Bonding stress and reliability of high power GaAs-based lasers

GaAs-based lasers were bonded to oxygen-free high-conductivity (OFHC) copper heat sinks using a eutectic PbSn solder or a silver-filled conductive epoxy, and life tested. Epoxy-bonded devices were observed to have a larger failure rate on life test than solder-bonded devices. Bonding stress, as measured by the degree of polarization (DOP) of photoluminescence, was found to be the largest in epoxy-bonded devices. As well, the type of heat sink and bonding adhesive affected the stress in the laser material, with bonding stress increasing when there was a larger mismatch of coefficients of thermal expansion between the laser material, adhesive, and heat sink. Results suggested that heat sink material and bonding adhesive contribute to stress within the laser material and the resulting performance of the device.