Flip chip packaging rework

1. A process for reworking and recovering a die for a flip chip application, the process comprising:

providing the die comprising a plurality of under-bump metallurgy (UBM) stacks on a substrate, wherein each of the UBM stacks is in contact with a first bond pad and is formed in a trench to the first bond pad defined by a passivation layer and a polyimide layer, wherein each of the UBM stacks comprises a sputtered adhesion layer including a seed layer thereon, a plated conductive layer, and a barrier layer; and solder in direct contact with the UBM stacks, wherein an intermetallic forms at an interface between each of the UBM stacks and the solder;

applying a liquid etchant to selectively remove one layer at a time each of the solder, the barrier layer, the plated conductive layer, and the sputtered adhesion layer;

removing the polyimide layer;

depositing a nitride layer;

depositing and patterning a photosensitive polyimide layer to expose the first bond pad;

depositing and patterning a redistribution layer extending from the first bond pad to a second bond pad at a different location;

depositing and patterning a passivation layer to expose the second bond pad; and

forming a second UBM stack and a second solder ball thereon on the second bond.

2. The process of claim 1 , wherein the sputtered adhesion layer comprises a titanium-based metal; the seed layer comprises copper; the plated conductive layer comprises a copper-based metal; and the barrier layer comprises a nickel-based metal.

3. The process of claim 1 , wherein the solder is lead free.

4. The process of claim 3 , wherein applying the liquid etchant for removing the lead-free solder comprises spraying or immersing the solder in a solution comprising nitric acid.

5. The process of claim 1 , wherein the solder is lead-based.

6. The process of claim 5 , wherein applying the liquid etchant for removing the lead-based solder comprises spraying or immersing the solder in a solution comprising acetic acid and hydrogen peroxide.

7. The process of claim 2 , wherein applying the liquid etchant for removing the sputtered adhesion layer comprises spraying or immersing the adhesion layer in a halogen-free solution.

8. The process of claim 2 , wherein applying the liquid etchant for removing the plated conductive and the barrier layers comprises spraying or immersing the conductive and the barrier layers in a solution comprising nitric acid.

9. The process of claim 2 , wherein applying the liquid etchant for removing the intermetallic comprises spraying or immersing the intermetallic in a solution comprising a chloride-based or bromide-based nitric acid solution.

10. The process of claim 2 , wherein the titanium-based adhesion layer comprises titanium-tungsten composed of 5 at. % to 50 at. % titanium and 95 at. % to 50 at. % tungsten.

11. The process of claim 2 , wherein the plated copper-based conductor layer comprises copper within a range of 95 at. % to 100 at. %.

12. The process of claim 2 , wherein the nickel-based barrier layer comprises nickel within a range of 50 at. % to 100 at. % nickel (Ni).

13. A process for reworking and recovering a substrate for a flip chip application, the process comprising:

applying a liquid etchant to selectively remove solder from the substrate;

removing a solder mask and a copper short;

applying and patterning a solder mask;

curing the substrate;

exposing the solder mask to an oxygen plasma ash process to roughen a surface thereof, and

reapplying solder to the substrate.

14. The process of claim 13 , wherein the substrate comprises a ceramic packaging substrate or a laminate packaging substrate.

15. The process of claim 13 , wherein the solder mask comprises a photosensitive polyimide.

16. The process of claim 13 , wherein the solder comprises an under-bump metallurgy (UBM) stack and removing the solder comprises removing one layer of the UBM stack at a time.

17. The process of claim 13 , wherein the UBM stack comprises a sputtered titanium-based adhesive layer; a copper conducting seed layer; a plated copper-based conductive layers; and a nickel-based barrier layer.

18. A process for reworking and recovering a wafer for a flip chip application, the process comprising:

providing the wafer comprising a plurality of under-bump metallurgy (UBM) stacks, wherein each of the UBM stacks is in contact with a bond pad and is formed in a trench opening in a passivation layer and a polyimide layer to the bond pad, wherein each of the UBM stacks comprises a titanium-based adhesion layer, a copper-based conductive layer, a sputtered copper seed layer, and a nickel-based barrier layer; and a solder in direct contact with the UBM stacks, wherein an intermetallic forms at an interface between the UBM stacks and the solder;

applying a liquid etchant to selectively remove one layer at a time each of the solder, the nickel-based barrier layer, the copper-based conductive layer, the titanium based adhesion layer and the intermetallic;

oxygen plasma ashing the polyimide surface to increase surface roughness thereon;

sputter depositing a titanium adhesion layer and a copper based seed layer onto the bond pad and the polyimide;

applying, exposing, and developing a photoresist onto the titanium-based adhesion layer to form a pattern;

plating a copper-based conductor layer and a nickel-based barrier layers onto the exposed portion of the sputtered copper-based seed layer and titanium-based adhesion layers in the pattern; and

etching the copper-based conductor layer and the nickel-based barrier layer to reform the UBM stack.

19. The process of claim 18 , wherein applying the liquid etchant for removing the adhesion layer comprises spraying or immersing the adhesion layer in a halogen-free solution.

20. The process of claim 18 , wherein applying the liquid etchant for removing the conductive and the barrier layers comprises spraying or immersing the copper-based conductive layer and the nickel-based barrier layers in a solution comprising nitric acid.