Rework Procedures for Stress-Free Epoxy and Thermoplastic Adhesives

AIT’S flexible die attach, component attach and substrate attach adhesives have a dramatic advantage over the more traditional epoxy attached devices. They can be reworked readily with the application of stress concentration with twisting or torque.

Rework of Epoxy and Thermoplastic Adhesive Joints are Primarily Mechanical in Nature

Both epoxy and thermoplastic adhesive bonding can be strong and tough to break. Because of the flexibility built into the polymer network, AIT adhesives tend to be easier to rework at elevated temperature. In some cases, the epoxy network may be swollen with suitable solvent for easier removal. Most of the thermoplastic adhesives may be dissolved or softened with suitable solvent for easier removal and cleaning.

Bond and adhesive materials are easier to break when stresses are concentrated to exceed its tensile or shear strength (Figure 1). Thus torque and peel stresses initiated at corners or some localized points will require much less force and thus easier to perform.

Figure 1. Reworking Procedure with Heat and Stress Concentration


Method 1:

  1. Heat the bonding area to 80°C-150°C. Heat locally if other components are sensitive to heat.
  2. Rework should be done using tool that can hold onto the die/component and be able to apply 10 foot-pound of torque. The tool should be able to tilt or twist the component/die, providing a stress concentration up to 500 psi to provide the necessary stress for debonding. Avoid applying stress directly upward if the die or component is sizable (Remember 1 square inch of bonded area will require 100-500 pounds!)
  3. Remove component/die with tool and stress concentration.
  4. Apply RS 816 solution on the adhesive residue with suitable tool. Make sure the solution is applied to the residue only. Allow solution to soak and work for 20 minutes or more. Multiple applications of RS 816 can be used if desired. Soaking can be done at room temperature. Remove adhesive residue with a tough nylon brush or equivalent non-abrasive tool.
  5. Apply new adhesive and bond component/die according to normal bonding procedures.

Method 2:

  1. Apply RS 816 onto bond-line. Let it soak for 30 minutes or longer. Replenish if appropriate. Adhesive should swell for ease of rework.
  2. Repeat Method 1, steps 1-5, where step 2 is optional.

For more information and recommendation assistance, please contact AIT sales and engineering:


AIT technical sales and service department can also be reached at: 1-609-799-9388 or 1-800-735-5040 (EST) and Fax: 609-799-9308