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eutectic will mean significantly higher manufacturing materials costs. Also, during wave soldering, the molten and flowing wave will tend to dissolve certain surface finishes, which may eventually build up and change the composition of the solder alloy. Different solder alloys have different metals dissolution properties. Therefore, using the same lead-free solder alloy for wave soldering as for reflow may be impractical. Some of the overt costs and impacts of moving to lead-free solders were mentioned previously in this chapter. There are other potentially hidden costs. Soldering equipment may not have the bandwidth to handle the higher temperatures of some of the pb-free alloys. Reflow ovens may need to be constructed out of different materials to handle long-term effects of the higher temperatures. Fan bushings and polymeric seals to maintain inert atmosphere integrity may not withstand much above the temperature regimes required for Sn-Pb processing. These same considerations apply to wave soldering. Hand soldering irons will require higher temperatures, and more boards will likely have to be scrapped due to localized charring while trying to attain reflow during the hand soldering operation or at repair. Board materials, fluxes, and such may require reformulating, which is also likely to drive costs higher.

1.4.7 Equipment Changes In some cases, soldering equipment changes are required to accommodate higher process temperatures and contact with materials other than Sn and Pb. Such changes are discussed in more detail in Chap. 47.

1.4.8 Scrapping and Material Mistakes There will be costs associated with segregating materials (Pb d versus Pb-free) and associated increased floor space for carrying two inventories (Pb d and Pb-free). Noncompliant materials will have to be scrapped or sold off to those still using leaded processes. It is anticipated that in the early throes of the conversion to Pb-free, parts inventories occasionally will be inadvertently mixed, which may impact finished goods reliability and also make these products unacceptable for import to Europe after July 1, 2006, due to tenets of the RoHS directive.

1.4.9 Training Every facet of manufacturing is touched by this change, whether it is the soldering process, solder joint inspection, electrical testing, material inventories, bill-of-materials verification, purchase specifications, inventory separation, and incoming materials inspection. The adaptations of RoHS and Pb-free standards for printed circuit assembly certainly require the most extensive changes that the electronics industry has ever needed to make. Great care has to go into training of personnel at every level of printed circuit assembly (PCA) building and support.

In newtonian theory, there are three types of mass. The rst two types describe the response of a body to inertial and gravitational forces, while the third type is used to describe the gravitational eld that results when a given body acts as a source. More speci cally,

1.4.10 Reliability Testing The change of materials and solders to accommodate the elimination of Pb necessitates reliability testing of the Pb-free assemblies to ensure that reliability is comparable to that of Sn-Pb assemblies. Reliability test methods, parameters, and models will have to be refined to match material properties of Pb-free assemblies.

1.4.11 In-Circuit Test (ICT) Since the process temperature for most lead-frees are higher than for eutectic- or near-eutectic Sn-Pb solder, any flux residues associated with No-Clean soldering are more thoroughly baked onto PWB surface metals. This inhibits electrical test probe contact. Even with today s No-Clean solder pastes and with Sn-Pb solders, electrical probing can be a challenge. Often the residues that cover test points necessitate multiple seating cycles of the test probes to penetrate the flux residue.

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The relative benefits of removing or reducing lead remain controversial Some studies have shown a net negative effect due to the energy materials and processes required for the production and use of replacement lead-free materials Whatever the long-term environmental impact, the short-term consequences clearly create a technical challenge to ensure reliable, costeffective printed circuit assemblies There are neither drop-in replacements for Sn-Pb solder nor industry wide consensus for a single-solder alloy The alloys that are most promising have significant challenges due to raw materials pricing, limited reliability data, and yet-to-be-determined interactions with other materials It has taken many years to understand the properties of Sn-Pb solder, its metallurgical behavior, solder joint properties, and soldering methodologies Any new solders will have to undergo scrutiny to determine key characteristics of process and reliability.