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Large variations in defect levVoid els should be expected For some board types, small increases or no increase will be seen, whereas for others a Note poor significant (more than 10 times) increase in DPMO valtoe formation ues will be seen These defect levels will vary from one manufacturing site to another Inspection and especially automated inspection will be a significant help in addressing the tighter process window acceptable for a lead-free process For process control, pre-reflow inspection will provide the biggest Void benefit The obvious benefit is that solder paste inspecLead-free tion (SPI) and pre-reflow automated optical inspection (AOI) systems provide early defect and potential defect FIGURE 536 An x-ray image of a detection and prevention specifically by identifying the lead-free example defects that are expected to increase with the use of lead-free solder (opens, bridges, and so on, as previously mentioned in this chapter).

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An additional benefit and perhaps the most valuable one is the insight that the process engineer can gain by evaluating the results from SPI and AOI systems as lead-free materials are adopted By integrating SPI and AOI systems in the manufacturing process as they move to lead-free materials, and then using the data for process optimization, the manufacturer can eliminate most of the process difficulties that a lead-free process creates This implementation will in turn allow users to bring lead-free lines up to speed more quickly and efficiently, saving on labor, materials waste, and so on After reflow, the main objective is to identify defects so that repair action can take place For this manual visual inspection,AOI post-reflow, or automated x-ray inspection, can be used Even with good process control, defect levels are likely to increase, especially for higher-complexity boards.

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If defect levels are higher, then a good inspection strategy becomes more valuable..

Printed circuit board real estate continues to be coveted Boards are getting smaller and smaller as more and more capabilities are built on them To keep up with this trend, complex packages and devices and miniature devices are cropping up Many would argue that a 0402 chip component is small, but small becomes subjective when you consider 0201s and 01005s The 01005 component s sizes typically range from 010 mm (0004 in) 0304 mm (0012 in) to 020 mm (0008 in) 040 mm (0016 in), depending on the supplier Note that the 0201 typical is 060 mm (00236 in) 030 mm (00118 in), thus it s quite a jump With devices on this size order, the design considerations are large and the propensity for defects is higher.

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Inspection must catch the defects, but at these sizes, approaching the eye of a needle, it is not practical to conduct inspections visually, and thus such automated test and inspection become paramount Automated test and inspection continues to spur the development of camera and algorithm technology to keep up with the throughput, coverage, and size requirements demanded by the industry Miniaturization in itself is quite a driver for these technologies Add this to the material changes that are going on with materials changes such as lead-free materials, and the need for automated test and inspection only increases AOI systems including three-dimensional (3-D) and two-dimensional (2-D) solder paste and pre- and postreflow component inspection are typically lead-free-ready, as are x-ray test systems, with a few minor programming updates The advancement of the miniaturization movement also drives technologies such as multichip modules (MCM), system-in-a-package (SIP), and so on.

These devices or boards, depending on how one refers to them, have many interconnects among themselves in addition to the requirements that they pose when the entire MCM, SIP, etc, is adhered to a printed circuit board The number of hidden joints increases, the types of hidden joints increase, and the complexity of the attachment to the SMT board in general increases All of these are contributors to the ongoing need for increase defect containment and defect coverage that only automated inspection and testing bring..

Visual inspection is the visual comparison by a human of some attribute of the printed circuit assembly with specified standards that describe the acceptable range for that attribute. The inspector normally picks up the printed circuit assembly or places it under a microscope and carefully observes particular attributes, such as the condition or bend radius of component leads or the wetting of solder joints to a lead. Visual inspection always involves human judgment in comparing the attribute to its conditions of conformance to standards.

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