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Historically, tin‐lead solder has been a commonly used joining material in electronics manufacturing. Environmental and health concerns, due to the leaching of lead from landfills into ground water, have necessitated legislation that restricts the use of lead in electronics. The transition from tin‐lead solder to a lead‐free solder composition is imminent. Several alternative solder alloys (and their fluxes) have been researched for electronics assembly in the last few years. The objective of this research was to develop a systematic selection process for choosing a “preferred” lead‐free solder paste, based on its print and reflow performance.

After a detailed study of industry preferences, published experimental data, and recommendations of various industrial consortia, a near eutectic tin‐silver‐copper (SAC) composition was selected as the preferred alloy for evaluation. Commercially available SAC solder pastes with a no‐clean chemistry were extensively investigated in a simulated manufacturing environment. A total of nine SAC pastes from seven manufacturers were evaluated in this investigation. A eutectic Sn/Pb solder paste was used as a baseline for comparison. While selecting the best lead‐free paste, it was noted that the selected paste has to perform as good as, if not better than, the current tin‐lead paste configuration used in electronics manufacturing for a particular application. The quality of the solder pastes was characterized by a series of analytical and assembly process tests consisting of, but not limited to, a printability test, a solder ball test, a slump test, and post reflow characteristics such as the tendency to form voids, self‐centring and wetting ability.

Each paste was evaluated for desirable and undesirable properties. The pastes were then scored relative to each other in each individual test. An aggregate of individual test scores determined the best paste.

This paper summarizes a systematic approach adopted to evaluate lead‐free solder pastes for extreme reflow profiles expected to be observed in reflow soldering lead‐free boards.

Morton International Inc. have purchased Hoechst AG's printed circuit materials business including their Ozatec dry film and liquid primary imaging photoresists, Ozatec liquid photoimageable solder masks and related process equipment. Concurrently, Hoechst and its US subsidiary Hoechst Celanese Corporation purchased Morton's semiconductor photoresist business. Completion of these transactions was effective from 4 August 1993.

This conference, in the series being run by the National Physical Laboratory to help the electronics assembly industry consider the problems of CFC phase‐out, was essentially an updated repeat of the event held on 30 April, which had been a complete, standing‐room‐only sell‐out. Surprisingly, this repeat performance also attracted a full house and the format used has proved to be the most popular of all the NPL non‐CFC options conferences.

There can have been few periods in the history of the electronics soldering industry when the introduction of new technologies was so widespread and prevalent. Many of these changes have the objective of improving the efficiency of the process, and examples of this might be nitrogen soldering and the new developments in reflow soldering. Other changes, however, are being forced upon the industry by the impact of environmental legislation, and examples in this case include the ban on the use of CFCs and the growing pressure to replace lead‐containing solders with non‐toxic alternatives. The content of the soldering session reflected these concerns, with papers on nitrogen soldering, developments in reflow soldering and environmental issues.

Results for reflow soldering are presented from a three‐year EC funded project “IDEALS” to develop lead‐free soldering solutions. On the basis of fundamental data from the literature, a shortlist of candidate lead‐free solders was selected, and results from tests on physical and soldering characteristics, and wetting balance testing, led to the choice of SnAg3.8Cu0.7, melting at 217°C. Implications for solder paste medium development are discussed. Differences in alloy density, melting point, and surface tension relative to conventional solders were found to give higher levels of internal voids, reduced spread on copper, and rougher, duller joints. Reflow process window studies showed that sound reliable joints could be obtained with a peak temperature as low as 225°C. Reliability was tested on soldered test boards using thermal shock cycling, power cycling, and vibration. Overall the SnAg3.8Cu0.7 gave results approximately equivalent to conventional solders, and different board finishes had no significant effect. The effects of Sb and Bi were also evaluated. No justification was found for minor additions of Sb, but 2‐5 per cent Bi was found to allow a reduction of the peak reflow temperature, though at the cost of reduced reliability if any Pb was present.

Multicore Solders Ltd have appointed Richard Hart (38) as marketing manager. Prior to accepting his new position, Mr Hart was responsible for marketing at DEK where his career spanned 11 years. During this time he travelled extensively for that company organising, as part of his role, major seminars in India, Singapore, USSR, Israel and the Republic of Ireland, as well as the United Kingdom.

The leaching of lead from electronic components in landfills to ground water is harmful to health and to the environment. Increasing concern over the use of lead in electronics manufacturing has led to legislation to restrict its use as a joining material. Consequently, significant recent research efforts have been geared to identification of suitable lead‐free solder pastes. Typically, lead‐free solder pastes contain a very active flux in an effort to improve wetting. These aggressive fluxes have the tendency to explode (or burst) and create flux spatter, causing many process problems with sensitive electronic components. The purpose of this paper is to propose solution procedures to minimize/eliminate these flux spatters, particularly, on gold fingers in memory modules when lead‐free solder pastes are used.

Four no‐clean, lead‐free Sn‐Ag‐Cu (SAC) alloy‐based solder pastes consisting of four different flux systems from three different vendors were evaluated. Two types of reflow profiles (linear and ramp‐soak‐ramp) were also evaluated. Experiments were also conducted to optimise the soak temperature and soak time to determine a broader process window for lead‐free volume production with minimal flux spatter on the contact fingers of memory modules. In order to validate our findings the recommended profile and paste was adopted in production. Additional experiments on a board with a different surface finish were also carried out to validate the recommendations.

Flux spatter can be reduced/eliminated through proper selection of flux chemistry and reflow profile optimisation. The experimental study conducted indicates there is a reduction in the occurrence of flux spatter when a ramp‐soak‐ramp profile is used with lead‐free solder pastes.

Demonstrates that flux spatter can be reduced/eliminated by carefully choosing a soak profile and appropriate flux chemistry.

In the production of printed circuit assemblies, the demand for higher reliability levels has increased over the years. In order to achieve a high level of soldering quality, it is essential that solderability is built into the system at all stages and various factors must be taken into account. In the first section of this paper some of these factors are discussed. The various solderable coalings that are available are reviewed, some of the problems that can be encountered are illustrated and the effects of impurities in solders discussed. In the second part of the paper, the use of circuit boards having fused tin/lead coatings is discussed from the solderability point of view.

Dr B. T. K. Barry has been appointed Director of the International Tin Research Institute with effect from 1 October 1985 following the retirement of Dr D. A. Robins. Dr Barry joined the Institute's Research Department in 1962, subsequently became Head of Publications and in 1975 was appointed Assistant Director with special responsibility for the network of Tin Information Centres. He thus has had long experience of all the Institute's functions and activities and his appointment at a time when links are being forged between ITRI and the Association of Tin Producing Countries will provide a smooth transition from the previous Director.