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All of these requirements can be attributed to solderability testing, even though at first glance it would appear to have nothing to do with it. Being able to test to a protocol that meets the previous requirements provides useable data for process development and improvement and hopefully will facilitate a much shorter development time than might otherwise be the case. Classic solderability testing, using dip and look techniques, cannot meet any of the previous requirements. 42.3.3 The Wetting Balance and Measurement System Analysis (MSA) For solderability testing there is only one method that has the potential to meet the requirements of MSA and that is testing by wetting balance. Not all wetting balances are, of course, created equal and the ease of use, or lack there of, can have a serious impact on the final MSA analysis and ultimate acceptance of the data. Part of the problem in previous evaluations of the wetting balance has been the samples used for testing the performance of the machine.Typically, with GR&R or MSA, samples are tested repeatedly by numerous people in a random order. When testing with a wetting balance, soldering a part is required. This means that it is a one use item that cannot be tested again. Testing components clearly is not an option, as the natural variation from a plating process (assuming it is one that is in control), may contribute enough variation to fail the evaluation. To get around this one-time test, the solution has been to place known weights that are calibrated and certified on to the wetting balance (which is measuring force as a function of displacement of a sensor) and then record the force measurement as a function of the weight applied. Calibrated weights in the range of 100 milligrams to 5 grams were used

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and this was thought to provide the necessary range and usability for running a GR&R test. The results obtained from numerous round-robin industry studies have been terrible, with no correlation test site to test site or machine to machine from the same manufacturer being obtainable let alone obtaining an acceptable MSA, until the methodology and equipment was understood. A very detailed study was performed on the failed GR&R s of the past and an examination into the source of variation was undertaken. The results showed that slight misplacement of the test weight could have a huge impact on the result, especially in the lower weight ranges where small components are typically tested. Figure 42.3 shows normalized data from one round of testing with calibrated weights.The correct value should be 0.98 mN. It is clearly evident that the degree of spread and variation in this one-person test, which is typical for this type of test, would result in a rejection of the wetting balance as a scientifically acceptable measuring device for solderability force measurements.

2 (1 + 1 2 )2 1 1 2 1 2

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1.06 1.05 1.04 1.03 1.02 1.01 Normalized mN 1.00 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91 0100 mg 0200 mg 0400 mg Test weight

FIGURE 42.3 Normalized data for one individual from a placing the test weights wetting balance test the correct value is 0.98 mN.

42.3.4 Wetting Balance Protocol to Meet the Requirements of an Acceptable GR&R What was needed was a test protocol that allowed the wetting balance to be used for what it was designed for: measuring solderability. This required producing a test sample that is considered uniform and consistent, sample to sample. This known good coupon was created and subsequently a test protocol developed. This detailed test protocol maybe found in the Appendix sections of the ANSI-JSTD-002 and ANSI-JSTD-003 documents. 42.3.4.1 Wetting Balance Protocol Development. This protocol was run using three types of wetting balance. To demonstrate the power of both the protocol and the wetting balance, three individuals were requested to run the test at every location: an expert in wetting balance

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