the impact of lead-free soldering processes on defense industry electronic assembly practices
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The Impact of Lead-free Soldering Processes on Defense Industry Electronic Assembly Practices. Dave Hillman Rockwell Collins SMTA Huntsville Chapter 2011. The goal of Today’s Presentation/Discussion: Educate – Entertain - Engage!. - PowerPoint PPT PresentationTRANSCRIPT
The Impact of Lead-free Soldering Processes on
Defense Industry Electronic Assembly
Practices
Dave HillmanRockwell Collins
SMTA Huntsville Chapter 2011
The goal of Today’s Presentation/Discussion: Educate – Entertain - Engage!
Impact of Lead-free Soldering Processes on Defense Industry Electronic Assembly Practices
Agenda:
• Background
• Specifications
• Lead-free Topics of Interest - in no particular order!
Graph Source: ELECTRONICS INDUSTRIES MARKET DATA UPDATE, Spring 2010
Whenever there is a challenge, there is an opportunity…………..
The Predominate Component Surface Finish Is……
Graph Courtesy of CALCE Consortium, 2009ish
Operational Service Life (Years)
< 1%
29%
8%
62%
Medical Equipment
Cars
SatellitesMissiles
Aircraft
Spacecraft
Industrial Products
Major Home Appliances
Cell Phones
Desktop PCs
Network Servers
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Lead-Free Transition = In
creasing Difficulty
Military and Aerospace sectors have little influence on the global transition to Lead-
Free (<1% Market Share)
Influence of Lead-free Soldering on the Defense Industry Products
Military/Aerospace Electronic Products Characterization:
• Life Critical & Flight Critical Applications• Extremely Stable Qualified Material Lists• Significant Use Life ~ 20-30 Years Not Uncommon• Manufacturing Mode: High Mix/Low Volume• Design Cycle Mode: Deliberate and Long ~ 12 Months• Customer Certification
* Nothing is set in stone – and there is no guarantee that “legacy” products will have infinite exemption or exclusion status
Graphic source: M. Kelly, SMTAI 2007, “Case Study: Qualification of a Lead-free Card Assembly &^ Test Process of a Server Complexity PCBA
Impact of Lead-free Soldering Processes on Defense Industry Electronic Assembly Practices
Impact of Lead-free Soldering Processes on Defense Industry Electronic Assembly Practices
Agenda:
• Background
• Specifications
• Lead-free Topics of Interest (in no particular order!
LEAP WG Actionable Deliverables
GEIA-STD-0005-1, Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-free Solder
Used by aerospace electronic system “customers” to communicate requirements to aerospace electronic system “suppliers”
GEIA-STD-0005-2, Standard for Mitigating the Effects of Tin Whiskers in Aerospace In High Performance Electronic Systems
GEIA-STD-0005-3, Performance Testing for Aerospace and High Performance Electronic Interconnects Containing Lead-Free Solder and Finishes
Used by aerospace electronic system “suppliers” to develop reliability test methods and interpret results for input to analyses
GEIA-HB-0005-1, Program Management / Systems Engineering Guidelines For Managing The Transition To Lead-Free Electronics
Used by program managers to address all issues related to lead-free electronics, e.g., logistics, warranty, design, production, contracts, procurement, etc.
GEIA-HB-0005-2, Technical Guidelines for Aerospace and High Performance Electronic Systems Containing Lead-Free Solder and Finishes
Used by aerospace electronic system “suppliers” to select and use lead-free solder alloys, other materials, and processes. It may include specific solutions, lessons learned, test results and data, etc.
GEIA-HB-0005-3, Rework and Repair Handbook for Aerospace and High Performance Electronic Systems Containing Heritage SnPb and Lead-Free Solder and Finishes
GEIA-HB-0005-4, Impact of Lead Free Solder on Aerospace Electronic System Reliability and Safety AnalysisUsed to determine, quantitatively if possible, impact of lead-free electronics on system safety and certification analyses, using results from tests performed per GEIA-STD-0005-3
GEIA-STD-0005-1, Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-free Solder (Published)
*Used by aerospace electronic system “customers” to communicate requirements to aerospace electronic system “suppliers” – Lead-free Control Plan
Influence of Lead-free Soldering on the Defense Industry Products
GEIA-STD-0005-2, Standard for Mitigating the Effects of Tin Whiskers in Aerospace In High Performance Electronic Systems (Published)
*Tin Whisker Protocols and Procedures
Influence of Lead-free Soldering on the Defense Industry Products
GEIA-HB-0005-2, Technical Guidelines for Aerospace and High Performance Electronic Systems Containing Lead-Free Solder and Finishes
* Used by aerospace electronic system “suppliers” to select and use lead-free solder alloys, other materials, and processes.
200 cycles: SnPb (left) and SAC (right)
Influence of Lead-free Soldering on the Defense Industry Products
Project documents, test plans, test reports and other associated information will be available on the web:
NASA-DoD Lead-Free Electronics Project:
http://www.teerm.nasa.gov/projects/NASA_DODLeadFreeElectronics_Proj2.html
Joint Test Protocol
Project Plan
Final Test Reports
Super Resource
Influence of Lead-free Soldering on the Defense Industry Products:The Basis for Understanding Lead-free Soldering – The “One” Cell
Impact of Lead-free Soldering Processes on Defense Industry Electronic Assembly Practices
Agenda:
• Background
• Specifications
• Lead-free Topics of Interest
(In No Specific Order!)
Influence of Lead-free Soldering on the Defense Industry Products: Process Robustness: Alloy Proliferation
Graph Source: W. Liu and N. C. Lee, “Novel Sacx Solders with Superior Drop Test Performance”, SMTAI 2006
Influence of Lead-free Soldering on the Defense Industry Products: Process Robustness: Alloy Proliferation
Graph Source: G. Henshall et al, “iNEMI Pb-Free Alloy Proliferation Project” SMTAI 2008.
The Material Engineers are still playing in the sandbox………
Influence of Lead-free Soldering on the Defense Industry Products: Process Robustness
Graphic Source: The Lead Free Electronics Manhattan Project – Phase I, Contract # N00014-08-D-0758
Influence of Lead-free Soldering on the Defense Industry Products: Process Robustness
Photos Courtesy of Celestica
Influence of Lead-free Soldering on the Defense Industry Products: Process Robustness
Left Photos courtesy of NPL/Bob Willis
Equipment Issues - Wave Solder• Molten Tin is Corrosive!
(Photo Sources:“Lead-Free Technology and the Necessary Changes in Soldering Process and Machine Technology”, H. Schlessmann, APEX 2002 Conference Proceedings and “Real Life Tin-Silver-Copper Alloy Processing”, A. Rae et al, APEX Conference Proceedings, 2003
Corroded Solderpot Hardware Corroded Wave Solder Impeller
Influence of Lead-free Soldering on the Defense Industry Products: Process Robustness
Equipment Issues - Soldering Irons
(Photos “Under The Plating”, American Hakko Products Technical Report, July 2002)
18,000 Soldering Hits!
(Sn63 Solder Alloy !)
Influence of Lead-free Soldering on the Defense Industry Products: Process Robustness
• Equipment Issues - Soldering Irons
• Available Temperatures Ranges Seem Useable
• Tip Maintenance Becomes More Critical
• Use of Hot Air Systems Gaining Ground
(Graph Source: “Dissolution rates of iron plating on soldering iron tips in molten lead-free solders”, Takemoto et al, Soldering & Surface Mount Technology, Vol. 16, No. 3, 2004
Influence of Lead-free Soldering on the Defense Industry Products: Process Robustness
Influence of Lead-free Soldering on the Defense Industry Products: Mixed Metallurgy
Test Results: Solder Joint Failure @ 137 Cycles for SAC BGA in SnPb Reflow Process
Influence of Lead-free Soldering on the Defense Industry Products: Mixed Metallurgy
Influence of Lead-free Soldering on the Defense Industry Products: Mixed Metallurgy
Large AgSn Platelets
Influence of Lead-free Soldering on the Defense Industry Products: Mixed Metallurgy – New Physics ???
Influence of Lead-free Soldering on the Defense Industry Products: Mixed Metallurgy
Pb PhasePb Phase
SAC BGA Reworked with SAC Solder Paste, Original Solder Joint was SnPb, Magnified View of Crack with Pb Phase Present- Failed after 822 Thermal Cycles
Influence of Lead-free Soldering on the Defense Industry Products: Mixed Metallurgy
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W2 RRX - SRM MED
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SnAgCuBi/SnPb
W2 RRX - SRM MED
F=25 / S=0
Key: Solder Alloy/Component Finish
Mixed Metallurgy• Interaction of lead and bismuth in a bismuth containing LF solder
alloy: Joint Council on Aging Aircraft (JCAA)/ Joint Group on Pollution Prevention (JGPP) LF Solder program.
• Solder Alloy Included in Test Program:
– Sn3.4Ag1.0Cu3.3BiWith SnCu and SnPbTSOP Component
– Weblink:http://acqp2.nasa.gov/JTR.htm)
What is HOP – incomplete coalescence of the BGA solderball and the solder paste deposit
Head On Pillow (HOP)
Head On Pillow (HOP)Graph Source: P. Su, “Effects Of Component Warpage On Board Assembly Defects And Effective Mitigation Measures”, SMTAI 2010
Graph Source: P. Su, “Effects Of Component Warpage On Board Assembly Defects And Effective Mitigation Measures”, SMTAI 2010
Head On Pillow (HOP)
Graph Source: P. Su, “Effects Of Component Warpage On Board Assembly Defects And Effective Mitigation Measures”, SMTAI 2010
Head On Pillow (HOP) – Component Warpage
Incorrect Solder Paste Deposit
Head On Pillow (HOP)
Head On Pillow (HOP) – Incorrect Reflow
Pad Cratering
Graphic Courtesy of B. Roggeman, Unovis Consortium
Pad Cratering
Fillet Lifting and Shrinkage Voids
Fillet Lifting and Shrinkage Voids Are An Inspection Issue, Not A Reliability Issue
• Conformal Coating– Silicone
Conformal Coat Photo Shown Here.
– NOT a Cure-All, Lower Risk.
– Conformal Coating Only Captures and Does Not Eliminate.
Tin Whiskers
Photo Courtesy of Bob Ogden
Tin Whiskers
Chart Courtesy of Dr. Tom Woodrow, “CALCE Part Reprocessing, Tin Whisker Mitigation and Assembly Rework Symposium”, 2008
• Conformal Coating Thickness Plays a Role
• Have You Characterized Your Coverage Consistency?
• References You Should Read:• 2010 CALCE 4th Tin Whisker Symposium, Hunt/Wickham
Tin Whiskers
• Soldering Process– Assembly
Processes Will Cover Pure Tin on Small Parts with Solder
– There Are Geometry Limitations Dependent on Component Construction
– Where Is Your Process Data???
Tin Whiskers
The Concept of a System of Risk Mitigation
Chart Courtesy of CALCE Consortium
An Example:
• Automotive Industry segment: Unintended Consequences of Pure Tin Surface Finishes
Photo Source: NASA Engineering and Safety Center Technical Assessment Report, TI-10-00618, “Technical Support to the National Highway Traffic Safety Administration (NHTSA) on the Reported Toyota Motor Corporation (TMC) Unintended Acceleration (UA) Investigation”, January, 2011.
Rules Of a Tin Whisker Mitigation Plan
Graphic Courtesy of D. Pinsky, Reference: “Controlling Tin Whisker Risk: Implementation of Appropriate Mitigations”, IPC Tin Whisker Conference 2010
(Data courtesy of Nihon Superior/K. Sweatman
Influence of Lead-free Soldering on the Defense Industry Products: Copper Dissolution
ENIG – 1.5mil Copper – 60 Sec ImSn – 1.5mil Copper – 60 Sec
Influence of Lead-free Soldering on the Defense Industry Products:Copper Dissolution
Impact of Lead-free Soldering Processes on Defense Industry Electronic Assembly Practices: Conclusions
* The implementation of lead-free soldering technology is achievable if conducted in a measured, controlled, methodical manner.
* We need significant coordination and collaboration within the military/aerospace industry segment to avoid non-value added efforts
Questions ?