validity of the ipc rose method 3-23-10 · 2015-01-14 · • bgas • 0.20” centers • nc &...
TRANSCRIPT
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Validity of the IPC R.O.S.E. IPC
Method 2.3.25 Researched
IPC APEX 2010 Technical Conference
Dr. Mike Bixenman, Kyzen Corp.
Steve Stach, AAT
April 6, 2010
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Agenda
• Why is Cleanliness Testing Important?
• What is a “ROSE” Cleanliness Test?
• Miniaturization and Flux Changes
• R.O.S.E. Testing Limitations
• Improving R.O.S.E. Testing
• Inferences from the Data Findings
• Conclusions
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Cause of Fire
No single ignition source of the fire was
conclusively identified.
Determination
The most probable initiator was an electrical
arc in the sector between the -Y and +Z
spacecraft axes
January 27, 1967
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How Circuit Board Residues
Affects Reliability? • Ionic Residues Facilitate Electro-Chemical Reactions
– Promotes Dendrites, Conductive Anodic Filaments
• Bulk Residues Create Cross Talk in High Speed Circuits
– Degrades 10 Gigahertz signals, Matched Impedance Lines
• Bulk Residues Trap other Contaminations
– Finger soils, other fluxes, chemicals, particulate
+
Image courtesy of NASA
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History of the Cleanliness Test
• In the 1960’s
– DoD concerned about PCB failure
– Ionic contamination cited at the root cause
• Quality assurance and process control needed
• Task Force Objectives
– Quantitative process control method
– Detect ionic contamination
– Establish Pass / Fail criteria
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What is a “ROSE” test
“Resistivity Of Solvent Extract”
• Industry standard test for circuit board cleanliness
(Mil-P-28809 in 1971)
• Measures the ionizable residues remaining on a
circuit board or assembly
0 1 2 3 4
Ionic Concentration (NaCl equivalent PPB)
1/R
(Conductance
µSiemens)
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Manual ROSE Method
• Procedure
– Rinse each board with
50ml of reagent grade IPA
and H20 in a 75%/25%
mixture per inch square
– Measure the resistance
drop
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Automatic “ROSE” testers
• Automated “ROSE” testers were developed
• Using Spray-under-immersion to minimize CO2
interference
• Deionization filters wereused to re-new IPA/water test
solution
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Payback - Circuit Board Cleanliness?
• Manufacturing ROI - Improved Yields
• Product ROI – Better Product Performance
• Service ROI – Happy Customers
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Miniaturization and New Fluxes
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Miniaturization
• Increases soldering complexities
– Wetting
– Surface tension
– Oxidation resistance
– Oxygen barrier
• Flux residues bridge conductors
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High Density Components
• Challenge the definition of circuit board cleanliness
• No good method for detecting residues under components
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1970’s 1980’s 1990’s 2000’s
• QFNs
• 0.16” Centers
• Lead Free
• Lead Free
Fluxes
• Very High
Density• QFPs
• BGAs
• 0.20” Centers
• NC & WS
Fluxes
• High Density• Thru Hole• 0.1” Centers• Wave Solder• Active
Fluxes
• SMT
• 0.05” Centers
• Reflow Solder
• RMA Fluxes
• 2 sided
boards
Manual ROSE
ROSE TesterSMT Tester
PCB Assy & ROSE
Trend Lines
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ROSE Testing Limitations
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ROSE Limitations
• Initially designed for Rosin based fluxes
• IPA and/or water is not a good extraction
solvent for modern day fluxes
– Higher temperature reflow profiles
– New temperature resins and polymers
– Higher flux activity required
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Improving ROSE Testing
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Rethink the ROSE Test Platform
• Two driving factors
1. Extraction solvent (Static Dissolution Rate)
• To completely dissolve the residues
2. Higher Energy (Dynamic Dissolution Rate)
• Shorter test times
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Like Dissolves Like
Teas Chart showing Hansen Solubility Ranges
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Engineered Extraction Solvents
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Innovative Extraction Solvents
• Flux residues differences
1. Characterize flux residues
2. Place fluxes with similar solubility in classes
3. Engineered extraction solvents that dissolve
flux residues
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Response
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Like Dissolves Like
Modern
Fluxes
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Test Methodology
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Solubility Testing
1. Two extraction solvents
tested
1. IPA / H20
2. Engineered extraction
solvent
2. Four flux families tested
1. Water Soluble ~ Lead-Free
2. Rosin ~ Tin-Lead
3. No-Clean ~ Tin-Lead
4. No-Clean ~ Lead-Free
3. Static time = 10 minutes
4. Temperature
• 20C
• 40C
• 60C
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Flux Classification Extraction Solvent Time
Shaker
Table Grade
Visual
Cleanliness
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
IPA/H2O 10 min. 100 RPM (1-6)
Extration Solvent 10 min. 100 RPM (1-6)
No-Clean
Tin-Lead 3
No-Clean
Lead-Free 1
No-Clean
Lead-Free 2
No-Clean
Lead-Free 3
Rosin
Tin-Lead 1
Rosin
Tin-Lead 2
Rosin
Tin-Lead 3
No-Clean
Tin-Lead 1
Water Soluble
Lead-Free 1
Water Soluble
Lead-Free 2
Water Soluble
Lead-Free 3
No-Clean
Tin-Lead 2
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Water Soluble Lead-Free 1
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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Water Soluble Lead-Free 2
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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Water Soluble Lead-Free 3
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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Rosin ~ Tin-Lead 1
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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Rosin ~ Tin-Lead 2
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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Rosin ~ Tin-Lead 3
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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No-Clean ~ Tin-Lead 1
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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No-Clean ~ Tin-Lead 2
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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No-Clean ~ Tin-Lead 3
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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No-Clean ~ Lead-Free 1
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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No-Clean ~ Lead-Free 2
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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No-Clean ~ Lead-Free 3
ReagentGrade
Table 120C Image 40C Image 60 C Image
IPA/H2O
1 @ 20C
1 @ 40C
1 @ 60C
New
Reagent
Design
1 @ 20C
1 @ 40C
1 @ 60C
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Summary of Data Findings
0.00
1.00
2.00
3.00
4.00
5.00
6.00
WS
1
Lead_F
ree
WS
2
Lead_F
ree
WS
3
Lead_F
ree
Rosin
1
Tin
_Lead
Rosin
2
Tin
_Lead
Rosin
3
Tin
_Lead
No-C
lean 1
Tin
_Lead
No-C
lean 2
Tin
_Lead
No-C
lean 3
Tin
_Lead
No-C
lean 1
Lead_F
ree
No-C
lean 2
Lead_F
ree
No-C
lean 3
Lead_F
ree
IPA / H2O @ 20°C IPA / H2O @ 40°C IPA / H2O @ 60°C
New Reagent @ 20°C New Reagent @ 40°C New Reagent @ 60°C
Score
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Inferences from the Data
• IPA/H2O does not dissolve many of today’s
flux residues
• We need engineered extraction solvent to
dissolve/test flux residues
• More than one engineered solvent may be
needed depending on flux type
• The data indicates that temperature can
accelerate dissolution of most flux residues
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Our Industry Needs ROSE Test
Improvements
• Engineer/test new solvent blends
• Develop/build new test instrument compatible with the new test solvents
• Evaluate dynamic energy methods to accelerate test
• Establish test sensitivity levels sufficient to detect flux trapped under critical parts