Impact of the Öko-Institut Recommendations on an Avionics OEM : Dave Hillman Rockwell Collins IPC Brussels June 2008

Impact of the Öko-Institut Recommendations on an Avionics OEM Agenda: High Performance Use Environment OEM Characterization Visual Impact Example Consequences of Material Changes on OEM Impact of New RoHS Material Additions Conclusions

Impact of the Öko-Institut Recommendations on an Avionics OEM High Performance Electronic Products Characterization: Life Critical & Flight Critical Applications Extremely Stable Qualified Material Lists Significant Use Life ~ 20-30 Years Not Uncommon Manufacturing Mode: High Mix/Low Volume Design Cycle Mode: Deliberate and Long ~ 12 Months Customer Certification * Nothing is set in stone – and there is no guarantee that “legacy” products will have infinite exemption. exemption/exclusion Graphic source: M. Kelly, SMTAI 2007, “Case Study: Qualification of a Lead-free Card Assembly & Test Process of a Server Complexity PCBA

Impact of the Öko-Institut Recommendations on an Avionics OEM

Impact of the Öko-Institut Recommendations on an Avionics OEM (Graphic courtesy of L. Whiteman ACI)

Addresses issues that are: AIA-AMC-GEIA Lead-free Electronics in Aerospace Project Working Group (LEAP WG) Formed in 2004 AIA – Aerospace Industries Association AMC – Avionics Maintenance Conference GEIA – Government Electronics and Information Technology Association Includes all stakeholders (market segments, supply chain, geographic regions) ~90 meeting attendees 10 active task groups Addresses issues that are: Unique to aerospace and military Within control of aerospace and military Copyright © 2006 Boeing. All rights reserved. PPT cell courtesy of Lloyd Condra, Boeing

LEAP WG Actionable Deliverables GEIA-STD-0005-1, Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-free Solder Used by aerospace electronic system “customers” to communicate requirements to aerospace electronic system “suppliers” GEIA-STD-0005-2, Standard for Mitigating the Effects of Tin Whiskers in Aerospace In High Performance Electronic Systems GEIA-STD-0005-3, Performance Testing for Aerospace and High Performance Electronic Interconnects Containing Lead-Free Solder and Finishes Used by aerospace electronic system “suppliers” to develop reliability test methods and interpret results for input to analyses GEIA-HB-0005-1, Program Management / Systems Engineering Guidelines For Managing The Transition To Lead-Free Electronics Used by program managers to address all issues related to lead-free electronics, e.g., logistics, warranty, design, production, contracts, procurement, etc. GEIA-HB-0005-2, Technical Guidelines for Aerospace and High Performance Electronic Systems Containing Lead-Free Solder and Finishes Used by aerospace electronic system “suppliers” to select and use lead-free solder alloys, other materials, and processes. It may include specific solutions, lessons learned, test results and data, etc. GEIA-HB-0005-3, Rework and Repair Handbook for Aerospace and High Performance Electronic Systems Containing Heritage SnPb and Lead-Free Solder and Finishes GEIA-HB-0005-4, Impact of Lead Free Solder on Aerospace Electronic System Reliability and Safety Analysis Used to determine, quantitatively if possible, impact of lead-free electronics on system safety and certification analyses, using results from tests performed per GEIA-STD-0005-3 Copyright © 2006 Boeing. All rights reserved. (Published) (in ballot) PPT cell courtesy of Lloyd Condra, Boeing

Impact of the Öko-Institut Recommendations on an Avionics OEM Failure Phenomena Due to a Materials Change

Impact of the Öko-Institut Recommendations on an Avionics OEM *Determining, quantitatively if possible, impact of material substitutions on system safety and certification is a significant task 200 thermal cycles: SnPb solder (left) and SAC solder (right)

Impact of the Öko-Institut Recommendations on an Avionics OEM Material - Beryllium Beryllium is a highly regulated and controlled material within aviation electronics market segment. Beryllium has extensive applications in electronic component construction and as metal alloy constituent. Metal alloys utilizing Beryllium as an alloy constituent have unique performance characteristics for which a substitute material may not exist.

Impact of the Öko-Institut Recommendations on an Avionics OEM Material - Nickel Nickel is widely used as substitution material for current RoHS prohibited materials: Cadmium and Hexavalent Chromium. Nickel has extensive applications in electronic component construction, plating, and as metal alloy constituent. The addition of Nickel to the current RoHS prohibited materials list would result in the requalification of another substitute material for Cadmium and Hexavalent Chromium, provided a substitute material exists.

Impact of the Öko-Institut Recommendations on an Avionics OEM The Periodic Table is a Finite Material Set Table Courtesy of Sargent Welch Scientific Co.

Impact of the Öko-Institut Recommendations on an Avionics OEM The compact fluorescent light bulb is an example of controlled use of a hazardous material resulting in a better technology Material substitutions require due diligence test/evaluation efforts to determine applicability for a industry use segment compatibility before a substitution can be accomplished

Impact of the Öko-Institut Recommendations on an Avionics OEM Conclusions: The High Performance Use Environment Industry Segment is not a “stand alone” entity - material changes to the global industry supply base impact all industry use segments. A critical parameter of material assessment is the balance of material elimination versus material restricted use The implementation of new materials of High Performance Use Environment technologies is achievable if conducted in a measured, controlled, methodical manner.