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techniques can severely compromise the integrity of the PCB. It is almost impossible to look at a PCB after assembly and definitively state that the fault lies entirely with the PCB manufacturer or with the assembly organization. 51.6.2 PCB Issues Created by Lead-Free Assembly

Fig 838: A deployed micromirror with a view of the hinge [16]

Copper reduction Lead-free solder, when molten, rapidly dissolves copper into it. One must be very careful when using lead-free solder on copper surfaces without a protective barrier of some type (e.g., nickel); otherwise, the copper conductors may be reduced to a point where they are not adequate for the design. Base material degradation Base materials begin to degrade and decompose during soldering and can reduce the insulating properties of the resin system in the base material. Conductive anodic filament (CAF) As the base material system degrades, the resistance to CAF formation decreases. Delamination In extreme cases, the resin system can lose cohesive or adhesive properties, causing catastrophic failure. Increased expansion causing premature PTH failures Base materials expand when exposed to soldering temperature. This expansion becomes pronounced above the Tg of the resin system in the base material. The increased temperature of lead-free soldering can cause premature failure of the PTHs due to this increased expansion. See Fig. 51.3 for PTH expansion characteristics with temperature. Solderability Lead-free solder does not wet as well to solderable surfaces as leaded solder does, so pad size, solder quantity, and flux type and quantity must be taken into account.

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FIGURE 51.3 Z-axis expansion characteristics of 150 C Tg PCBs versus temperature. (Courtesy of Microtek Laboratories.)

Standards and customer documentation establish minimum quality and acceptability requirements for the inspections performed. If the PCB does not meet these requirements, it becomes nonconforming. This does not necessarily mean the PCB is scrapped, although this is often what happens to nonconforming PCBs. What it does mean is that with a generic standard, samples that do not meet the stated requirements must be dispositioned outside

the standard. To determine whether a nonconforming PCB is or is not scrap, a material review board (MRB) must be established to evaluate the nonconformance(s). The MRB is usually made up of one or more representatives from the departments of quality, production, and design. The purpose of the materials review board is to effect positive corrective action within a short time to eliminate the cause of recurring discrepancies and prevent recurrence of similar discrepancies. The MRB s responsibilities include:

Reviewing questionable PCBs or materials to determine conformance with acceptability, quality, and design requirements Reviewing nonconforming PCBs for effects on design functionality Authorizing repair or rework of nonconforming PCBs when appropriate Establishing responsibility and/or identifying causes for nonconformance Authorizing the scrap of excessive quantities of materials

Microelectro-mechanical Systems (MEMS)

A serial communication device or IC that converts a byte of data into serial bits and transmits it out at a certain rate Similarly, it receives incoming serial bits and assembles these bits into a byte for the host watchdog timer: A special timer that is used specifically for the purpose of resetting the system if it overflows A piece of program resets the watchdog timer every so often before the watchdog timer expires However, if the program fails to reset the timer, indicating that the program has crashed or entered into some infinite loop (indicating unwanted and unexpected program or system behavior), the watchdog timer overflows and this generates a processor reset signal..

When all else fails and the PCBs do not meet the intended end product use, they need to be scrapped.

The cost of the assembled PCB continues to increase because of density, complexity, and rising material and component costs. The value added to the PCB can be 10 to 20 times the cost of PCB. If it is found that a nonconforming PCB is the cause of failure, the total cost of the assembly process is likely to be passed on to the PCB manufacturer.

Using Industry Standards There are both advantages and disadvantages to using industry standards for acceptability and quality requirements. 51.9.1.1 Advantages International standards represent a consensus of what is possible and common for acceptance. They increase the likelihood of PCB users getting what they expected. The PCB manufacturer is unlikely to become as expert in complying with a customer specification as it would an industry standard. The more experience the quality personnel at the PCB manufacturer obtain in acceptability criteria, the better they will be at spotting nonconformance. Industry standards are a great place to start developing company-specific requirements for acceptability and quality.

51.9.1.2 Disadvantages International standards are developed by a cross section of the industry. The resultant standards often represent the least common denominator requirements in order to satisfy the broad range of participation. Although these standards may meet most of a PCB buyer s needs, they often leave deficiencies that necessitate additional requirements being imposed upon the PCB supplier.

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