Fabrication of Pressure Conductive Silicone Rubber Socket Device by Shape-Controlled Nickel Powders Produced by High-Energy Ball Milling

The pressure conductive silicone rubber socket (PCR) is one of the promising test socket devices in high-speed testing environments. In this study, we report highly dense PCR device channels comprised of high aspect-ratio flake-shaped Ni powders. The shape-controlled Ni powders are prepared by the high-energy milling process. The scanning electron microscopy (SEM) and particle size analyzer (PSA) results of the synthesized powder samples showed well-defined flake type Ni powder morphology, and the powder sizes are distributed in the range of ~24–49 μm. The cross-sectional SEM study of the fabricated PCR revealed that the channels consisting of flake Ni powder are uniformly, densely distributed, and connected as face-to-face contact. The resistance of the PCR channels comprised of flake-shaped Ni powders showed ~23% lower resistance values than the spherical-shaped Ni powders-based channels, which could be due to the face-to-face contact of the powders in the channels. The magnetic properties study for the flake-type Ni powder showed a high remanence (~2.2 emu/g) and coercivity (~5.24 mT), owing to the shape anisotropy factor. Finally, the fabricated highly dense and conductive channels of the silicone rubber socket device by shape-controlled Ni powder could be a potential test socket device.