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Lead-Free Soldering Any acceptance criteria decision should define lead-free materials and processes acceptability. Until the advent of the European Union s adoption of the Directive on Restriction of Hazardous Substances (RoHS), which went into effect in July 2006, all electronic design and also production control was based on the precedent that soldering processes would be accomplished with tin-lead (SnPb) soldering materials. Tin-lead solder has specific properties that were instrumental in the multitude of component attachment methods that evolved for production of electronics. Had the solder of choice over the years been other than tin-lead, many of these common configurations might have evolved differently. The current reality is that component designs intended for tin-lead attachments are being soldered with various lead-free alloys, driven by the requirement to remove lead from electronic products. Acceptability for these designs has not changed that much, as reflected in current IPC acceptability standards. The attachments still need to have solder that flows over the connection interface surfaces, forms a fillet, and wets to the constituents that form the attachment. What has changed significantly is the surface appearance of the resulting solder connection. Most lead-free solders exhibit surface roughness that would cause concern for those accustomed to the normal appearance of tin-lead. In fact, if solder finishes created by tin-lead had the same surface appearance, they would have rightly been considered contaminated or overheated.The current IPC-A-610 standard provides a side-by-side contrast of similar solder connections accomplished with both tin-lead and lead-free solder alloys for appearance perspectives. Outside of the considerations of acceptability appearance, there are additional concerns for materials compatibility issues and adverse properties such as hot tear, tin whisker, tin pest, accelerated and increased process temperature exposure, and others. These considerations should be developed elsewhere in this reference. This section presents common possibilities for acceptance criteria.

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Military, Space, and Commercial Specifications Reference to these types of specifications is common in the applicable markets No great amount of detail will be discussed; however, they are all worthy of some discussion since they can provide a great deal of insight into the rationale of product acceptability and its origin 52121 Military Specifications Military specifications have been widely accepted for use in many markets outside of their intended military products The one with the most relevance to workmanship or acceptability criteria at the assembly level was MIL-STD-2000, a unified standard created from several individual services and production standards It was created to combine the various requirements into a single standard to make it easier for military contractors to implement a single performance requirement.

Many lower-level supporting specifications for components, designs, materials, and printed circuit boards (PCBs) were part of the family of documents to support performance and acceptance requirements as a package Each specification was designed to be compatible with the eventual success of the end product In an effort to increase understanding by all of the parties involved, and to ease compliance issues, the services provided training and certification at various locations throughout the country, and even at some international locations The typical training audience often included customer representatives as well as producersThe title of MIL-STD-2000 was Standard Requirements for Soldered Electrical and Electronic Assemblies However, all of the military soldering requirements standards, including MIL-STD-2000, have been rescinded for future production through DoD acquisition reform initiatives.

Nevertheless, some products still use the requirements because they have been adopted internationally and because they provide relative benefit for the product s specific industry segment MIL-STD-2000 was an extensive document that defined the nonconformance conditions that required disposition as rework, repair, or use as is This of course required some action by the manufacturer to evaluate a given defect anomaly and make a decision regarding its impact on the form, fit, or function of the intended use It also allowed some level of customer involvement concerning these decisions if the contract prescribed it MIL-STD-2000 also limited the assembly materials for a manufacturer in terms of the solder alloys, flux activity levels, cleanliness, conformal coating, solder mask, and their acceptance conditions, either through a flow down to a supporting specification or internal requirements.