The growth and morphology of the intermetallic compounds formed at the solder joint between the Sn-9Zn-2.5Ag lead-free solder and the Cu substrate have been investigated in this study. The planar CU6Sn5 formed after soldering transforms to a scalloped Cu5Znx after aging at 180 degrees C for 250h. However, the Cu5Zn8 decomposes and the scalloped Cu6Sn5 reforms at the interface close to the solder alloy after aging for 400h. The eta'-Cu6Sn5 transforms to the eta-Cu6Sn5 as aged at 180 degrees C. The interdiffusion coefficient of Cu and Sn in the Cu6Sn5 is determined as 2.58 x 10(-13) cm(2) s(-1), and that of Cu and Zn in the Cu5Zn8 layers is determined as 3.36 x 10(-14) cm(2) s(-1) at 180 degrees C, from the estimated thickness of the intermetallic compound (IMC). On the other hand, they are determined as 3.43 x 10(-13) and 2.36 x 10(-14) cm(2) s(-1), respectively, from the microbeam EDS analysis. (c) 2005 Elsevier B.V. All rights reserved.