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Lead-Free Selective Solder GuidelinesProduction Floor |
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Authored By:Ramon Mendez, Ismael Marin Celestica Monterrey, Mexico Helen Lowe Celestica Toronto, Canada TranscriptAs the use of lead-free alloys has increased in electronic assemblies, much work has been done to develop Design for Manufacturability guidelines for the new materials. However, there are still some challenges remaining with wave solder, which is a complex process with many interacting factors. One such challenge is achieving good pin-through-hole barrel fill on thicker PCBs, particularly for power and ground pins connected to multiple plane layers. One important factor in the selective wave solder process is the size of the selective pallet opening around the PTH pins. It has been observed that larger pallet openings generally provide better barrel fill than smaller ones, but further research is needed to determine the recommended pallet opening for more thermally challenging product designs. The recommended pallet opening can then be used to determine Design for Manufacturability guidelines for the component keep out from the PTH pins on the solder side of the board. This paper presents the outcome of a study done with a thick, thermally challenging test vehicle wave soldered using a wide range of selective pallet opening sizes. In the first part of the investigation, a Design of Experiment was performed to optimize the wave solder process parameters and in the second phase, the optimized process parameters were held constant to focus on varying the pallet opening size only. The results for the various pallet opening sizes and their interaction with the other design factors is discussed. SummaryAs the use of lead-free alloys has increased in electronic assemblies, much work has been done to develop Design for Manufacturability (DFM) guidelines for the new materials. However, there are still some challenges remaining with wave solder, which is a complex process with many interacting factors. One such challenge is achieving good Pin Through Hole (PTH) barrel fill on thicker PCBs, particularly for power/ground pins connected to multiple plane layers. One important factor in the selective wave solder process is the size of the selective pallet opening around the PTH pins. It has been observed that larger pallet openings generally provide better barrel fill than smaller ones, but further research is needed to determine the recommended pallet opening for more thermally challenging product designs. The recommended pallet opening can then be used to determine DFM guidelines for the component keep out from the PTH pins on the solder side of the board. This paper presents the outcome of a study done with a thick, thermally challenging test vehicle wave soldered using a wide range of selective pallet opening sizes. The test vehicle is 3.05mm (0.120") thick with twenty copper layers, including ten plane layers, and is populated with several PTH component types. Other design variables include pin to hole clearance, and quantity of plane layers connected to each pin. The PCBs were assembled with a Pb-free alloy (Sn-Ag-Cu) and also SnPb as a baseline. In the first part of the investigation, a Design of Experiment was performed to optimize the wave solder process parameters and in the second phase, the optimized process parameters were held constant to focus on varying the pallet opening size only. The results for the various pallet opening sizes and their interaction with the other design factors will be discussed. ConclusionsThe results from this study confirmed the conclusions from prior work that Pb-free selective wave soldering is much less robust than with SnPb solder, and more sensitive to variations in the product design. Much greater attention must be paid todesign features, such as the component orientation, quantity of plane connections, PTH hole sizes, and SMT keepouts around the PTH pins, in order to achieve acceptable yields on thick, thermally challenging PCBs. Key findings related to the selective pallet opening for Pb-free wave solder on a thick, complex board:
Some interesting observations in addition to the selective pallet opening results:
Initially Published in the IPC Proceedings |
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