Nordson DAGE4000 Bond Tensile Tester

Nordson DAGE4000 Bond Tensile Tester
Introduction: Industry benchmark platform for bonding testing

In the field of semiconductor packaging and electronic assembly manufacturing, bond strength testing is a key link to ensure product quality and reliability. The Nuoxin DAGE 4000 push-pull force testing machine, with its modular design, excellent repeatability accuracy, and comprehensive calibration system, has become an industry benchmark platform for traditional and emerging packaging applications. For process engineers, quality control personnel, and equipment maintenance experts, a deep understanding of the calibration logic, operational optimization methods, and diverse testing applications of the platform not only helps to improve production line yield, but also effectively extends equipment service life and reduces the risk of misjudgment caused by testing errors.

This article will systematically explain the efficient usage path of the Noxin DAGE 4000 from six dimensions: ergonomic design, software configuration strategy, intelligent load sensor system, precision calibration process, core testing application methods, and technical specification compliance. Whether you are new to this device or looking to further explore its potential features, the following content can serve as a practical guide for daily operation and fault prediction.

Ergonomic design and fatigue avoidance during operation

Electronic packaging testing often requires operators to repeatedly perform subtle actions for a long time, which can easily induce repetitive strain injuries. At the beginning of its design, the Noxin DAGE 4000 incorporated operator health as a core consideration, significantly reducing body load through multiple adjustable mechanical structures.

2.1 Adjustable working height and line of sight angle

The device body supports infinite height adjustment of the workbench, and operators of different heights can keep their forearms level with the workbench to avoid continuous shoulder and neck tension. The viewing angle of the microscope eyepiece also supports independent adjustment, coupled with a soft arm support that can move forward and backward, allowing the operator to maintain a natural sitting posture when performing wire pull or ball sheet, without excessive wrist bending.

2.2 Dual Hand Adaptation Console

The joystick control unit provides three modes of operation: left hand, right hand, and simultaneous operation with both hands. Users can quickly switch according to their personal habits. The functions of joystick buttons (such as start testing, zero return, step movement) can also be remapped through software to avoid finger muscle fatigue caused by fixed button positions. For left-handed operators, the system supports fully mirroring XY movement control to the left joystick without the need for re adaptation.

2.3 Cloud synchronization of operator configuration files

Advanced software embedded operator configuration manager, which can store the following personalized parameters:

Operator name and permission level

Preferred joystick hand and button mapping scheme

Microscope multi position preset (such as objective height and light source intensity for different packaging types)

Quick call list for commonly used testing programs

The above configuration can be exported to the local network or USB storage. When the operator transfers to another device of the same model, all operating habits can be restored with just one click of import, achieving a "zero learning curve" deployment across machines. This feature is particularly useful for production lines with multiple 4000 models - shift change or on duty personnel do not need to be reset and can directly enter an efficient working state.

Intelligent Load Sensor System: Reliability Assurance from Hardware to Data

One of the core innovations of the Norsen DAGE 4000 is its Quick Release Intelligent Load Cartridge. This system not only simplifies the process of testing range switching, but also achieves full lifecycle management of sensors through embedded electronic components.

3.1 Mechanical Structure: Tool free Replacement and Onboard Storage

The replacement of sensors in traditional push-pull force testing machines usually requires the use of a screwdriver to disassemble, reconnect cables, and perform tedious zero calibration. The 4000 sensor adopts a self-locking quick release interface, and the sensor can be removed from the Z-axis drive end by pulling the release ring. When installing a new sensor, simply align it with the guide slot and push it in until it makes a "click" sound, the entire process should not exceed 30 seconds.

There are two dedicated sensor storage slots on the right side of the body, which can temporarily store unused sensors. The storage slot is equipped with a protective cover, and when the sensor is removed, its probe cover automatically pops up to prevent the precision strain gauge or probe from accidental collision. This design makes multi range alternating testing (such as conducting a 10kg pull-out force test first, followed by a 250g ball shear test) extremely smooth.

3.2 Intelligent electronic features: One sensor with multiple ranges

Each load sensor stores the following calibration data internally:

Unique serial number and production date

Last five calibration records (including date, ambient temperature, pass/fail status)

Linearity correction coefficient (multi-point nonlinear compensation algorithm)

Overload history alarm flag

After the device is powered on, the host will automatically read the sensor parameters and verify whether they are within the valid calibration cycle. If the sensor is detected to exceed the calibration tolerance zone (such as strain gauge drift exceeding 0.01% due to long-term use), the system will issue a clear alarm and prevent the test from being executed, thus eliminating the generation of invalid data from the source.

The most noteworthy thing is that a single sensor can software select up to 10 different range options. By default, the factory provides four measurement ranges (such as 0-250g, 0-500g, 0-1kg, 0-5kg), and users can apply to unlock the other six customized measurement ranges (such as 0-100g for testing extremely fine gold wires). Range switching does not require hardware replacement, only the required full-scale value needs to be specified in the testing program, and the DSP chip inside the sensor automatically matches the corresponding amplification factor and filtering parameters. The minimum selectable range is as low as 5% of the full range deflection. For example, for a 10kg sensor, high-resolution measurement of 500g full range can be achieved, avoiding the additional cost of purchasing a low range sensor separately for small force values.

3.3 Friction free system and low force detection

All sensors adopt Noxin DAGE's patented frictionless bearing structure, eliminating the hysteresis and dead zone caused by traditional sliding components. In force testing below 10g (such as fine pitch gold ball shearing), the frictionless design ensures a smooth and non step like force rise curve, with repeatability better than ± 0.5g. This feature is crucial for micro solder joint testing in MEMS sensors or optoelectronic devices.

3.4 Quick release hook system

For wire testing, a quick change hook can be installed at the front end of the sensor. The hook is fixed by magnetic suction and card slot, and can be easily replaced with tools of different diameters (such as 50 μ m, 100 μ m, 200 μ m) or shapes (straight hook, curved hook, shovel shape) by pulling and inserting with bare hands. The "automatic hook finding" function provided by the system: In the microscope field of view, the operator only needs to click the mouse near the welding line, and the Z-axis will automatically drive the hook to move to the preset safe approach height, and then slowly descend until the hook accurately hooks the top of the wire arc. The entire process does not require manual adjustment, significantly improving the throughput of large-scale testing.

Comprehensive calibration mechanism: from mechanical plane to load link

Calibration is the cornerstone of ensuring the validity of test data. The Norsen DAGE 4000 provides an automated calibration system that spans the entire chain of XY plane, Z-axis depth, and load sensors, and all processes comply with ISO 9001:2008 and UKAS traceability requirements.

4.1 Test plane calibration (XY plane)

Using the randomly attached optical cross calibration plate (glass substrate, line width 2 μ m, position accuracy ± 0.5 μ m), perform the following steps:

Fix the calibration board on the workbench and adjust it to a horizontal position.

Run the "Plane Calibration" wizard, and the device will automatically move to nine feature points at the four corners and center of the calibration board.

The software calculates the deviation between the actual coordinates and theoretical coordinates of each point through image recognition algorithms, and generates a nonlinear correction mapping table.

After calibration, the absolute positioning accuracy of the system at any position within the full stroke (220mm × 220mm) is better than ± 10 μ m, and the repeated positioning accuracy is ± 5 μ m. For the precision XY platform option with a stroke of 50mm, the accuracy can be further improved to ± 3 μ m.

This calibration is recommended to be performed every six months or supplemented when the ambient temperature changes by more than 5 ℃.

4.2 Z-axis vertical accuracy calibration

The Z-axis stroke is 65mm, with a positioning accuracy of ± 10 μ m throughout the entire stroke range, and within the most critical 2mm test window (i.e. the height range from near the needle tip to the contact solder joint), the accuracy can reach ± 2 μ m. For shear testing, when using a 250g shear sensor to step down from a height of 25 μ m, the total step back to zero accuracy reached an astonishing ± 1 μ m (verified by a laser interferometer).

Z-axis calibration uses laser displacement sensors or specialized height gauges. The equipment provides a semi-automatic process: the operator places the standard block on the workbench, and the Z-axis descends at low speed until the measuring needle touches the surface of the block. The system records the reading of the grating ruler at this time. Repeat five times and take the average as the zero point. Then the Z-axis rises to different heights (such as 10mm, 20mm, 50mm), touches the standard block again, and calculates the linearity of the grating ruler. If the deviation exceeds the threshold, the software prompts to adjust the encoder compensation coefficient.

4.3 Self calibration and linearity verification of load sensors

The Noxin DAGE 4000 supports two calibration modes:

Mode 1: Traceability calibration using standard weights

The operator selects the sensor to be calibrated and installs a dedicated hook on the force measuring end.

Load certified standard weights in order (e.g. 2g, 5g, 10g, 20g, 50g, accuracy level F1 or above).

The software records the output code value corresponding to each weight and automatically fits a polynomial calibration curve with the highest order up to 7 degrees.

Calibration information is directly written into the internal EEPROM of the sensor, and a printed report with a UKAS traceability statement can be generated.

Mode 2: Quick verification without weights

For daily inspections, users can choose the "electronic calibration" function. The system injects known equivalent electrical signals into the sensor bridge through a built-in precision resistor network to simulate standard force input.

This mode can quickly verify the linearity of the sensor within 30 seconds and determine whether it is still within the tolerance range. Although it cannot replace the legal traceability of weight calibration, it is sufficient for daily functional confirmation before class starts.

4.4 Calibration Fixtures and GR&R Identification

For customers who require Measurement System Analysis (MSA), Norsen DAGE provides a dedicated calibration fixture kit. This fixture contains multiple metal blocks with fixed geometric dimensions (such as 1mm high solder balls, 0.5mm long gold wires, etc.), which can be repeatedly installed at the same position on the XY worktable. By continuously measuring the same standard part more than 20 times and using the built-in GR&R calculation template, the repeatability and reproducibility of the equipment can be quickly calculated. Typical results show that the% GR&R of the 4000 system is typically below 10%, meeting the stringent requirements of automotive electronics (IATF 16949) and medical equipment manufacturing.

Detailed explanation of core testing applications

Based on the precise mechanical and control foundation mentioned above, the Norsen DAGE 4000 is capable of performing various industry standard tests. The following are four typical application scenarios and their key parameter settings.

5.1 Cold ball drawing

Applicable objects: Lead free solder balls in chip level packaging (CSP) or ball grid array (BGA), especially when there is bottom filling glue below the solder balls, conventional ball pushing can easily cause premature cracking of the glue layer, while cold ball pulling can directly evaluate the bonding strength between the solder balls and copper pads from the vertical direction.

Operation process:

Select a dedicated "hook and loop style claw" with slight serrations on the inside, which can firmly bite the upper hemisphere of the solder ball.

Set the drawing speed to 2mm/s (to avoid brittle fracture caused by impact load).

The maximum pulling force can reach 10kg (requires the use of a 10kg sensor).

After the test is completed, the fracture modes are usually divided into: ductile fracture inside the solder ball (qualified), IMC layer brittle fracture (requiring optimization of reflow curve), and copper pad peeling (PCB quality issue).

Compliant with standards: JETTA EIAJ ET-7407 and JEDEC JESD22-B115A.

5.2 Chamber Shear

Applicable object: Convex points in ultra-thin chips or inverted chips. Due to the extremely small spacing between adjacent convex points (<100 μ m), traditional flat cutting knives are prone to deformation and short circuiting of adjacent convex points.

Technical characteristics:

Use a V-shaped or U-shaped section shear blade, only in contact with the top area of the solder ball, with the blade tip extending between adjacent rows of solder balls.

Set the cutting height to 30%~40% of the original height of the solder ball to avoid the blade crushing the sphere.

The recommended shear speed is 1mm/s, which makes it easier to capture the maximum shear force.

The cavity shear can provide the maximum possible shear force value without damaging the surrounding structure, especially suitable for fan out wafer level packaging.

5.3 Vector Pulling

Application scenario: External pins (such as TQFP, LQFP) in lead frame packaging, which may experience interface delamination after bending testing or thermal cycling. Traditional vertical drawing cannot simulate the actual direction of force.

Implementation method:

The equipment is equipped with a rotatable pulling module, and the pulling hook can apply tension at any angle of 0 °~90 ° in the XZ plane.

The operator first selects the edge of the target pin under the microscope, and then sets the pulling direction (for example, at a 45 ° angle to the extension direction of the pin).

The Z-axis drives the hook to move along the set vector while recording the force displacement curve.

Vector drawing can effectively expose the bonding defects between the lead and the plastic package, and is commonly used in failure analysis laboratories.

5.4 Regional cutting

Background: In advanced BGA or CSP packaging, solder balls are arranged in multiple rows and high-density arrays (such as 0.35mm pitch, 10 rows x 10 columns). The traditional method requires ball by ball cutting, which is extremely inefficient.

Region cutting principle:

Equipped with a wide blade cutting knife (the width can cover the entire row of solder balls, for example, 5mm width covers 15 0.35mm solder balls).

Set the cutting height to 50% of the original height of the solder ball and advance horizontally at a constant speed (usually 0.5mm/s).

The sensor records the total force value during the entire shearing process and divides it by the number of solder balls to obtain the average single ball shear force.

This test can quickly screen for batch consistency, especially suitable for sampling inspection on production lines.

Compliant with standards: All the above tests meet the requirements JEDEC JESD22-B117A（BGA bump shear）、MIL STD 883（die shear, wire pull, stud pull） And ASTM F1269 (ball bond sheet).

Summary of Technical Specifications and Compliance

For the convenience of engineers to quickly evaluate whether the equipment meets their own process requirements, the following are the core technical parameters and compliance certifications of the Noxin DAGE 4000.

6.1 Mechanical System Specifications

Parameter indicators

Dimensions (width x depth x height, including joystick and forearm support) 425mm x 730mm x 670mm

Equipment weight 45kg

XY worktable stroke 220mm (X) × 220mm (Y)

The maximum Y-axis thrust of the workbench is 100kg (standard), with an optional 200kg; the maximum X-axis thrust is 5kg

Z-axis travel 65mm

Z-axis maximum test speed 5mm/s

Z-axis maximum tension/thrust 10kg (5mm/s in tension mode)

Total system accuracy ± 0.25% full-scale deflection (selected load range)

Maximum load sensor accuracy/repeatability 0.01% (100ppm), certified by UKAS

The overall ball shear Z positioning accuracy is ± 1 μ m (laser verification)

6.2 Requirements for Power and Gas Sources

Power supply: 100/110V or 220/240V AC, 50/60Hz switchable.

Air source (for automatic workbench or clamping): 4 bar clean and dry air, plastic tube outer diameter 6mm/inner diameter 4mm.

Vacuum source (for workpiece adsorption): minimum 500mm Hg.

6.3 Compliance with International Standards

Equipment manufacturing strictly follows:

ISO 9001:2008 Quality System

European CE directives: EMC Directive (2004/108/EC), Low Voltage Directive (2006/95/EC), Machinery Safety Directive (2006/42/EC)

RoHS (2002/95/EC) Hazardous Substance Restrictions

Simultaneously meet the following industry testing standards:

Cold ball drawing: JEDEC JESD22-B115A, EIAJ ET-7407

BGA bump cutting: JEDEC JESD22-B117A

Golden ball cutting: ASTM F1269

Gold wire drawing: MIL STD 883 (destructive and non-destructive)

Chip cutting: MIL STD 883

Column pulling: MIL STD 883

Inverted chip drawing: JEDEC JESD22-B109

Daily Maintenance and Best Practices

To maintain the above accuracy in the long term, it is recommended to establish the following maintenance system:

7.1 Daily Inspection Items

Visually inspect whether the sensor probe is bent or adhered to foreign objects.

Perform an electronic calibration without weights to confirm that the zero drift of the sensor does not exceed ± 0.1% of the full range.

Clean the surface of the workbench and vacuum holes to prevent blockage by solder ball fragments.

7.2 Weekly maintenance

Clean the microscope objective and circular light source with neutral cleaner and non-woven fabric.

Test the repeatability of standard calibration fixtures (such as 1mm steel balls) and record the range of three measurements.

7.3 Quarterly Maintenance

Perform a complete weight calibration and update the sensor compensation coefficient.

Check the condition of the XY guide rail grease, and replace it with a special low volatility grease if it has hardened.

Verify the emergency stop button and safety light curtain function.

7.4 Annual Maintenance

Invite authorized service engineers to conduct a geometric accuracy re inspection of the entire machine, including XY perpendicularity, Z-axis perpendicularity to the workbench plane.

Replace all pneumatic pipeline filters.

Upgrade the device firmware to the latest version and obtain optimized calibration algorithms.