The morphology of tin whiskers on a matte tin finish on a phosphor bronze substrate was observed by SEM. The samples were prepared by a sulfate-based bath and held at 328 K/100% RH for several different time increments. The results show that, besides the fluted whiskers, there are tin whiskers with new morphologies, ribbon-like whiskers. The ribbon-like whisker has a section size of about 5 microns in width and 2.5 microns in thickness and it may be straight or bent with kinks to form some irregular shapes. Whiskers with different morphologies can co-exist on the tin finish with the same aging condition. It is suggested that the formation of ribbon-like whiskers takes place when a new recrystallization grain nucleates and abnormally grows in the finish prior to whisker growth.
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