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EP06 view

CLEANING AND CONTAMINATION OF ELECTRONICS COMPONENTS AND ASSEMBLIES

by B. N. Ellis

Pages--365 + xxi; Tables--17; Figures--99; References--159; Size--23 x 15 cm.
ISBN 0 901150 20 7

Code: EP06

Contents of this page:

Description
Some Worldwide Reviews
About the author
Table of Contents

Description

This book is a practical guide for all persons who are in any way concerned with cleaning or contamination control of either components or assembled circuits. It is also useful to those specifying components and, in particular, printed circuits. It equally covers the theoretical side to a sufficient extent to allow the average engineer or technician who is not a specialist in the field to understand the mechanisms involved in contamination and cleaning.

As a reference book, the text is divided into seven parts, logically divided into some thirty chapters illustrated by photographs, line drawings, graphs and tables. Each chapter has its own reference list. The introductory section comprises an historical background to cleaning in the electronics industry, a very complete chapter of definitions of all the terms employed and in the particular context, a short chapter on units employed, a theoretical treatise on the mechanics, physics and chemistry of cleaning (in simple terms) and one on the cost of cleaning.

The second part comprises come seven chapters cataloguing the diverse ways that contamination can occur in the electronics industry, whereas the third part describes, over three chapters, what effects contamination can have during the various manufacturing processes of components and assemblies and over the whole of their subsequent lives. Part 4 will be considered as being the most important by some production engineers because its four chapters describe all the currently used methods of cleaning and flux removal for the small, medium or large user with considerable detail on the products usually employed.

The fifth section deals with ionic contamination control. The first two chapters discuss respectively the American military specifications and the new British DEF standards. The third one gives a general view of the different instruments commercially available for measuring or detecting ionic contamination. The last chapter of this section gives an insight into some aspects of the theory of ionic contamination measurement and the solutions used for it. The next part treats the detection and measurement of contamination by other methods, with particular emphasis on non-ionic contaminants. Insulation resistance measurement is discussed in a separate chapter of this section. The last part, divided into three chapters, relates to the particular problems imposed by the use of surface mounted components and solder creams and pastes.

It is felt that this book will become a valuable reference work for the bookshelves of all companies involved in any aspect of electronics, particularly component, printed or hybrid circuit manufacturers or assemblers.

Some Worldwide Reviews

"The publishers are to be complemented in adding to their range of reference books for our industry one which will become cleaning in process and who wish to know more of the reasons for the methods which are being recommended. It is the sort of book which you can pick up and read a chapter in isolation and feel that you have read an article of merit. For those of us who know Brian Ellis well, we can not only read but we can actually see him expounding his ideas in his own inimitable style.

A book well worth having on the reference bookshelf."

Circuit World (UK)

About the author

Brian N.Ellis is an electronics engineer, whose general and academic education took place in Edinburgh. After completing military service in 1954 he was employed by a number of companies in the UK before moving to Switzerland in 1963. By a gradual process he has gravitated from pure electronics towards electronics packaging, notably in soldering technology and printed circuit manufacture. He was instrumental in introducing the first production line using wave soldering with water soluble fluxes in Switzerland in the period 1964 to 1967. On the basis of some original work towards the improvement of the solderability of printed circuits, he was responsible for building up what was, in the late 1960s, the most technically evolved PCB manufacturing plant in Switzerland and for making this a viable operation. In 1974, he founded his own company, Protonique SA, where his realisation of the potential of applying the computer to the analysis of contamination measurement, led to successful development which rapidly promoted his Company to the forefront in this area of technology. Since the foundation of Protonique, it was realised that the electronics assembly industry was responsible for much pollution of the air, water and the soil. This subject has been at the forefront of Brian Ellis' thinking since the 1970s and he has contributed much to this theme.

Other professional activities have included working on a Commission (which he chaired from 1975 to 1980) for elaborating the Recommendations "Circuits Imprimés" of the Groupement de l'électronique de Suisse occidentale (GESO). In 1989, he was appointed the official Swiss delegate to the United Nations Environment Programme (UNEP) Solvents, Coatings and Adhesives Technical Options Committee (STOC): this is instrumental to the Parties to the Montreal Protocol towards the phasing out of ozone-depleting solvents. He is a member of the Steering Group and Chairman of the Electronics Working Group of the STOC. He has sat on a number of IPC Committees and was vice-chairman of the Aqueous Cleaning Working Group. He also sits on an ISO Committee Working Group studying Surface Insulation Resistance (SIR). Mr Ellis has also published nearly two hundred technical papers, many of which have been presented at conferences throughout the world.

Amongst the awards presented to Brian Ellis, there are two United Nations Environment Programme Certificates and the United States Environmental Protection Agency honoured him in 1994 with the Stratospheric Ozone Protection Award for Individual Leadership in CFC Solvent Elimination "in recognition of exceptional contributions to global environmental protection".

A Chartered Engineer, Mr Ellis is also a Member of the Institute of Electrical Engineers, where he has also presented papers to the Swiss Chapter.

Table of Contents

PREFACE

CHAPTER ONE

Historical Background

1.1 The Need for Cleanliness

1.2 The Chemical Evolution

1.3 Machine Evolution

1.4 Contamination Control

CHAPTER TWO

Definitions

CHAPTER THREE

Units

CHAPTER FOUR

The Theory of Cleaning

4.1 Physical Bonds

4.2 Chemical Bonds

4.3 Micelle Information

4.4 The Mechanics of Cleaning

4.5 Cleaning Methods

4.5.1 Dissolution

4.5.2 Solubilisation

4.5.3 Saponification

CHAPTER FIVE

The Cost of Cleaning Electronics Assemblies

CHAPTER SIX

Contamination Due to Laminate Manufacture

6.1 Copper Contamination

6.2 Glass Fibres

6.3 Epoxy Resins

CHAPTER SEVEN

Contamination Due to Pnnted Circuit Manufacture

7.1 Introduction

7.2 Workshop Operations

7.2.1 Reception

7.2.2 Panel Shearing and Preparation

7.2.3 Drilling

7.2.3.1 Burrs

7.2.3.2 Hole Quality

7.2.3.3 Smearing and Desmearing

7.2.4 Deburring and Abrasive Cleaning

7.2.5 Image Transfer

7.2.5.1 Choice of Aqueous or Solvent Image Transfer

7.2.6 Plating and Chemical Operations

7.2.7 Solder Resist or Mask, Legend

7.2.7.1 Preparation

7.2.7.2 Application

7.2.7.2.1 Silk-screened Monocomponent Resists

7.2.7.2.2 Silk-screened UV Resists

7.2.7.2.3 Silk-screened Two Component Resists

7.2.7.2.4 Solvent-type Dry Film Solder Resists

7.2.7.2.5 Aqueous Type Dry Film Solder Resists

7.2.7.2.6 Solvent Type Wet Film UV Solder Resists

7.2.7.3 Curing

7.2.8 Tinning and Fusing

7.2.8.1 Fusing Electroplated Coatings

7.2.8.1.1 Infra-red Fusing

7.2.8.1.2 Immersion Fusing

7.2.8.1.3 Vapour-phase Fusing

7.2.8.2 Hot Tinning

7.2.8.2.1 Hot Air Levelling

7.2.8.2.2 Hot Bath Levelling

7.2.9 Drying

7.3 Degassing and Blow-holes

7.3.1 Causes

7.3.1.1 Drilling

7.3.1.2 Laminate Air Entrapment

7.3.1.3 Humidity Absorption

7.3.1.4 Resin Composition

7.3.1.5 Water Inclusion

7.3.1.6 Hydrogen Inclusion

7.3.1.7 Resin Smear

7.3.1.8 Particle Inclusions

7.3.1.9 Pockets

7.3.1.10 Organic Deposits

7.3.1.11 Photoresist

7.3.1.12 Copper Cleaners

7.3.1.13 Residues from Fusing or Tinning

7.3.1.14 Flux and Oil

7.3.2 Conclusions

7.4 Multilayer Circuits

7.4.1 Inner Layers

7.4.1.1 Degreasing

7.4.1.2 Abrasive Cleaning

7.4.1.3 Blackening

7.4.1.4 Rinsing

7.4.1.5 Drying and Dehumidifaction

7.4.1.6 Inner Layer Testing

7.4.1.7 Epoxy Photoresists

7.4.2 Prepreg

7.4.3 Resin Smear and Desmearing, Etchback

7.5 Packing

7.5.1 Polyethylene

7.5.2 Paper

7.5.3 Aluminium Foil

7.5.4 Vacuum Packing

CHAPTER EIGHT

Contamination Due to Components

8.1 Hot-tinned Leads

8.1.1 Copper Wire

8.1.2 Alloy Wires

8.1.3 Lead Frames

8.1.4 Chip Components

8.2 Plastic Problems

8.3 Oils and Greases

8.4 Hot-tinned Screens or Shields

8.5 Electroplated Parts

8.6 'Cleanability' of Components

CHAPTER NINE

Contamination Due to Hybrid Circuit Manufacture

9.1 Thick Films

9.1.1 Thick Film Substrates

9.1.1.1 Alumina Substrates

9.1.1.2 Vitreous Substrates

9.1.1.3 Glass

9.1.1.4 Other Ceramics

9.1.2 Conductor and Dielectric Inks

9.1.2.1 Contamination from the Frit

9.1.2.2 Organic Contamination

9.1.2.2.1 Solvents

9.1.2.2.2 Binders

9.1.2.2.3 Rheological Additives

9.1.3 Trimming

9.1.3.1 Abrasive Trimming

9.1.3.2 Laser Trimming

9.1.3.3 Post-trimming Treatment

9.2 Thin Films

9.2.1 Substrates

9.2.2 Co-deposits

9.3 Add-on Components

9.4 Permitted Cleanliness Levels

9.5 Encapsulation and Sealing

9.5.1 Encapsulation

9.5.2 Hermetic Sealing

CHAPTER TEN

Contamination due to PC Assembly

10.1 Goods-in and Handling

10.1.1 Handling

10.1.1.1 Fingerprints

10.1.1.2 Gloves

10.1.1.3 Food, Drink and Tobacco

10.1.1.4 Airborne Contamination

10.1.1.5 Tools

10.1.1.6 Inspection Procedures

10.1.2 Recontamination on Arrival

10.2 Storage

10.3 Assembly

10.3.1 Temporary Masking

10.3.2 Component Mounting

CHAPTER ELEVEN

Contamination Due to Soldering

11.1 Fluxing and Soldering

11.2 Rework

11.2.1 Desoldering

11.2.2 Hand Soldering

11.3 Solder Creams

CHAPTER TWELVE

Contamination Due to Cleaning

12.1 Residues from Cleaning Solvents

12.1.1 Organic Solvents

12.1.2 Water

CHAPTER THIRTEEN

Effects of Ionic Contamination

13.1 Corrosion

13.1.1 Electrolytic Corrosion

13.1.2 Stress Corrosion

13.1.3 Corrosion of Trimmed Leads

13.2 Leakage Currents

13.3 Coating Adhesion

13.3.1 Blistering and Vesication

13.3.2 Voids

13.4 Dendrites

13.5 Multilayer Adhesion

CHAPTER FOURTEEN

Effects of Non-ionic Contamination

14.1 Leakage Currents

14.2 Coating Adhesion

14.3 Particulate Contamination

14.4 Micro-organic Contamination

14.5 Multilayer Adhesion

CHAPTER FIFTEEN

Problems Caused by Synthetic Polymers

15.1 Brief Resume' of Polymer Chemistry

15.2 Epoxy Resins

15.2.1 Polymerisation Conditions

15.2.2 Non-stoichiometric Polymerisation

15.2.3 Additives

15.3 Effects of Poor Polymerisation

15.3.1 Ionic Contamination

15.3.2 Chemical 'Tenderness'

15.3.3 'White Deposits'

15.3.4 Insulation Resistance

15.4 Tests for Good Polymerisation

15.4.1 Ionic Contamination Test

15.4.2 Electrical Resistance Test

CHAPTER SIXTEEN

Cleaning and Flux Removal using Organic Solvents

16.1 Solvent Types

16.1.1 Chlorinated Solvents

16.1.1.1 Chlorinated Solvent Blends

16.1.1.2 Solvent Stability

16.1.1.3 Operator Safety

16.1.1.3.1 Skin Contact

16.1.1.3.2 Eye Contact

16.1.1.3.3 Ingestion

16.1.1.4 Environmental Problems

16.1.1.4.1 Water Pollution

16.1.1.4.2 Air Pollution

16.1.1.5 Fire Hazards

16.1.2 Fluorinated Solvents

16.1.2.1 Pure Solvents

16.1.2.1.1 F-113

16.1.2.1.2 F-112

16.1.2.1.3 F-il

16.1.2.2 Azeotropic Mixtures

16.1.2.3 Zeotropic Mixtures

16.1.2.4 Other Mixtures

16.1.2.5 Solvent Stability

16.1.2.6 Vapour Stability

16.1.2.6.1 Practical Effects of Vapour Degradation

16.1.2.7 Safety Measures

16.1.2.7.1 Operator Safety

16.1.2.7.2 Air Pollution

16.1.2.7.3 Fire Hazards

16.1.3 Other Solvents

16.1.3.1 Alcohols

16.1.3.1.1 Methanol

16.1.3.1.2 Ethanol

16.1.3.1.3 1-Propanol

16.1.3.1.4 2-Propanol

16.1.3.1.5 1-Butanol, 2-Butanol (1) and Tertiary Butyl Alcohol

16.1.3.1.6 Isobutanol

16.1.3.1.7 Fire Hazards

16.2 Solvent Cleaning Methods

16.2.1 Manual Methods

16.2.2 'Kiss' Cleaning

16.2.3 Vapour Phase Cleaners

16.2.3.1 Solvents

16.2.3.2 Constructional Materials

16.2.3.3 Energy Requirements

16.2.3.4 Solvent Economy

16.2.3.5 Design Enhancements

16.2.3.5.1 Desiccator

16.2.3.5.2 Spray Lance

16.2.3.5.3 Extra Sumps

16.2.3.5.4 Ultrasonic Agitation

16.2.3.5.5 Work Holders

16.2.3.5.6 Automatic Parts Transfer

16.2.3.5.7 Zeotropic Distillation

16.2.3.6 In-line Cleaners

16.3 Distillation

16.3.1 Reflux Distillation

16.4 Resistance of Synthetic Materials to Solvents

CHAPTER SEVENTEEN

Cleaning and Flux Removal using Water

17.1 General

17.2 Water-soluble Flux Removal

17.3 Soldering Oils

17.4 Other Contaminants

17.5 Wash Period

17.6 Water Quality

17.6.1 Water Purification

17.6.1.1 Softening

17.6.1.2 Thermal Decalcification

17.6.1.3 Mixed Bed Deionisation

17.6.1.4 Separate Bed Deionisation

17.6.1.5 Reverse Osmosis

17.6.1.6 '18 megohm' Water

17.6.1.7 Distilled Water

17.6.1.8 Water Standards

17.6.1.9 Open and Closed Circuits

17.6.1.10 Water Additives

17.6.1.11 Water Temperature

17.7 Waste Water Treatment

17.7.1 pH

17.7.2 Phosphates, Nitrates and Nitrites

17.7.3 Surfactants

17.7.4 Metals

17.7.5 Anions

17.7.6 Flux

17.8 Operator Safety

17.8.1 Ingestion

17.8.2 Skin

17.8.3 Eyes

17.8.4 Inhalation

17.8.5 Temperature

17.8.6 Noise

17.9 Machines for Water-soluble Flux Removal

17.9.1 Batch Machines

17.9.1.1 'Dishwasher' Batch Machine

17.9.1.1.1 Recirculatory 'Dishwasher' Machines

17.9.1.2 High-throughput Cleaners

17.9.1.2.1 Handling

17.9.1.2.2 Drying

17.9.1.3 Conveyorised Batch Cleaners

17.9.2 In-line Machines

17.9.2.1 Constructional Materials

17.9.2.2 Modular or Monobloc Construction

17.9.2.3 Conveyor Type

17.9.2.4 Prewash Compartment

17.9.2.5 Main Wash Compartment

17.9.2.6 Rinsing

17.9.2.7 Drying

17.9.2.8 Other Features

17.9.2.8.1 Loading

[CHs 18-23 to be added!]

CHAPTER TWENTY-THREE

Technical Notes on Conductivity Measurements and Ionic Contamination Control Solutions

23.1 Conductivity Measurement:General

23.1.1 D.C. Conductivity Meters

23.1.2 A.C. Conductivity Meters

23.1.3 'Ballistic' Conductivity Meters

23.2 Temperature Compensation

23.2.1 Reference Temperature

23.3 Measuring Cell Design

23.4 Ionic Contamination Control Solutions

23.4.1 Mixtures

23.4.2 Components

23.4.3 Choice of Solution Percentage

23.4.4 Solution Quantity

23.4.5 Absolute Interpretation of Results

23.4.6 Other Physical Parameters of Solutions

CHAPTER TWENTY-FOUR

Extraction Methods for Non-ionic Contamination Control and Measurement

24.1 Water-soluble Contaminants

24.2 Alcohol-soluble Contaminants

24.3 IPC Acetonitrile Test

24.4 Ion Chromatography

CHAPTER TWENTY-FIVE

Insulation Resistance Control

25.1 Insulation Resistance

25.2 Measurement of Surface Insulation Resistance

25.2.1 Climatic Cycling for S.I.R. Testing

CHAPTER TWENTY-SIX

Other Methods of Detecting, Controlling and Measuring Contaminants

26.1 Optical Methods

26.2 Vesication Test

26.3 Halide Tests

26.4 Particulate Contamination

26.5 Ion Identification

CHAPTER TWENTY-SEVEN

Special Problems Related to Surface Mounted Components

27.1 General

27.2 Surface-mounting Component Types

27.3 Use of Adhesives

27.4 Soldering

27.5 Flux Removal

27.5.1 Solvents

27.5.1.1 Ultrasonic Cleaning

27.5.2 Aqueous Cleaning

CHAPTER TWENTY-EIGHT

Special Problems Related to Solder Pastes and Creums

28.1 Metallic Component

28.2 Flux Composition

28.3 Cream Application

28.4 Component Assenibly

28.5 Drying

28.6 Reflow Soldering

28.7 Cleaning

28.8 Solder Balling

CHAPTER TWENTY-NINE

Cleaning and Contamination Measurement of SM Hybrid and PC Assemblies

CHAPTER THIRTY

Protective Coatings

30.1 Reasons for Protective Coatings

30.2 Preparation for Protective Coatings

30.3 Types of Protective Coatings

30.3.1 Coating Configurations

30.3.1.1 Conformal Coating

30.3.1.2 Non-conformal Surface Coating

30.3.1.3 Potting and Casting

30.3.2 Single Component Coatings

30.3.2.1 Phenolic Lacquers

30.3.2.2 Urethane Lacquers

30.3.2.3 Acrylic Lacquers

30.3.2.4 Other Lacquers

30.3.3 Two Component Coatings

30.3.3.1 Epoxy Resins

30.3.3.2 Polyurethane Resins

30.3.3.3 Silicone Elastomers

30.3.3.4 Other Resins

30.3.4 Evaporated Coatings

30.4 Methods of Application

30.4.1 Dipping

30.4.2 Spraying

30.4.3 Brushing

30.4.4 Injection

30.5 Curing

30.6 Operator Safety

30.6.1 Dermatological Effects

30.6.2 Vapour Inhalation

30.6.3 Fire Hazards

CHAPTER THIRTY-ONE

Repairs and Rework

31.1 When Should Rework be Done?

31.2 Desoldering

31.2.1 Braids and Tresses

31.2.2 Suction

31.2.2.1 Hand Pump

31.2.2.2 Rework Station

31.2.3 Desoldering Bath

31.3 Removal of Conformal Coatings

31.3.1 Cutting and Peeling

31.3.2 Thermal Removal

31.3.3 Chemical Removal

31.3.4 Abrasion

31.3.5 Laser

31.3.6 Plasma

31.4 Track Repairs

31.5 Gold-plated Contact Repair

31.6 Cleaning Reworked Circuits

31.7 Reprotecting Reworked Circuits

APPENDIX ONE

Proposed Specification for the Classification of Components According to their Resistance to Cleaning Products

Introduction

1 Scope

2 Application

3 Classifications

3.1 Code

3.2 Multiple Codes

3.3 Suffixes

4 Resistance

4.1 Electrical Characteristics

4.2 Mechanical Characteristics

4.3 Lubrication

4.4 Electrical Contacts

4.5 Markings

4.6 Climatic Testing

4.7 Solvent Removal

4.8 Ultrasonics

5 Cleaning Product Resistance

5.1 Class S0

5.2 Class S1

5.3 Class S2

5.4 Class S3

5.5 Class W0

5.6 Class WI

5.7 Class W2

5.8 Class W3

5.9 Class W4

5.10 Class AO

5.11 Class NO

6 Suffixes

6.1 Suffix D

6.2 Suffix P

6.3 Suffix S

APPENDIX TWO

MIL-P-28809A: Extract of Paragraphs Related to Contamination (paragraph numbers are from the original)

3 Requirements

3.4.5 Soldering Flux

3.5.3.3 Post Soldering Cleaning

3.5.3.4 Measling and Crazing

3.5.3.5 Delamination, Blistering or Softening

3.6.1 Coating Area

3.6.10 Cleanliness (see 4.8.2)

3.6.10.1 Resistivity of Solvent Extract (see 6.6)

3.8.7 Humidity

4 Quality Assurance Provisions

4.5.2 Inspection Lot for Cleanliness Verification

4.8.2 Cleanliness and Resistivity of Solvent Extract (see 3.6.10)

4.8.2.1 Preparation of Solvent Extract Test Solution

4.8.2.2 Preparation for Test

4.8.2.3 Test Procedure

6 Notes

6.4 Flux Removal

6.6 Resistivity of Solvent Extract (see 4.8.2)

6.6.1 Alternate Methods

6.7 Ultrasonic Cleaning

40 General

40.5 Cleanliness

40.5.1 Resistivity of Solvent Extract

 

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