IPC Conformal Coating Material & Application “State of the Industry”
Assessment Project
Dave Hillman, Tina BerthiaumeRockwell Collins
IPC/SMTA Cleaning & Coating Conference
Agenda
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• Background• IPC Committee Task Plan
• Test Materials• Test Vehicle• Metallographic
Sectioning Plan• Conformal Coating
Measurements• Anticipated Results
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Background
Graphic Courtesy of CALCE Consortia
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Background
Graphic Courtesy of CALCE Consortia
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Background
Graphic Courtesy of CALCE Consortia
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Background
Graphic Courtesy of CALCE Consortia
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Background
Graphic Courtesy of PERM group
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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.
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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
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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)
• Committee Results Review at APEX Conference and IPC Committee meeting at SMTA Fall Conference
• Task Group Final Report “Roughly” Scheduled for 2015
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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
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Coating Coverage and Thickness Assessment Method: Metallographic Cross-sectioningDetails:
• 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
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Components Being Assessed: 25 per TV and 3 TV per Coating/Application Set
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Processing: Photodocumentation
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Processing: Photodocumentation
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Processing: Photodocumentation
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Processing: Photodocumentation
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Careful Removal From Test Vehicle (Gold Sputtering/Protective Cap Layer)
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Metallographic Cross-sectioning: Cold Mount, Off Angle Grind/Polish
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Measurements: Standards Calibrated Metallographic Scope
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
JSTD-001Conformal Coating Material & Application Industry Assessment
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Measurements: Maximum, Minimum, and Top of Component Examples
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Material: UR
Application Process:
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
Application Detail
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Application Detail
Material: SR
Application Process:
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).
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Application Detail
Material: ER
Application Process:
Atomized Spray Coating, 10 passes each in X & Y axis, IR Profile followed by Batch Cure 45 min, 1 - 3 mils
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
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IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
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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
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Questions ???