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 ???