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HANDBOOK OF AQUEOUS CLEANING TECHNOLOGY FOR ELECTRONIC ASSEMBLIES

by F. R. CALA & A. E. WINSTON

Pages--295+xvi; Tables--72; Figures--62; References--365.
ISBN 0 901150 31 2

Code: EP32

Contents of this page:

Description
About the Authors
Table of Contents

Description

The current efforts to eliminate CFCs in the defluxing of electronic circuit boards have resulted in a need for effective alternatives. Aqueous cleaning systems has become a leading choice for this replacement. The use of water to clean, rather than solvents, can bring advantages in the areas of cleaning, worker safety and the environment.

Circuit assembly manufacturers have generally been comfortable with solvent cleaning, because this method is effective and they have not had to be concerned with issues such as metal corrosion or waste water treatment. Although aqueous cleaning has many advantages over solvent cleaning, conversion to this technology results in new problems with which the industry is unfamiliar. even those who have been using water to clean may not be getting the most out of their current system or be aware of recent important advances. Because of a generally limited knowledge base, choice of aqueous cleaning systems, optimisation, problem solving, worker safety issues, environmental concerns and bewildering legal restrictions cause needless frustration and worry.

This book explores all aspects of aqueous cleaning including the chemistry of aqueous saponifiers, performance, equipment used, measurement, waste treatment needed, safety and environmental issues relating to the selection and effective use of aqueous cleaning systems to deflux and clean electronic circuit board assemblies. Its emphasis is on the practical, while giving a clear presentation of the underlying principles. Readers will be able to gauge their understanding of the key chapters by working through challenging problems taken from real life situations and then referring to the solutions given.

This book covers current aqueous cleaning technology but suggests ways to plan for future developments when installing and starting up an aqueous cleaning process now. Insight is given as to where the industry, cleaning requirements and regulations are headed.

About the Authors

Anthony Winston (Tony), who received his Bachelor’s degree in chemistry at the University of Nottingham in England in 1966, has been involved in various facets of Research and Development for almost 30 years. Much of his career was spent at Church & Dwight Co., Inc., of Princeton, New Jersey, most recently in the position of Director of New Technology.

During his 25 years at Church & Dwight, Mr Winston was involved in all aspects of research, product and process development of several successful industrial and consumer products. In 1971, his efforts as a chemist resulted in the launch of the first successful non-phosphate laundry detergent produced in the United States.

More recently, Mr Winston has led the development of new aqueous industrial metal cleaning technology designed to provide safe environmental alternatives to the use of hazardous solvents. Together with the co-author, Dr Frank Cala, they developed the first inorganic aqueous saponifiers for cleaning and defluxing electronic circuit assemblies. These products are highly effective in removing fluxes, are much safer to work with than other alternative products and are environmentally benign.

Mr Winston recently accepted a new position as Vice President of Technology and Clinical Research at Enamelon, Inc., of East Brunswick, New Jersey, where he is leading the development of promising new technology in the oral health care area.

He is the author and co-author of about fifty United States Patents, the majority of which cover various novel cleaning compositions or related technology. He has authored and co-authored a number of technical papers and has also taught day courses on aqueous cleaning technology.

 

Frank Cala holds a PhD in physical chemistry, which he received from Rutgers University in the United States. His university based research was in the fields of thermodynamics, kinetics and photochemistry. He holds the position of Senior R&D Manager at Church & Dwight and is responsible for the technical development of industrial cleaners. He has been with Church & Dwight for 18 years and had previously been with Colgate Palmolive for 7 years. Dr Cala’s corporate experience includes 25 years of formulating both consumer products and industrial cleaners and in bringing these to market. For the past several years he has focused on cleaning agents for electronic assemblies and has been very active in this area. He is the author or co-author of many papers and patents on the subject of cleaning electronic assemblies.

Dr Cala has chaired numerous technical sessions on cleaning electronic assemblies and has presented many papers in this area. He has taught full-day courses on cleaning at major electronics conferences in the USA. He is a member of the Board of Directors of the Alliance for Cleaning Technologies. Additionally, he is a member of the Test Method Validation Team (TMVT) for Phase 2 testing of electronic cleaning agents in the USA.

Table of Contents

CHAPTER 1

Introduction to Assembly Cleaning

1.1 Why Clean?

1.2 Types and Sources of Contamination

1.3 Soil Chemistry

1.4 Solder Masks

1.5 Solder Balls

1.6 Other Sources of Contamination

1.7 Energy Needs in Cleaning

1.8 Cleaning Challenges

1.9 Requirements for Acceptable Cleaning

1.10 Other Related Cleaning Tasks

1.11 Corrosion

1.12 Human Safety Concerns

1.13 Environmental Issues

CHAPTER 2

Cleaning Alternatives

2.1 Introduction

2.2 Solvent Cleaning

2.3 Semi-Aqueous Cleaning

2.4 Aqueous Cleaning with Saponifiers

2.5 Aqueous Cleaning Without Additives

2.6 No-clean Fluxes and Pastes

2.7 Specialised Cleaning Methods

2.8 Choosing a Cleaning Alternative

CHAPTER 3

Water Quality

3.1 Importance of Water Quality

3.2 Definitions

3.3 Factors Affecting Water Acceptability

3.4 Water Quality Requirements

3.5 Water Purification Methods

3.6 Water Quality Measurement

CHAPTER 4

Aqueous Cleaning Modalities

4.1 Introduction

4.2 Aqueous Cleaning Without Additives

4.2 Additives for Water Soluble Flux Cleaning

4.3 Aqueous cleaning Products

4.4 Organic Versus Inorganic Saponifiers

4.5 Product Form

4.6 Materials for Spot Cleaning of Circuit Assemblies

CHAPTER 5

The Rôle of Alkalinity and Buffering

5.1 The Importance of Alkalinity and pH

5.2 Definitions

5.3 Properties of Acids, Bases and Salts

5.4 Mode of Action

5.5 Requirements for Effective Cleaning

5.6 Types of Alkalis

5.7 Effect of Alkali Type and Concentration on pH

5.8 Measurement of pH and Alkalinity

5.9 Alkalinity as a Measure of Saponifier Concentration

CHAPTER 6

The Rôle of Surfactants

6.1 Introduction

6.2 Definitions

6.3 Structure

6.4 Properties of Surfactant Solutions

6.5 Mechanisms of Action

6.6 FOAM

6.7 Applications

6.8 Selection of Surfactants for Circuit Assembly Cleaning

CHAPTER 7

Solvents and Other Ingredients

7.1 Introduction

7.2 Solvents

7.3 Foam Control Agents

7.4 Corrosion Inhibitors

7.5 Alkaline Builders

7.6 Hydrotropes

7.7 Oxidisers

CHAPTER 8

Aqueous cleaning Equipment

8.1 Introduction

8.2 In-line Conveyorised Equipment

8.3 Batch Equipment/Non Ultrasonic

8.4 Ultrasonics/Issues and Approaches

8.5 Choosing Equipment for the Optimum Performance

8.6 Equipment Maintenance

CHAPTER 9

Measuring Cleaning Effectiveness

9.1 Introduction

9.2 Visual Examination

9.3 Ionic Analyses

9.4 Non-ionic Analysies

9.5 Direct Surface Analysies

9.6 Surface Insulation Resistance (SIR)

9.7 CFC Alternatives Assessment Programmes

CHAPTER 10

The Cleaning Process

10.1 Introduction

10.2 Start-up

10.3 Measuring Cleaning Agent Concentration

10.4 Wash Time

10.5 Wash Temperature

10.6 Rinse Water Conditions

10.7 Common Cleaning Problems

10.8 Impact of Other Assembly Operations

10.9 Process Optimisation

10.10 Choosing an Aqueous Based Defluxing Agent

CHAPTER 11

Material Compatibility

11.1 Introduction

11.2 Metal Corrosion and Surface Changes

11.3 Non-Metallic Materials

11.4 Equipment Considerations

11.5 Testing

CHAPTER 12

Waste Water Treatment

12.1 What Must be Removed and Why

12.2 Definitions

12.3 Regulations

12.4 Municipal Waste Treatment Systems

12.5 Treatment Alternatives

12.6 Membrane Technology

12.7 Assembling Complete Treatment Systems

12.8 Waste Water Analyses

CHAPTER 13

Human Safety and Occupational Health

13.1 Introduction

13.2 Material Safety Data Sheets

13.1 Classification of Human Health Effects

13.4 Flammability

13.5 Reactivity

13.6 Health Hazards Associated with Saponifiers

13.7 Flammability Hazards from Saponifiers

13.8 Reactivity Hazard from Saponifiers

13.9 Hazards from the Boards Being Cleaned

13.10 Heavy Metals in Waste Solutions

13.11 Materials used to Recycle Ion Exchange columns

13.12 Ozone used for Waste-water Treatment

13.13 Safety Equipment

13.14 Safety Rules

13.15 Saponifier Spills

13.16 Treatment of Injuries

CHAPTER 14

Support Services

14.1 Introduction

14.2 Suppliers

14.3 Federal, State and Local Agencies

14.4 Additional Sources of Support

CHAPTER 15

Future Trends in Aqueous Cleaning

15.1 Introduction

15.2 The Need for Cleaning in the Future

15.3 Materials and Soils

15.4 Requirements for Acceptable Cleaning

15.5 Aqueous Cleaning Technologies

15.6 Equipment Trends

15.7 Environmental Concerns, Worker Safety and Regulations

15.8 Planning for Future Needs Now

CHAPTER 16

Problem Solving

16.1 White Residues

16.2 Poor Flux Removal

16.3 Excessive Ionic Readings

16.4 Oily Residues on Assemblies

16.5 Discolouration of Metal Components or Joints

16.6 Removal of Component Markings

16.7 Colourations on Assemblies

16.8 Foaming in the Wash

16.9 Foaming in the Rinse

16.9 Rapid Consumption of Saponifier

16.10 Gel-like Material in the Wash

16.11 Pump Leaks

16.12 Rapid Consumption of Exchange Resins

16.13 Frequent Plugging of Reverse Osmosis or other Membranes

16.14 Unfilterable Precipitates During Treatment to Drain

16.15 Deposits on Equipment and Nozzles

16.16 Odours

16.17 Sample Problems

CHAPTER 17

Quality Management in the Cleaning of Electronic Assemblies

17.1 Definition of Quality

17.2 The Profitability of Quality

17.3 Quality Standards

17.4 Implementing a company Wide Quality Program

17.5 Setting Cleaning Specifications

17.6 Supplier Participation

17.7 Complying with Specifications

17.8 Quality and the Waste Treatment Process

17.9 Process Corrections

 

 

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