for ceramic multi-chip modules (MCM-C). Thick-film resistors with lowTCRs(Du Pont, 2041, nominal sheet resistivity 10 kohm/sq.) and thick-film NTC thermistors with high negative TCRs (EMCA-Remex, 4993, nominal resistivity 1 kohm/sq.) which were developed for alumina substrates, were evaluated on glassy LTCC substrates. The electrical and microstrutural characteristics of films fired on alumina or co-fired on "green" LTCC substrates were compared. The electrical characteristics (TCRs, sheet resistivities and noise indices) of 2041 resistors fired on both substrates are similar indicating that the resistors are compatible with the LTCC material. In the case of the NTC 4993 thermistors the resistivities, beta factors and noise indices of the thermistors fired on LTCC substrates significantly increased, indicating the interactions between the thermistor layers and the LTCC substrates. The changes in the electrical parameters were attributed to the diffusion of a silica-rich phase from the LTCC into the thermistor films. Debeloplastni upori z nizkimi in visokimi odvisnostmi upornosti od temperature na LTCC substratih Kjučne besede: debeli filmi, upori, NTC, LTCC, interakcije, električne karakteristike Izvleček: Keramika z nizko temperature žganja (LTCC - Low temperature co-fired ceramics) se sintra pri temperaturah, tipičnih za debeloplastno tehnologijo, to je okrog 850°C. Uporablja se za izdelavo keramičnih večplastnih struktur (MCM-C), Debeloplastni upori z nizkimi TCR (Du Pont, 2041) in debeloplastni NTC termistorji (EMCA Remex, 4993), ki so bili razviti za žganje na inertnih AI2O3 substratih, so bili testirani na steklastih LTCC podlagah. Primerjane so električne in mikrostrukturne karakteristike plasti, žganih na AI2O3 in LTCC podlagah. Električne karakteristike (plastne upornosti, TCR in šum) 2041 uporov, žganih na obeh vrstah podlag, so primerljivi, kar pomeni, da so testirani upori kompatibilni z reaktivnimi LTCC podlagami. Za NTC 4993 termistorje so rezultati pokazali, da upornosti, beta faktorji (strmina odvisnosti upornosti od temperature) in šum narastejo po žganju na LTCC podlagah. Spremembe električnih karakteristik pripisujemo predvsem difuziji SiO? bogate steklaste faze med žganjem iz LTCC v NTC upore. Introduction Ceramic multi-chip modules (MCM-Cs) are multilayer substrates with buried conductor lines, which means they have a high density of interconnections. An additional advantage of the smaller size and higher density is the ability to integrate screen-printed resistors, or occasionally, capacitors and inductors. These screen-printed components can be placed either beneath the discrete components on the surface of the multilayer dielectric or buried within the multilayer structure. Low-temperature co-fired ceramic (LTCC) materials, which are sintered at the low temperatures typically used for thick-film processing, i.e., around 850°C, are widely used for the production of MCM-Cs, especially for telecommunications and automotive applications. LTCCs are either based on crystallisable glass or a mixture of glass and ceramics; for example, alumina, silica or cordierlte (Mg2Al4Sl50i8) /1-6/. The composition of the inorganic phase in most LTCC tapes is similar to, or the same as, materials in thick-film multilayer dielectric pastes. To sinter to a dense and non-porous structure at these, rather low, temperatures, it has to contain some low-melting-point glass phase. This glass would (or could) presumably interact with, for example, thick-film resistors leading to changes in the electrical characteristics. Some of the results for the resistor/LTCC combinations and the influences on the electrical characteristics can be found in /7-10/. The main required characteristics for thick-film resistor materials are a long-term stability and relatively narrow tolerances of the sheet resistivities after firing. A very important characteristic is a low temperature coefficient of resistivity (TCR), which for most modern resistors is around or under 100x10"®/K. However, for temperature-sensing or temperature compensating applications the resistors with a large temperature dependence of resistivity - thermistors-are required. The thermistors with negative TCRs have very large and strongly non-linear temperature vs. resistivity dependence. The dependence of the specific resistance pvs. temperature is described by: p = po X exp(B/T) (i; where po is the resistivity (ohm.cm) at "infinite" temperature, T(K) is the temperature and B (K) is the thermistor constant (also called the beta factor or the coefficient of temperature sensitivity). Resistivity at "infinite" temperature is determined by the total number of "B" lattice sites in a spinel structure that can take part in the "hopping" conductivity process (there is no contribution to the overall conductivity if ions with different valences are on the A sites because the distance between the two A sites in a spinel lattice is too great for an electron "hopping" mechanism). The B is defined as the ratio between the activation energy for electrical conduction and the Boltzman constant. Basically it is a "steepness" of the resistivity vs. temperature curve. For the calculation of B from measured resistances at different temperatures the equation (1) is normally rewritten as Co R mill / ,--0 '-'i - \ 1 T V / / \ \ . £ / I ■ / / \ '/ \ ! ...... B = ln(Ri/R2)/(1/Ti-1/T2) (2) where T(K) is again the temperature and Ri and R2 (ohm) are the resistances atTi and T2, respectively. These materials with large, negative TCRs (NTC) are based on solid solutions of transition-metal oxides. Mostly, due to their long-term stability, the compounds are solid solutions of Mn304, C03O4 and NiO oxides with the spinel structure /11-13/. The general formula of the spinel structure is AB2O4. It is based on oxygen atoms arranged in an fee (face-centred-cubic) structure containing tetrahedral (A) and octahedral (B) lattice sites. The electrical charge transport is via the hopping of electrons between the B^"" and B'*"' ions present at the octahedral sites in the lattice. This is shown schematically in Fig. 1 forthe NiO-doped Mn304. The spinel Mn304 (Mn 2Mn O4) is non-conducting. When some of the manganese 3+ ions are substituted by the nickel 2+ ions the same number of manganese ions change their valence from 3+ to 4+ in order to preserve the overall electrical neutrality. Electron hopping between the Mn^"" and the Mn''^ can take place. The values of the resistivities and the beta factors of the NTC materials depend on the ratio of the oxides. The resistivities range from a few hundred ohm.cm to a few tens of kohm.cm, and the beta factors from 2500 K to 4000 K. These electrical characteristics are shown in the ternary phase diagram of Mn-Co-Ni-oxides forthe resistivities (Fig. 2.a) and the beta factors (Fig. 2.b) /13/. The compositions with minimum resistivities, and maximum and mini- Conductivity " electron "hopping" "A" sites "B" sites Mn2+ O4 - non-conducting xNP+ xMn''+(2-x)Mn3+ O4 - conducting Mn"-*- + e- —-.......-> Mn3+ Fig. 1. Conductivity mechanism in NiO-doped Mn304 spinei - schematic Fig. 2. a: Ternary phase diagram of Mn-Co-Ni-oxides. The minimum resistivity is indicated by the arrow/13/ B max B iiiin rfS (no^Kj Co Fig. 2.b: Ternary phase diagram of Mn-Co-Ni-oxides. The maximum and minimum beta factors are indicated by the arrows/13/ mum beta factors are indicated by arrows. The solid solutions with the lowest resistivities (rich on manganese oxide) also have the lowest temperature coefficients of expansion, i.e. 8.2 x 10'®/K. A partial substitution of the iron ions (3+) on the B sites or the copper ions (1 +) on the A sites increases or decreases the resitivities, respectively /14-17/. The fired thickness of the thick-film layers is usually between ten and twenty micrometers. As mentioned before, the resistivities of the different spinel compositions are between a few hundred ohm.em and a few tens of kohm.cm, and can be increased up to 1 Mohm.cm with the partial substitution of manganese ions with iron ions. These are useful values for pellet-type components. How- ever, due to the dimensions of the thick-film resistors the values of the sheet resistivities (ohm/sq.) are between two and three orders of magnitude higher than the resistivities (ohm.cm) of the materials themselves. The glass phase, which is added for better sintering of the thick-film layers at relatively low firing temperatures (850°C), further increases the resistivity. Therefore, materials for thick-film NTC resistors usually include some phase with a low specific resistance, generally RUO2. RuOa has a relatively low specific resistivity, 40 x 10"®ohm.cm, and a positive, linear, metallic-like dependence of resistivity vs. temperature, with a TCR of 7000x10"®/K for single crystals and a few 1000x10'®/K for sintered microcrystalline samples /18,19/. The addition of ruthenium oxide decreases the specific resistance, reduces the noise and improves the stability of the resistors. However, due to the RuOg high, positive and linear metallic-like TCR /14,20/ it also decreases the beta factors. As most of the thick-film resistors were developed for firing on alumina substrates their compatibility with (rather glassy) LTCC substrates needs to be evaluated. The aim of this work is to compare the electrical and microstrutural characteristics of the low TCR "normal" thick-film resistor 2041 (10 kohm/sq., Du Pont) and the 4993 NTC thermistor (1 kohm/sq., EMCA Remex) fired on 96% alumina and co-fired on Du Pont LTCC 951 substrates. The 2041 resistor was chosen because of its high stability and low noise. The conductive phase is based on a mixture of RUO2 and PbaRuaOe.s /21,22/. The nominal beta factor of NTC 4993 thermistors is 1200 K. As mentioned above, both thick-film materials were developed for alumina substrates. The X-ray spectra of the Du Pont LTCC 951 tapes, unfired and fired at 850°C, are shown in Fig. 3 /23/. The unfired material is a mixture of alumina and glass. After firing, peaks of anorthite ((Na,Ca)(AI,Si)408) phase appear. The peaks of alumina and anorthite are denoted by "A" and asterisk, respectively. Experimental The 2041 resistors and NTC 4993 thermistors were screen printed and fired for 10 min at 850°C on 96% alumina and on green LTCC (951, Du Pont) substrates. The LTCC substrates were made by laminating three layers of LTCC tape at 70°C and at a pressure of 200 bar. The thick-film resistors were terminated by Pd/Ag electrodes that were pre-fired at 850°C on alumina substrates, and cofired together with the printed thermistors and LTCC substrates. The dimensions of the resistors for the microstructural analysis and the X-ray diffraction (XRD) analysis, which were printed and fired without conductor terminations, were 12.5x12.5 mm^. For the microstructural investigation the samples were mounted in epoxy in a cross-sectional orientation and then cut and polished using standard metallographic techniques. A JEOL JSM 5800 scanning electron microscope (SEM) equipped with an energy-dispersive X-ray analyser (EDS) was used for the overall microstructural and compositional analysis. Note that boron oxide, which is also present in the glass phase, cannot be detected in the EDS spectra because of the low relative boron weight fraction in the glass and the strong absorption of the boron K« line during EDS analysis in the glass matrix. Dried thermistors (150°C) and thermistors fired at 850°C were analysed by X-ray diffraction (XRD) analysis with a Philips PW 1710 X-ray dif-fractometer using Cu K», radiation. X-ray spectra were measured from 2 9=20° to 2 6=70° in steps of 0.02°. Cold (from -25°C to 25°C) and hot (from 25°C to 125°C) TCRs were calculated from resistivity measurements at - 25°C, 25°C, and 125°C. The current noise was measured in dB on 100-mW loaded resistors using the Quan Tech method (Quan Tech Model 315-C). Results and discussion 160 ■ 140 ; — 120 ,850 deg.C ■J 100 ^ A ; LTCC Du Pont 951 60 tü ^^ I Green tape ■viLvw^ L^Jiil 40 45 50 2theta (dag.) Fig. 3: X-ray spectra of green and fired (850°C) Du Pont LTCC 951 tapes/16/. Thepeal , i j Ru02 40 45 50 2 theta (deg.) 65 70 Fig. 8: The X-ray diffraction spectra of the NTC 4993 thermistors fired at 850°C on aiumina and on LTCC substrates. The spectrum of ruthenate, denoted "Ru02", is aiso inciuded. Peal