Dave Hillman, Tina Berthiaume, Preston Schaaf Rockwell Collins PERM 23 IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Dave Hillman, Tina Berthiaume, Preston Schaaf Rockwell Collins PERM 23

Agenda Background IPC Committee Task Plan Test Materials Test Vehicle Metallographic Sectioning Plan Conformal Coating Measurements Results To Date Looking At “Future”

Background Graphic Courtesy of CALCE Consortia

Background Graphic Courtesy of CALCE Consortia

Background Graphic Courtesy of CALCE Consortia

Background Graphic Courtesy of CALCE Consortia

Background Graphic Courtesy of PERM group

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project IPC-JSTD-001E Subcommittee Task Team: Conformal Coating Material & Application “State of the Industry” Assessment The goal of the project is to document the current “State of the Industry” of conformal coating application on printed wiring assemblies. The project will look at the major conformal coating types (i.e. AR, ER, UR, SR, XY) and method of application (i.e. spray, dip, brush). The project will not evaluate individual companies or specific conformal coating products – plan is to do a “blind” task activity. Study will produce baseline data on what thickness/coverage the industry is/can achieve with conformal coating materials.

Conformal Coating Types: AR = acrylic ER = epoxy UR = urethane IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Conformal Coating Types: AR = acrylic ER = epoxy UR = urethane SR = silicone XY = paralyene Application Method: Machine or Manual Spray Dip Brush Other Application Volunteers to collect and retain detailed documentation of application method –NO IP will be disclosed. Sufficient baseline application process details have been disclosed for every application method. Test Vehicle

Task Group coating/application tasks complete: IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Current Status: Task Group coating/application tasks complete: ~12 volunteer conformal coating facilities utilized ~ 95 individual test vehicles processed 5 Conformal Coating materials covered (AR, ER, UR, SR, XY) Task Group application methodologies covered: Manual Spray Automated Spray (stream) Automated Spray (atomized) Dipped Brushed Vapor Deposition (on XY only) Reviewed Every 6 Months: APEX Conference and IPC Committee meeting at SMTA Fall Conference

Manual Spray: AR = 1, UR = 3, SR=3 IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Project “Statistics” Application Method: Manual Spray: AR = 1, UR = 3, SR=3 Automated Spray: AR = 4, UR = 6, SR = 3, ER = 2 Vapor Deposited: XY = 1 Dip Deposition: AR =1 Manual Brush: AR=1 Manual Syringe/Automated Spray: AR =1 Cure Method: Thermal UV Air/Thermal/UV combinations General: 3 Different Automated Spray Systems, Multiple Spray Angle/Pass Combinations

Processing: Photodocumentation IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Processing: Photodocumentation

Processing: Photodocumentation IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Processing: Photodocumentation

Processing: Photodocumentation IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Processing: Photodocumentation

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Components Being Assessed: 25 per TV and 3 TV per Coating/Application Set

Will “cap coat” gold layer for metallographic section purposes IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Coating Coverage and Thickness Assessment Method: Metallographic Cross-sectioning Details: Will gold sputter to define conformal coating outer edge before potting Will “cap coat” gold layer for metallographic section purposes Will cross-section from two angles Straight On Profile Lots of Photographs with general assessment before cross-section (photos, flat thickness measurement) Task Group Metallographic Process Document Available on IPC Kavi Site

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Careful Removal From Test Vehicle (Gold Sputtering/Protective Cap Layer)

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Photo documentation of cross sections from two angles:

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

Measurements: Standards Calibrated Metallographic Scope IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Measurements: Standards Calibrated Metallographic Scope

Measurements: Maximum, Minimum, and Top of Component Examples IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Measurements: Maximum, Minimum, and Top of Component Examples

Example Application Details: IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Example Application Details: SR Manually Sprayed with Binks Model 2001 conventional gun at angle (approximately 45 degree) with applications at every 90 degrees (the boards are rotated to receive the angle spray from 4 sides to prevent shadowing). UR Asymtek C740 equipment, SC300 atomizing head, 0.26 mm nozzle, 10 Degree flute, 10 psi fluid pressure, 30 psi atomizing pressure, 4 passes per path direction procedure. ER Atomized Spray Coating, 10 passes each in X & Y axis, IR Profile followed by Batch Cure 45 min, 1 - 3 mils.

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

Multiple Opportunities for Comparison: Application Method IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Multiple Opportunities for Comparison: Application Method Manual Spray: AR = 1, UR = 3, SR=3 Automated Spray: AR = 4, UR = 6, SR = 3, ER = 2 Vapor Deposited: XY = 1 Dip Deposition: AR =1 Manual Brush: AR = 1 Manual Syringe/Automated Spray: AR =1 Final Report anticipated to address thin coating areas and potentially “critical coating” areas similar to “critical solderability” areas

Opportunities for Data Collaboration with Current Studies: IPC Conformal Coating Material & Application “State of the Industry” Assessment Project Opportunities for Data Collaboration with Current Studies: NPL Conformal Coating Study 13 Companies 32 Conformal Coating “products/formulations” 49,152 Individual Leads ONE Component with ONE Failure after 12 Months Controls (uncoated) Failed after 1 Month NASA Urethane Study 13+ Years, 3 mils Thick Has No Whisker Protrusion Lockheed Martin Test (Woody/Fox Set) 10+ Years, 3 mils Thick Has No Whisker Protrusion

If You Want Access to the Committee Activities: IPC Conformal Coating Material & Application “State of the Industry” Assessment Project If You Want Access to the Committee Activities: Contact Teresa Rowe =  TeresaRowe@ipc.org Committee = 522 arr J-STD-001 Conformal Coating Material & Application Industry Assessment Kavi site = committee document depository

Questions ??? Graphic Source: Iowa State University Ag Extension Office 2012 PPT “Having A Bad Day”