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This type of bond has an inherently grainy look and can even have microfractures within caused by motion-induced interruption of orderly crystal growth during solidification The cooling rate at the tail end of the process is as important as at the onset of heating Extreme cooling rates may result in component cracking or electrical performance degradation induced by differential contraction of materials..

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Numerous considerations are crucial for successful circuit board assembly and useful product life Assembly processes and materials that result in solder-joint formation can also have a profound effect on long-term solder-joint reliability as well as a product s environmental exposure and handling during its lifetime Design and assembly engineers need to take into consideration temperature extremes and thermal excursion ramps that the product may endure as well as anticipated mechanical shock and vibration, the number of power (on-off) cycles expected over its lifetime, exposure to airborne particulates, gaseous pollutants, humidity, and handling Such exposures may impact the printed circuit assembly (PCA) during soldering, when being handled on the factory floor, or while in the hands of the product s end user These are but a sampling of variables that influence product reliability and should be considered in defining design and assembly attributes.

PCA designs are most often driven by electronic device availability, electrical performance requirements, affordability, and the product s end-use environment and operating conditions This chapter will strictly avoid offering up generalized rules for all soldering process applications The materials and requisite solder-joint reliability properties for a desktop computer are markedly different from those for the ignition system printed circuitry associated with the engine of a motor vehicle Similarly, mobile electronics (mobile phones, laptop computers, PDAs, etc) have the added requirements of mechanical shock-resistance as well as high-volume manufacturing needs, including low cost, ease of assembly, and high yields In some cases, the cost to repair a PCA or an entire product may exceed the value of the combined material and labor content of the first-pass assembled product.

It is also well understood that the reliability of a repaired assembly is not as good as a properly soldered first-pass printed circuit assembly due to additional board handling and solder-joint degradation as a result of re-soldering The solder flux chemistry and how it is applied and heated may also impact product reliability These points reinforce the need to understand PCA processes thoroughly and to solder properly the first time There are fundamental rules that will become evident in discussions of metallurgies, fluxes, and processes If these rules are heeded, the results are optimal soldering yield and the best reliability However, the only way to know whether an assembly will endure its intended use and environment is to develop appropriate accelerated testing methods that can accurately gauge product field reliability..

It is incumbent on the PCA process engineer to understand the materials properties and phenomena that influence the soldering process and the reliability of the finished assembly. A basic understanding of mechanics, thermodynamics, metallurgy, and chemistry and how they apply to a finished solder joint is required for good PCA process engineering. The process engineer should influence product design for best manufacturability and reliability and also assemble boards with the highest reliability possible given the board design, materials variables (surface finishes, solder, solder flux, etc.), and components that comprise the bill-ofmaterials. Additionally, there are certain critical rules one could follow for incoming printed circuit board cleanliness, solder purity, etc. These are best described in standards documents, such as those published by the IPC. There are also abundant pitfalls in soldering. Too much gold in tin-lead solder will cause solder-joint embrittlement. Too high a process time or temperature can have the same effect on solder joints. Contamination of tin-bismuth solder joints with lead (Pb) can cause joint failure. The residues left by some fluxes can be corrosive. Electrochemical migration induced by flux corrosion products is a common mode of circuit failure that is difficult to pinpoint by electrical testing. Dendritic filaments can form between two board features of differing electrical potential. Because these microscopic dendrites have limited current-carrying capability, they may act as miniature fuse links that may break and re-fuse, making the root cause of electrical failure quite difficult to diagnose and locate. Thus, there are many variables associated with circuit board assembly, and the process engineer has to rely on science and engineering fundamentals in order to contribute to intelligent PCA design and defect-free assembly.