Large-Scale Sonochemical Synthesis of Bi-Sn Eutectic Alloy Nanoparticles

Abstract

Lead-free Bi-Sn alloy is an alternative solder material with a low eutectic melting temperature and environmental compatibility. Although extensive research has been conducted on this Bi-Sn eutectic alloy, a lack of facile synthetic methods with scalability hinders the implementation of fine-patterned interconnectors for emerging electronic applications. In this study, we employed a facile sonochemical synthetic method to synthesize Bi-Sn alloy nanoparticles in large quantities. High-energy ultrasonication treatment of Bi-Sn bimetallic particles resulted in nanoparticle formation with repeated formation, growth, and collapse of induced gas bubbles. The size of the nanoparticles was controlled from 92 to 506 nm of the mean diameter with variations in ultrasonication power and irradiation time. The nanoparticles exhibited a stable eutectic melting point at 139.8 degrees C. Interestingly, the sonochemically synthesized nanoparticles exhibited coexistence of metastable Bi2Sn and stable Bi-Sn phases. Finally, we demonstrated that Bi-Sn eutectic nanoparticles could be synthesized at a gram scale of approximately 1.7 g for future mass production.