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Solder Mask Attack The chemicals involved in depositing PCB surface finishes can attack the solder mask. Immersion tin directly attacks the mask by chemical dissolution.Thiourea in the tin bath acts as a solvent for the mask. Exposure time and temperature of contact with the bath should be carefully watched. The surface should be tape-tested for mask adhesion. ENIG processing creates an environment that can lift slivers of solder mask. The temperature of the nickel bath is not the culprit; rather, the generation of hydrogen bubbles as a by-product of nickel plating at the interface is alleged to cause lifting of the mask. Immersion metals such as gold, silver, and tin remove metal as part of the chemical reaction. If the immersion bath removes copper from underneath the edge of the solder mask, slivers of mask lose adhesion and show up in tape testing. In all cases, the mask preparation steps are critical. If the copper is treated well to adhere to solder mask, the interaction from surface finish chemicals is greatly reduced. It is imperative that there is no wedge between the mask and the copper into which the surface finish chemicals can creep. In extreme cases of chemical entrapment, the chemical reactions are accelerated in the wedge, leading to nonuniform plating. Immersion silver, tin, and OSP can lead to excessive copper corrosion at the solder mask edge and result in electrical opens. This phenomenon is also known as solder mask interface attack.

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Table 32.12 compares surface finishes by type and property and summarizes the material presented in this chapter.

TABLE 32.12 Comparison of Surface Finishes by Type and Property HASL Flat Solderjoint Contact Wirebond Cost OEMs Fabs Reflows Shelf-life (months) Compliant Pin No Cu-Sn E-test, ICT No $ All Most 6 18 + OSP Cu-Sn No No 0.7 $ All Most 2 4 6 ENIG Ni-Sn E-test, ICT, keypad Al 3 $ Most 200 6 24 Pd Ni-Sn E-test, ICT, keypad Au, Al 5 $ Few Few 6 24 Tin Cu-Sn E-test No 0.8 $ 30 40 2 3 6 ++ Silver Cu-Sn E-test, ICT, keypad Au, Al 0.8 $ 150 250 6 12 mos. +

1. IPC-4552, Specification for Electroless Nickel/Immersion Gold (ENIG) Plating for Printed Circuit Boards, October 2002. 2. IPC-4553, Specification for Immersion Silver Plating for Printed Circuit Boards, June 2005. 3. IPC-4554, Specification for Immersion Tin Plating for Printed Circuit Boards, January 2007.

Isabella Davis gave the same presentation, called To PMO or Not to PMO, at least twenty-seven times. Her audiences were always small to midsized companies debating whether or not to create a Project Management Of ce that would coordinate their projects. To make her case, she asked the audience if they ever experienced speci c problems, and Isabella always used the acronym CLASS to help them remember the issues. CLASS stands for: Cost overruns Late project endings Anger or frustration among team members Scope creep Surprises The acronym never failed . . . until the twenty-eighth presentation, when Isabella forgot that the A stands for anger. Even though she had said this so many times, she just couldn t remember. If she had had just one note card with the CLASS code on it, no one would have ever known, and she would not have been embarrassed.

33.1.1 Definition and Terminology The term solder mask, as used in this chapter, is the same as the terms mask, soldermask, or solder resist, which are frequently used interchangeably in the printed circuit board (PCB) fabrication industry. The Association of Connecting Industries (IPC) has standardized on the use of solder mask, since that is the term most widely used in the industry. The existing definition for Solder Resist from IPC-T-50 is, A heat-resistant coating material applied to selected areas to prevent the deposition of solder upon those areas during subsequent soldering. With the evolution of PCB technology, solder mask coatings are now asked to provide much more functionality than simply a soldering aid.

33.1.2 Purpose When solder masks were first used, their purpose was to protect the circuitry of the PCB from solder during the assembly operation. Eliminating short circuits was the main objective. As the use of solder mask became more prevalent and the material properties improved, solder mask was used for other functions, such as to provide environmental protection to the assembled board, and to serve as a plating resist for final finishes, dielectric protection, and other functions that take advantage of the properties of the cured mask.

33.1.3 History Solder mask began with the use of two-part epoxy, thermally curable inks that were an offshoot of inks that were used in the printing industry. These inks were applied by screen printing with the use of a patterned screen, since these materials were not photoimageable. One-part inks that were ultraviolet (UV) curable were available soon after, but these also had to be applied by a patterned screen because they could not be imaged and developed.

Photoimageable solder masks were developed in the mid-1970s and were offshoots of photoresist materials used for patterning the circuitry. Photoimageable solder masks were developed in both liquid (LPI) and dry film (DFSM) and both were used widely. Today, more than 98 percent of the solder mask used is applied in liquid form, and most is photoimageable.

The use of solder mask continues to evolve with the technology. This section discusses some of the issues involved.