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The Pb-free alloy compositions are more prone to erode the wave machine s structures, such as the impeller, baffles, and pot walls New wave-soldering machines address this problem through the use of alternative steel alloys and ceramic coatings 40336 Condensation (Vapor Phase) Soldering Condensation soldering, also referred to a vapor phase soldering, uses a working fluid s heat of condensation to reflow the solder paste or solder preform to make the joints Because the condensation reflow process had its origins in the early days of surface-mount technology when production runs were more limited in volume, these machines were primarily batch-type units Subsequently, inline equipment was developed to attach the vapor phase reflow machine to the back end of the placement equipment for higher production volumes.

Two particular attributes of condensation soldering are (a) the temperature of the product cannot exceed the vaporization (or condensation) temperature of the working fluid, thereby preventing overheating of temperature-sensitive materials; and (b) the temperature is very uniform over all of the components and the substrate, thereby minimizing temperature gradients that could warp or crack component or laminate materials This process fell out of favor in the early 1990s, for two reasons First, the working fluid for Sn-Pb solder, Dupont s Freon TMF, was categorized as an ozone-depleting substance (ODS) Its use was initially restricted and then prohibited by the Montreal Protocols Second, the increasingly more complex circuit boards that were being designed with surface-mount technology required more precise control of the time-temperature profile, which lead to the development of multizone reflow furnaces having convective and infrared heating capabilities There has been a resurgence in the use of condensation soldering.

Alternative working fluids have been developed for both Sn-Pb and Pb-free processing that are compatible with.

environmental regulations Preheaters are added to reduce the thermal shock when parts entered the working fluid, thereby providing a more controlled time-temperature profile Lower capital cost and properties of the condensation heat source previously noted cause condensation or vapor phase reflow to be well suited for prototype development programs and small production volumes 40337 Hand Soldering As noted earlier, in the highly automated surface-mount assembly line having automated paste printing and component placement capabilities, hand soldering would not be particularly advantageous in terms of maximizing production volumes However, in some applications, the assembly process includes a hand-soldering operation For example, often odd-form components cannot be incorporated in a pick-and-place machine, or temperature-sensitive devices cannot be exposed to the reflow furnace environment Under these circumstances, the hand-soldering step is performed after mass soldering (reflow, wave, etc).

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