Solder Paste Wave Solder Flux Preforms Cleaners Stencils Wave Solder …/media/Files... · 2012. 3. 9. · • High reliability. • Low oxides, low drossing. • Solder bar, chunks,

Where do electronicsassemblers turn for value?

alpha

ALPHA® Full-line Selector Guide

Wave Solder FluxCored Wire

PreformsReclaim

CleanersAdhesives

Solder PasteWave Solder Metals

Stencils

ALPHA’s Strategic Value Proposition

ALPHA’s Customer Value Propositions:• Leading technology products• Sales/Support in every major electronics

geographic market• Local and consistent technical support

regionally and globally• Applications expertise• Continuity of supply ensured through

multiple manufacturing sites• Consistent product performance globally• Access to continuous new technology

development• Global OEM approval engagements • Manufacturing lot trace-ability • Six Sigma projects for process optimisation• High-reliability products• Channel Partner network (distribution)• Access to application laboratories• Accelerated technology customisation for

key customers• Delivered lowest cost of ownership • Solder scrap value recovery

When you commit to ALPHA producttechnology, we commit to your success.

We are committed to enhancing yourproductivity, yield and cost of ownership as you navigate through today’s electronicassembly challenges. We do this bydeveloping leading technology materialscombined with our world class processknowledge and applications expertise.

Table of Contents

Solder Paste 4

Wave Solder Metals 6

Wave Solder Flux 8

Cored Wire 10

Preforms 12

Reclaim 14

Cleaners 16

Adhesives 18

Stencils 20

Stencils (cont.) 22

2 www.alpha.cooksonelectronics.com

Alpha Sales Offices and Channel Partner Locations

www.alpha.cooksonelectronics.com 3

CHANNEL PARTNER LOCATIONS

• BulgariaFintech Ltd.00 35 92962 4756

• Czech republicERMEG s.r.o.00 420 48 510 2491

• DenmarkTeleinstruments00 45 76251818

• EgyptSigma00202 2633 6964

• FinlandMatronic00 358 927479126

• FranceUnivar00 33 4 37 91 42 60

• GermanyBlume Elektronik Distribution GmbH00 49 5063 2712-0HOPF Vertriebsgesellschaft GmbH00 49 6196 493-239Keinath Electronic consulting & equipment00 49 7072 91468-0Weidinger GmbH00 49 89 899132-0

• GreeceN.G.Zafiropoulos & Co. E.E.00 30 210 9566027

• HungaryNóniusz Szerszám00 36 1 329 6453

• IrelandPat Gayer00 353 87 3826 718

• IsraelHeadtech Engineering Ltd00 972-3-696-2132

• ItalyAlta S.R.L.00 39 055-759411Barbieri S.R.L.00 39 0125-230341Kosme s.a.s.00 39 049-8725062Pansystem SRL00 39 06-4130978Special Components S.R.L00 39 0362-346955

• NorwayBetek Consult AS0047 3331 0150

• PolandLenz Urzadzenia dla Elektroniki, F. Gorol00 48 32 227 2806

• PortugalPRODUTRONICA LDA00351 21 9246763

• [email protected] 36 30 4910160

• RussiaNPF DiPaul007 (812) 702-1269

• Slovenia/Croatia/MoldaviaINTERKONT Import-Export Berger GmbH00 49 8331 9799-0

• SpainInternational Metals Synergy, S.L00 34 91 6289433

• SwedenTecono00 46 70962332000 46 706307883

• SwitzerlandHilpert electronics AG00 41 56 483 2525

• TunisiaAdelec 00216 7083 8234

• TurkeyEsman Elektronik Ltd00 90 212 217 6620

• UKThe Solder Connection44 (0)1291 624400

• UkraineFerrumino Ukrajna Kft.00 380 93 686 2100

ALPHA® European RegionALPHA SALES LOCATIONS

• Belgium+32 14 44 50 [email protected]

• England+44 (0) 1483 758 [email protected]

• France+33 241 49 00 [email protected]

• Germany+49 2173 8490 [email protected]

• Hungary+36 24 460 [email protected]

• Italy+39 02 4533 [email protected]

• Ireland+35 318 4211 [email protected]

• Netherlands+31 35 695 [email protected]

• Scotland+44 (0) 1355 276 [email protected]


ALPHA® solder pastes are used in the assembly of PCBs for a variety of product applications, includinghand-held electronic devices, alltypes of computers, consumerelectronics, network servers,automotive systems, medical and military equipment and many others.

NO-CLEAN PRODUCTS

ALPHA® OM-5100• Broad latitude, no-clean;

appropriate for most tin-lead SMTapplications

• Higher reflow yields with excellentprint deposit consistency

• Reduced random and mid-chipsolder balls

ALPHA® OM-338T (ZHP)• Broad latitude, no-clean;

appropriate for most lead-free SMTapplications

• Wide reflow process window andoutstanding voiding resistance

• Ultra-fine pitch printing capability at up to 200mm/sec. (8 in./sec) print speed

ALPHA® OM-338 PT (ZHP)• Excellent in-circuit pin testability• Superior performance in closed-

head printers• Wide print process window up to

150mm/sec. (6 in./sec.)

ALPHA® OM-338 CSP (ZHP)• Broad latitude lead-free, no-clean

paste• 0.4mm pitch BGA enabling

technology• Excellent print capability across

various board designs

ALPHA® OM-340 (ZHP)• Broad latitude lead-free, no-clean

paste• Excellent in-circuit pin testability• Better spread and wetting

ALPHA® OM-350 (Halogen-Free)• Reduced defects (voiding, mid-chip

solder balls, BGA pillows)• Excellent paste-in-through-hole

performance• Best-in-class electrical reliability• Excellent print volume repeatability

up to100mm/sec.print speed

ZHP: ZERO Halogen Product

Halogen-free, per guidelines published in the following industry standards: IPC-4101B, IEC-61249-2-21 and JPCA-ES-01-1999.

WS-809 Water-Soluble 0.40mm (16 mil), 75% RH 36+ HOURS

Photomicrograph of fine-feature solderpaste deposits produced at 200mm/secprint speed.

OM-338PT 0.40mm (0.40mm) pitch

OM-338PT No-Clean Solder Paste

OM-338T No-Clean Solder Paste

WS-809 Water-Soluble Solder Paste

ALPHA® Solder Paste

Highest throughputand yield, andlowest cost ofownership fortoday's challengingelectronic assemblyprocesses.

• Leading technology products• Consistent product performance globally• Continuity of supply ensured through multiple manufacturing sites

TIN

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Tin-lead Lead-free Tin-lead Lead-free water-soluble no-clean no-clean water-soluble

LEA

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To fully support SMT printingrequirements, ALPHA also offers acomplete line of ALPHA® Stencilsand Cleaners.

ALPHA® Solder Paste

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WATER-SOLUBLE PRODUCTS

ALPHA® WS-809• Broad-latitude, water-soluble tin-lead

paste; appropriate for most SMTapplications

• Excellent balance of stencil life andcleanability

• Provides excellent voiding resistance• Delivers excellent throughput and

high first pass yield

ALPHA® WS-819• Long stencil life under varying

ambient conditions• Excellent resistance to BGA voids• Ease of cleaning with aqueous wash

systems


ND: None Detected

Pb-FREE ALLOYS SnPb ALLOYS POWDER SIZE

PERFORMANCE PRODUCT INDICATORS NAME

Universal, Highest Print ALPHA

®

• • • • • 88.5% M13 ROL0 88.3%Speed OM-338 T M04

ND

Universal, Pin Testable, ALPHA®

Enclosed OM-338 PT • • • • • 88.5% M15 ROL0 NA NDPrint Heads

Enabling 0.4mm ALPHA® • • • 88.3% M15 ROL0 83.5%M04 NDBGA Assembly OM-338 CSPHigh Soak Profile,

Paste in ALPHA®

• • • • • • • 89.0% M17 ROL0 TBD

ALPHA has been manufacturing soldering alloys for over 125 years.Today, with eight manufacturing loca-tions globally, ALPHA is the largestsupplier of solder alloys for the elec-tronics assembly industry.

Our ongoing commitment toresearch and development hasenabled us to understand the com-plexities of alloy performance result-ing in a product line that meets ourcustomers’ most demanding lead-free and tin-lead wave solderingprocesses and is backed by dedicat-ed customer technical support.

The ALPHA® line of wave solderingalloys consists of proprietary, specially developed products underour SACX® brand and the more common SAC and Sn/Pb alloys andother alloys that require third partylicensing.

ALPHA® solder metals offer the bestvalue for wave and selectivesoldering performance – qualityproducts at the lowest cost ofownership. And thanks to a global copy exact product policy,consistency of supply is assured.• High purity.• Excellent solderability.• High reliability.• Low oxides, low drossing.• Solder bar, chunks, anodes,

preforms and solid wires.• Vaculoy alloy conditioning

process.

Industry leadinglead-free and tin-lead alloysthat meetdemanding processrequirements.

The SACX Family of Alloys

Engineered for high performance on certain types of assemblies or inspecific applications, all SACX alloysdemonstrate excellent solderingperformance, low dross generation andhigh mechanical reliability. All SACXalloys are manufactured using ourproprietary Vaculoy conditioningprocess.

ALPHA® SACX 0807 • SAC305-like performance on

complex, dual sided assemblies• Low copper dissolution• Lower silver (.8%) means lower cost

ALPHA® SACX 0307• Perfect for standard assemblies• Excellent wetting and drainage

resulting in high yields• Great Value

ALPHA® SACX 0107• Great for single sided or simple dual

sided assemblies• Low copper dissolution

ALPHA® SACX 0307 Plus• Designed for use in wave, rework or

selective solder applications• Low copper dissolution during long

exposure times

ALPHA® SACX HASL• High-value, low-cost pad finish• Low consumption, uniform, flat

coverage

We also manufacture additional Pb-freealloys including the high-performingindustry standard SAC305, along with,SAC405, SAC387, SAC380, SA2515,and others. Each Pb-free alloy is also available in a copper-free version (i.e., SAC300) for solder potreplenishment and rebalancing.


ALPHA® Wave Solder Metals

WaveSoldering

ALPHA® Wave Solder Metals


For details of the range of popularALPHA® Fluxes, Cored Wire,Cleaning Materials and ReclaimServices, please refer to individualproduct literature or go towww.alpha.cooksonelectronics.com

Availability

ALPHA® quality wave solder metals areavailable in a choice of options to suityour process requirements. Solder bars(1 & 3.5kg), solid wire for automaticfeed, chunks, preforms and anodes.

For best results always use acompatible ALPHA® flux, available ina choice of solids content andactivator levels, with water washable,no-clean and VOC-free options.

AVAILABILITY

PROCESS BASE ALLOY ASSEMBLY CHARACTERISTICS PRODUCT NAME AM

ER

ICA

S

ASI

A

EU

RO

PE

Lead-Free Standard (

All ALPHA® EF-Series fluxes weredeveloped for SnPb and Pb-freeapplications and are halogen-free*.

WATER-BASED

ALPHA® EF-2210• VOC-free• Excellent soldering performance• Rosin free formulation results in

excellent cosmetics and pintestability

• Bellcore SIR compliant

ALPHA® EF-3001 and ALPHA EF-3215• Low-VOC formula – nonflammable• Resin bearing emulsion flux for high

reliability and performance –Bellcore SIR compliant

ALPHA® Wave Solder Flux

The ALPHA® branded fluxes are theleader in providing wave solderingprocess solutions. Our latest line of fluxes, including our EF-Series, is designed to provide the highestlevel of performance and reliabilityin its class. Specific flux productswere formulated to offer a safer andmore environmentally friendlyalternative.

All ALPHA® fluxes have beendeveloped using the latest ALPHAflux technology. ALPHA operatesmany flux production facilitiesaround the world. Each site followsstrict standards that assure highproduct quality and consistency.

Fluxes that deliverbest in classsoldering perform-ance and electricalreliability,including options that improveworker safety andare better for the environment.

ALCOHOL-BASED

ALPHA® EF-6000• Highly active for exceptional

soldering performance• Low solids (2%) for excellent

cosmetics and pin testability • IPC SIR compliant

ALPHA® EF-6100• High reliability – JIS SIR compliant• Low solids for excellent cosmetics

and pin testability • High soldering yields

ALPHA® RF-800 Rosin No-Clean Flux• Best selling low-solids (4%) flux in

the world• Excellent soldering on a wide

variety of assembly types• High reliability – JIS SIR compliant

ALPHA® EF-8000• Excellent solder performance on

complex two sided assemblies• Perfect for selective soldering

applications• High reliability – JIS SIR compliant

ALPHA® EF-9301 Flux• Excellent solder performance on

a variety of complex two sidedassemblies

• Halide bearing dulling flux• High reliability – JIS SIR compliant

ALPHA® EF-12000• high-solids (15%) dulling flux• Maximum wetting on a wide variety

of simple and complex assemblies• High reliability – JIS SIR compliant


* Halogen-free, per guidelines published in the following industry standards: IPC-4101B, IEC-61249-2-21 and JPCA-ES-01-1999.

FLUX PREHEAT SOLDER ELECTRICAL REGIONAPPLICATION TECHNOLOGY ALLOY RELIABILITY

FLUX TECHNOLOGY ROSIN SOLIDS PRODUCTS

Rosin-Free Low • • • • • • • • • • ALPHA EF-2210No-Clean Low • • • • • • • • • ALPHA NR-330

Low • • • • • • • • ALPHA EF-3215

Water-Based Rosin-Containing Low • • • • • • • • • ALPHA EF-3001No-CleanMed • • • • • • • • • • ALPHA EF-4102

Water SolubleHigh • • • • • • • • ALPHA WS-3355VF

High • • • • • • • • • ALPHA WS-375

Rosin-Free Low • • • • • • • • • ALPHA EF-6000No-Clean Low • • • • • • • • ALPHA LS-500A

Low • • • • • • • • • • • ALPHA RF-800

Rosin-ContainingLow • • • • • • • • • ALPHA RF-800T

Alcohol-Based No-CleanMed • • • • • • • • • • • • ALPHA EF-8000

Med • • • • • • • • • • • ALPHA EF-9301

High • • • • • • • • • • ALPHA HS-615-25

High • • • • • • • • • • • • • ALPHA EF-12000

Water-SolubleHigh • • • • • • • • • ALPHA WS-856

High • • • • • • • • • ALPHA WS-3355-11

High • • • • • • • • • ALPHA WS-857

ALPHA® Wave Solder Flux

Hand Fluxing and Related Products

• Flux Thinners• ALPHA® Flux Pens

- ALPHA® Aqualine: water-soluble- ALPHA® Guideline: rosin flux- ALPHA® Cleanline: very low residue

• Flux gel• Flux stop

To fully support wave solderingrequirements, ALPHA also offers wavesoldering alloys, solder wire, andcleaning chemistries.


† All fluxes recommended for Sn/Pb

SPR

AY

FOA

M

IR CO

NV

EC

TIO

N

SELE

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SOLD

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ING

PB

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IPC

BE

LLC

OR

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IR

QP

L/M

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JIS

HA

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AM

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ICA

S

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RO

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ASI

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IFIC

For the most up-to-date list of ALPHA® fluxes, or to find the right flux for your assembly or application, use our on-line Flux Selector. Go tohttp://www.alpha.cooksonelectronics.com and navigate to the wavesolder flux products page.

• Sales and Engineering Support in every major electronics geographic market• Continuity of supply ensured through multiple manufacturing sites• Access to continuous new technology development

Lead-free

For soldering of Lead-Freeassemblies, there are ALPHA coredwires available in the following alloyspecifications: SACX, SAC305,SAC405 and Sn96.5/Ag3.5

ALPHA® Telecore Plus• World’s no.1 selling cored solder

wire • No-clean, activated rosin flux

conforming to J-STD-004 ROL0• Bellcore compliant• Clear, tack-free, non-corrosive

residues, high SIR


ALPHA® Cored Wire

High-performance,fast wetting coredwires that meetthe most demandingreliabilitycriteria.

ALPHA® cored wires are available in achoice of high-purity alloys, diametersand flux percentages, with the choiceof no-clean, rosin/resin free and lead-free options. All alloys conform to ISO 9453.

The comprehensive range of ALPHA®

wires is designed to give excellentwettability, produce strong jointswithout spattering and leave minimalnon-corrosive residues with good SIRfor defect-free soldering.

ALPHA® Telecore XL-806• Low flux spatter for safer, more user

friendly operation• Fast wetting, ideal for rework, manual

assembly and “drag soldering”• Good Spread Characteristics for

excellent first pass solder joints• Low Fume for cleaner working

environment• Clear, non tacky no-clean residue • High resistance to charring for

improved board cosmetics• Good joint appearance makes

inspection easy• J-STD-004 ROM1 designation • Passes all reliability testing required

for ROL1 classificationALPHA® Telecore XL-810A newly developed cored wiredesigned for use in Pb-Free solderingoperations. Designed in conjunctionwith the development of Alpha®

Telecore XL-806, this product containsslightly less halides in order to meetthe ROL1 classification.

ALPHA® SMT Plus (ZHP)• Alpha’s “ZERO Halogen” cored

solder wire• Low flux content – less residues,

good cosmetics• J-STD-004 ROM0 classification• Excellent wetting

ALPHA® FT 2002 Rosin Free• Fully synthetic halide and rosin free,

no-clean• J-STD-004 ORL0• Drop in replacement for rosin cored

solders• Very good tarnish removing

properties and high SIR• Clear, hard residues can be safely

left on the board

ALPHA® Pure Core• Organic activated water

soluble flux• J-STD-004 ORM1• Washable even if cleaning is delayed

for several days• Very fast wetting

ALPHA® Fluitin 1532• Activated rosin flux• J-STD-004 ROM1• Good thermal stability in poor

soldering conditions• Clear, hard residues can be left on

the board

The ALPHA® range of quality solderwires is specifically designed forhand soldering, component attachand touch-up for surface mounttechnology. All products aremanufactured to ISO 12224-1specification and test methods.• For all hand and automated

soldering, component attach and rework operations.

• Minimal, non-corrosive fluxresidues for high solderingefficiency.

• Even core flux distribution.• Good solderability, strong joints.• Rosin/resin and lead-free options.• Meets leading specifications.

ZHP: ZERO Halogen Product


ALPHA® Cored Wire

Availability: Lead-Free Alloy-Flux

J-STD-004 ClassHalide ContentAcid Value

J-STD-004 Class

Availability: Tin-Lead Solder

• High-reliability products• Access to continuous new technology development

Numbers represent percentage of flux in alloy

FT-2002 SMT Fluitin 1535 Fluitin 1532

Alloy Melting or ORL0 ROM0 ROL1 ROM1 Solidus/Liquidus None None 0.35-0.45 0.80-1.10

Temp °C 250 362-402 170-190 170-190

Sn60/Pb40 183-190 105, 111 122 111, 122

Sn60/Pb38/Cu2 183-190 111, 122, 133

Sn63/Pb37 183 111, 122 105, 111 122

Sn62/Pb38/Ag2 178-190 105, 111 122

STANDARD FLUXES

FT-2002 Telecore+ Telecore Telecore SMT Fluitin 1532 PureCoreRosin-Free XL-806 XL-810 Water-Soluble

Alloy Melting orORL0 ROL0 ROM1 ROL1 ROM0 ROM1 ORM1Solidus/Liquidus

Temp °C

SAC305 217-221 122, 133 122, 133 122, 133 122, 133 111, 122 122, 133 133

SACX 0307 217-228 122, 133 122, 133 111, 122 122, 133

SACX 0807 217-225 122, 133 122, 133

SAC387 217-220 122

SAC405 217-225 111, 122 122, 133

Sn96.5/Ag3.5 221

Sn99/Cu1 228 122 122 122, 133

LAMINATION SPECIFICATIONS

MATERIAL THICKNESS (mm)

Copper .075 – .750

Solder .040 – .225


ALPHA® Exactalloy® Preforms

How does yourability to fine tune solder volumehelp increase yourprocess efficiencyand productperformance?

ALPHA® Exactalloy® solder preformsaddress a wide variety of solderingchallenges, including PBC assembly,automotive sub-assemblies,connectors and terminals, die attach,power module substrate attach,filtered connectors, and electroniccomponent assembly.

Size/Shape: Custom designed sizesand shapes provide exact soldervolume for specific applications,aiding the assembly process.

Flux Type: Based on the specificapplication, fluxes can be integratedwith an Exactalloy® preform. Ourapplications engineers can help youselect a flux that meets all applicableIPC standards. Color-coded fluxes are available for easy identification.

Key ALPHA® Exactalloy® PreformApplications

Preforms in Solder Paste: ALPHA®

Exactalloy® Preforms can be usedwith solder paste to selectivelyincrease solder volume. Tape-and-reel packaging provides a convenientmethod for the delivery of thepreform with standard pick-and-place assembly equipment. Thepreform is picked from the tape-and-reel packaging, and placed directlyinto the solder paste prior to reflow.Only a portion of the preform needsto contact the paste. ALPHA SolderPreform Tape & Reel packagingprovides you with a time-to-marketadvantage, solving your soldervolume issues during assemblyverification. Standard size 0402,0403, 0603 and 0805 and smallerALPHA® Preforms are readilyavailable in tape-and-reelpackaging.

Custom-designed shapes, sizes,alloys and flux types

Exactalloy® solder preforms areprecisely formed pieces of soldersuitable for volume manufacturing with very tight tolerances. They aremanufactured in a wide variety ofshapes, sizes, solder alloys and fluxdelivery systems to meet yourrequirements.

ALPHA® Exactalloy® PreformSelection Criteria

Alloy: Selection is based on meltingpoint and compatibility withsubstrate materials. Exactalloypreforms are produced in a largevariety of alloys to meet your specificapplication requirements. When usedin combination with solder paste, the preform alloymatches the paste alloy.

Bare pins, washers in place pre-reflow, post-reflow

Solder Washers for PCB Assembly:ALPHA® Exactalloy® Preform solderwashers provide you with an idealmethod of not only delivering theprecise solder volume and fluxneeded for through-holeconnections, but they also eliminatethe need for secondary solderprocesses. The preform solderwasher can be placed on theconnector pin during PCB assemblyusing pick and place equipment.Solder washers can also beintegrated into production usingvarious fixturing methods. Theconnector pins are then reflowsoldered at the same time as thesolder paste.

ALPHA Exactalloy Preforms in solder paste.

Fuse Alloys: The combination of theprecise solder volume and a specificmelt temperature provides a fusefunction, such as required in firesuppression systems. In addition tothe very precise fuse functionenabled by eutectic or near eutecticalloys, the solder can providemechanical strength for theassembly. ALPHA is leading theindustry in cost effective solutions.

Solder-Copper Laminates: Forapplications that require laminatedpreforms, we offer solder/copper/solder laminates in washer, square,rectangular and disc shapes. A widevariety of alloys is feasible.

Consult for specific solder-copper combinations


ALPHA® Exactalloy® Preforms

Tape and reel

• Access to continuous new technology development• Applications expertise• Accelerated technology customization for key customers

Solder Sleeves: ALPHA’s patentedmanufacturing methods provide thevast majority of the industry's volumefor solder sleeves used in solder-based wire harness connectors.These products are the life blood ofaeronautic, marine and specialtyvehicles. The end products providevibration resistant and moisture proofinterconnection solutions. Ask aboutplans to support RoHS and ELVcompliant offerings.

Solder Ribbon: ALPHA’s high qualitysolder ribbon product offeringprovides the flexibility to integratecustom solder preforms into yourproduct with your specialisedmaterial cutting and handlingequipment, ensuring a costeffectiveapproach for high volumeproduction.

Die Attach: Typically provided inhigh lead alloys, contaminate freesolder materials – combined withALPHA process knowledge andexpertise – offer a highly reliable dieattach solution for demanding powerapplications. Our continuous R&Defforts in this area are providing newcapabilities, further enhancing thecost performance of die attachsolutions.

Available Flux Types: Flux is acritical element in the solder system.ALPHA offers the widest variety offlux types to meet the mostdemanding applications, includingcolor indicators for identification ofRoHS versions on the shop floor. Askus about how our resilient flux isexpanding the range of potentialsolutions available for yourapplication.

WasherODMin = .020” (0.51mm)Max = 3.00” (76.0mm)

IDMin = .008” (0.2mm)Max = OD – .010” (0.25mm)

T (Thickness)Min = .002” (0.05mm)Max = .110” (2.80mm)

RectangleS (Side)Min = .020” (0.51mm)Max = 2.30” (58.00mm)


DiscD (Diameter)Min = .020” (0.51mm)Max = 2.10” (53.00mm)


SleeveODMin = .057”(1.44mm)Max = 1.05” (26.60mm)

IDMin = .049” (1.20mm)Max = 1.024” (26.00mm)

H (Height)Min = .024” (0.61mm)Max = .472” (12.00mm)

* Typical specifications shown, otherdimensions available upon request.

* Rosin Superactivated

Substrate Attach: The heart of thepower module that drives reliability isthe DBC substrate. ALPHA offers thehighest performance high Sn alloys inthe industry for the most demanding,highest reliability substrate to heatspreader attach. Ask about ournewest alloy offering that extendssystem reliability.

Flexible Packaging Options:Packaging options are available tomeet a variety of applications andassembly equipment requirementsand are designed to maximisecustomer process efficiency. High-speed preform placement can beimplemented using preforms packedon tape and reel, or in bulk feedercartridges. ALPHA also offers anassortment of trays, and bulkpackaging options. Argon packagingis available for specific alloys.

FLUX TYPE INTERNAL EXTERNAL

RMA (ROL1) yes yes

RA (ROM1) yes yes

NC (ROL0) yes yes

RSA* (ROH1) yes yes

WS (ORL0) yes consult

Resilient (ROL0) no yes

Prototypes and Specialty Shapes:ALPHA’s rapid prototyping abilityenhances time to market whileminimising tooling expenses neededto verify acceptable preformperformance.

ALPHA has a great deal ofexperience developing specialtyshapes. Please contact your salesrepresentative to learn more abouthow we can support your uniquepreform shape requirements.

SPECIFICATION GUIDELINES*

COMMON ALLOYS BY PRODUCT TYPE

ASSEMBLY LAMINATION SOLDER SUBSTRATE DIE LOW TEMP FUSEOVER COPPER RIBBON ATTACH ATTACH ALLOYS (95-150C)

SnAg PbSn SnAg PbSn SnAg PbSn SnAg PbSn SnPbCd InAg

SnAgCu PbSnAg PbSnAg SnAgCu PbSnAg SnAgCu PbSnAg SnPbInCd SnBi

SnSb PbInAg PbInAg SnSb PbInAg SnAgSb PbInAg SnPbIn SnBiAg

SnBi SnBi SnSb PbAg SnPbBi SnBiIn

SnSbCuNi SnIn SnInCd

SnBi SnZn


ALPHA® Reclaim ServicesALPHA reclaimmanagement: Leading the wayin environmentalresponsibility

As part of The ALPHA customer careprogramme, electronics assemblerscan take advantage of a safe,efficient reclaim service which willhelp companies meet theenvironmental and legislativerequirements, maximising the returnon their solder scrap. • Controlled collection and

reprocessing of solder scrap.• Conformance to state and federal

regulations.• Metal buckets supplied free

of charge.• ISO 14001 Certified facility• Freight paid to our facility• Certificate of recycling• Dedicated environmental and

reclamation staff.

We provide green buckets to helpcustomers keep their lead-freedross segregated so they canmaximise its value.

Solder Paste Recycling

Solder paste is a combination of flux and solder powder and assuch requires special reprocessingmethods. Unused solder pasteshould be segregated in aseparate container for recycling.

ALPHA is a major globalmanufacturer of solder paste, andhas all of the expertise required forits safe processing. These skills arenot necessarily available fromcompanies who do notmanufacture solder paste.

Upon request, we also supply acertificate of recycling which isyour proof the material wasrecycled.

Tough, sealable disposal bins for lead-free and tin-lead dross

ALPHA has invested heavily in anappropriate integrated packagingand transport system for solderreclaim . . . . Investment that reflectsour commitment to the products wemanufacture throughout theircomplete life cycle . . . . Investmentdesigned to save our customers timeand trouble.

ALPHA recycles millions of kgs oftin/lead bearing materials each year.

As the largest solder reclaimoperation in the world, ALPHAensures that solder scrap isprocessed in the most efficient waypossible which maximises the returnto the customer. We are the onlysolder manufacturer that has acomplete recycling facility.

Lead-free

Lead-free solders have not onlycreated technological challenges buthave increased the cost of materialsfor assembly companies. A way tooffset this cost is with the reclamationof your lead-free solder dross. ALPHAis able to recycle the numerous lead-free alloys being used by companiestoday. With our refining capabilitieswe are able to help customersmaximise the value of their materials.


ALPHA® Reclaim Services

Reclaim Services

ADVANTAGES

The solder scrap does not passthrough many different handlersbefore being recycled.

Credit for the solder scrap is thenseen directly in the cost center whereit is generated.

The company has high legal andmoral standards, and a globalpresence.

The company has invested in themost efficient processes for solderrecycling, ensuring that lead and othertoxic compounds are strictly controlledand do not get released into theenvironment. Cookson Electronics has been ISO14001 certified sinceMay 2002.

• Solder scrap value recovery• Delivered lowest cost of ownership• Six Sigma projects for process optimisation

Your reclaim contacts

ALPHA reclaim management: Leading the way in environmental responsibility

BENEFITS

1) There is a clear audit trail so thatcustomers can identify exactly wherethe solder scrap goes, and hence bereassured about its safe environmentalreprocessing. Companies and their employees will not risk legalimplications or adverse publicitycaused by any illegal disposal.

2) Customers can visit thereprocessing facility and conducttheir own audit on the recyclingprocess. A complete preauditpackage is available upon request

This means that the true cost of the wave solder process can bemeasured, hence any decisions thatinvolve costing (new designs, newsubcontract projects) can be takenbased on the true cost.

All cost credits remain with theassembly department.

Companies get the piece of mindthat the disposal of this solder scrapis being conducted in a legal andmoral way.

Customers are assured that they arebehaving in a responsible mannerwhich will protect the environment.

FACT / FEATURE

ALPHA recycles all kinds of solderscrap “Cradle to Grave”

ALPHA can supply new solder bar inexchange for solder dross. “New forold”

You can trust in ALPHA – the largestsolder manufacturer and recycler inthe world. Cookson Electronics is apublicly traded company.

BelgiumALPHA…Cookson Electronics NV Veedijk 33Turnhout, B-2300Phone: 32 1444 5000Fax: 32 1442 4779Email: [email protected]

United KingdomALPHA…Cookson Electronics Forsyth RoadSheerwater, Woking (Surrey) GU21 5RZPhone: +44 (0) 1483 758 400Fax: +44 (0) 1483 758 410Email: [email protected]

FranceALPHA…Cookson Electronics Z.I. du Cormier Boulevard de CormierCholet, 49300Phone: 33 241 49 00 11Fax: 33 241 49 00 19Email: [email protected]

GermanyALPHA…Cookson Electronics Elisabeth-Selbert-Strasse 4LangenfeldPhone: 49 2173 8490 300Fax: 49 2173 8490 310Email: [email protected]

HungaryALPHA…Cookson Electronics 2330 DunaharasztiJEDLIK ÁNYOS u. 2.Phone: 36 24 460 720Fax: 36 24 460 721Email: [email protected]

ItalyVia Riccardo Lombardi 19/1020153 MIilanoPhone: 39 02 4533 921Fax: 39 02 45339253Email: [email protected]

IrelandALPHA…Cookson Electronics Unit 52 Airways Industrial EstateDublinPhone: 353 1 842 1172Fax: 353 1 842 1361Email: [email protected]

The NetherlandsALPHA…Cookson Electronics Energiestraat 21NaardenPhone: 3135 695 5411Fax: 3135 694 8451Email: [email protected]


How does inadequatestencil and pcbcleaning impactyour process?

ALPHA® Cleaners

ALPHA offers a range of cleaningproducts specifically for electronicassembly manufacturing applications,covering all major types of cleaningprocesses: semi-aqueous, aqueousand manual/non-aqueous cleaning.

Stencil/Misprint Cleaners

The range of stencil/misprint cleanerswas developed specifically to replaceIPA and other low-flash point, flam-mable materials in both manual andequipment applications where per-formance, safety and environmentalproperties are of primary concern.Some products are applied at am-bient temperatures and dry quickly,with or without forced air. There arealso products that are recommendedfor most non-aqueous and aqueousstencil cleaning equipment.• ALPHA® SM-440• ALPHA® SM-110• ALPHA® SM-110E

Board Cleaning

Unlike traditional organic andinorganic saponifiers, ALPHA aqueousdefluxers are organic solvent-basedproducts that are either watersoluble or make stable emulsions inaqueous process equipment. Theproducts differ from semi-aqueousdefluxers in that they can be used in standard aqueousequipment, both metal and plastic.• ALPHA® SM-110• ALPHA® SM-110E• ALPHA® 2110• ALPHA® BC-2200• Armakleen E2001P• Armakleen 2003

Manual Cleaning Range

In addition to replacing CFCs in pro-duction defluxing, ALPHA also offersalternative products for manualbenchtop defluxing after touch-upand rework. These products areapplied at room temperature, rinsedwith fresh product, and dried withambient or forced air. The fluids aremore aggressive than CFCs and IPAand remove even the more difficultresidues.• ALPHA® SM-110• ALPHA® SM-110E

ALPHA® SM-110 Cold/ManualCleaner (liquid and pre-saturatedwipes)

• Dissolves no-clean, water solubleand rosin flux residues

• Fast evaporation, higher flash point;excellent solvency propertiesoutperform IPA

• Excellent compatibility with stenciland PCB materials; approved for use in printer underwipe systems

ALPHA® SM-110 E

• Specially formulated for use in non-aqueous stencil cleaning equipment

• Removes most types of solderpaste and epoxy products, such asSMD adhesives

ALPHA® 2110 Aqueous RosinCleaner

• Cleaning concentrate designed for efficient removal of rosin fluxresidues from PCBs using aqueoussaponification processing

• Excellent cleaning of PCBs inconveyorised, in-line aqueousmachines, even to ionic cleanlinessstandards in MIL-P-28809

ALPHA® BC-2200

• Aqueous defluxer: VOC-free, high-performance alkaline cleaner withexceptional wetting properties and detergency; ideal for use withlead-free flux formulations

• Well-suited for in-line or batch spray-in-air cleaning; can be used in ultrasonic equipment

• Removes reflowed rosin, no-cleanand water-soluble fluxes from PCBs

ARMAKLEEN® 2003

• Environmentally sensible, inorganic-based aqueous cleaner designed for in-line or batch equipment forcleaning PCBs

• Low surface tension allows forpenetration of low stand-off heights

Armakleen is a registered trademark ofChurch & Dwight Co., Inc.

ALPHA® Cleaners

PCB Cleaning Products

Product Matrix by Cleaning Technology

• Sales/support in every major electronics geographic market• Local and consistent technical support regionally and globally• Consistent product performance globally

STENCILS & MISPRINTS AQUEOUS SOLVENT-BASED SEMI-AQUEOUS(SAPONIFIERS & DETERGENTS) (WASH/NO RINSE) (WASH/RINSE OPTIONAL)

Printed rosin and no clean paste C A B JUncured SMD adhesives C A B JPaste on board / understencil wipes C A B J

PRINTED CIRCUIT BOARDS AQUEOUS SOLVENT-BASED SEMI-AQUEOUS(SAPONIFIERS) (WASH/NO RINSE) (WASH/RINSE)

Batch In line Batch In line Batch In lineReflowed rosin based paste residues G D E F G D E F A B A B J JReflowed no clean paste residues FGE G – – J JHigh temp. reflow residues (Hybrids) G G – – J J

MANUAL CLEANING AQUEOUS SOLVENT-BASED SEMI-AQUEOUS

Jigs, fixtures I A B JFinger cleaning, flux tanks, reflow condensers I A B JAdhesive dispense needles F A JBench top, general cleaning D E I A B

KEY PRODUCT FLASH POINT SOLUTION

A ALPHA® SM-110 41C+/106F+ SolventB ALPHA® SM-110E 53C/128F SolventC ALPHA® SM-440 None to boiling AqueousD ALPHA® 2110 99C+/210F+ AqueousE Armakleen 2003 None to boiling AqueousF Armakleen E2001P* None to boiling AqueousG ALPHA® BC-2200 None to boiling AqueousH ALPHA® SC-30 65C/149F SolventI ALPHA® AutoClean 40 100C+/212F+ AqueousJ ALPHA® BC-3300 180 (COC) Semi-aqueous

*Specifically formulated for use with cleaning that utilizes plastic parts.

Stenciland

Misprints

BoardCleaning

On-boardPrinter

GeneralCleaning &Equipment

Maintenance

ALPHA®

SM-440

ALPHA® SM-110 & SM-110E

ALPHA® 2110

Armakleen 2003& E2001P

ALPHA®

BC-2200

ALPHA®

BC-3300


ALPHA® SC-30

ALPHA®

AutoClean 40


Aqueous. Spray, ultrasonics and head cleaning stencils of raw paste/SMD adhesive. Use 10-15% @ 26-38°C

Solvent based. Manual or non-aqueous batch cleaner – removes raw paste/adhesive and flux residues.Also available in presaturated wipes. ALPHA SM-110E has higher flash point.

Aqueous saponifierIndustry Standard in SnPb applications, Flash point = 99°C, Used at 3-10% @ 65-76°C

Aqueous inorganic board cleaners. 2003 is the leading Armakleen board cleaner. E2001P is for use on machines with plastic parts. Machine maintenance is very important.

Aqueous. For SnPb and LF apps, Use in batch, in-line and ultrasonic applicationsAggressive, Low VOC, Typically used at 5-30% concentration and temperatures from ambient to 71°C

Semi-aqueous. High strength, for use in spray under immersion, ultrasonic and hand cleaning operationsFlash point = 82°C. Use at 100% concentration from RT to 65°C, Wipe or total immersion, Water rinse, Air dry

Solvent based. Manual or non-aqueous batch cleaner – removes raw paste/adhesive and flux residues.Also available in presaturated wipes. ALPHA SM-110E has higher flash point

Solvent based. Used for understencil wipe in printer

Aqueous cleaner for general cleaning of flux spray nozzles, ovens, pallets etc. Suitable for batchimmersion cleaning and manual wipe.

Solvent based. Manual or non-aqueous batch cleaner – removes raw paste/adhesive and flux residues.Also available in presaturated wipes. ALPHA SM-110E has higher flash point



ALPHA® Adhesives

Epibond® 7275-Seriessurface mountadhesives offerexcellent performance for all print and dispensingapplications.

• Non-slumping and non-stringing.

• Room temperature stability.

• Dispense, print and pin transferapplication.

• Consistent dot profile and fastcuring.

• High-visibility red or yellowoptions.

• Screen printable with ALPHA CUTlaser stencils to SMD adhesiveguidelines.

Epibond®* 7275-Series Surface MountAdhesives are designed for holding inplace bottom side – and some mixedtechnology – surface mountcomponents during the wavesoldering process. Epibond® are high-quality non-slumping and non-stringing adhesives applied by dot dispensing, printingequipment and pin transfer, givingconsistent dot profile and fast curing.

Epibond® Typical Cure Profile

A correct thermal profile is critical toensure that the adhesive achievesmaximum mechanical strength and ahomogeneous cure:• Ensure the material is heated to the

correct temperature for the specifictime.

• The maximum thermal ramp rate is 1.5 to 2.0°C/second to ensure ahomogeneous cure.

Printed adhesive Dispensed adhesive

Epibond® Typical Cure Profile

ALPHA® Adhesives

Typical Properties

UNCURED EPIBOND 7275 EPIBOND 7275-1

Description Original formula ideal for each Slightly less viscous modification of the deposition methods. of the 7275. Designed specifically for high- Preferred for certain application speed applications. equipment.

Composition Epoxy EpoxyColor Red RedS.G. (ASTM-D-793) 1.28g/cc 1.20g/ccViscosity (ASTM-D-1824)cps @ 1rpm (x1000) 2,900 2350cps @ 10 rpm (x1000) 390 290Shelf Life 9 months @ 5°C 9 months @ 5°C

6 months @ 23°C 6 months @ 23°CThixotropic index >6.0 (ASTM D-1824) >6.0 (ASTM D-1824)Dot profile W/H

ALPHA® Stencils

Helping you getfirst-time-rightpaste depositsthrough advancedstencil servicesand technology

A Complete Understanding of theScience of Printing Helps Us GetYour Stencil Right the First Time

• ALPHA® has an intimate knowledgeof the stencil printing processbased on its global experience asthe leading producer of stencils as well as advanced solder pasteproducts worldwide.

• ALPHA® understands that thestencil is an integral part of anyprecision printing process. Gettingit right the first time helps savetime and money.

• ALPHA® global team of 100+Research & Developmentpersonnel, stays on the cuttingedge of paste printing and stenciltechnology development.

• ALPHA’s global technical serviceand support team helps integrateour products and enhance youryields.

• ALPHA® has over 1,200 satisfiedstencil customers worldwide in allelectronics industry segments.

Years of Experience Help Us GetYour Stencil Right the First Time

With over 800 man years of combinedexperience in the stencil business, wehave more time invested in stenciland printing technology than anyother stencil producer.

• 250+ man years of CAD experienceglobally

• 400+ man years of manufacturingexperience globally

• 100+ man years of technical serviceexperience globally

• 60+ man years of stenciloperations managementexperience globally

Advanced Stencil Services Make UsEasy to Do Business With and HelpGet Your Stencil Right the First Time

• Our inside sales staff ensuresprompt, efficient start-up andtransfer to CAD contact forongoing orders and data transfer.

• Our ongoing development work in printing and global exposure tothe newest packages enables us torecommend stencil design rules tominimize defects and maximizestencil performance.

• Automated application of customerand OEM / Product-specific designrules through our patentedDIMENSIONS® system reduces the possibility of CAD errors andimproves first time right service.

• Our PCB scaling service canenhance yield and throughput.Scaling of stencil design tocorresponding PCB reducesdefects and rework.

• We regularly monitor and controlpositional accuracy of the stencilthat allows us to provide accurate,consistent stencil quality resulting in the highest possible print quality with the fewest possible mis-printing errors.

• Stepped stencils and uniqueaperture designs allow singlestencils designed for broad rangeof deposit volumes to provide theright paste volume where needed.In cases where a stepped stencil isnot practical or does not providesufficient volume, our engineerscan design a tape and reel preformoption to efficiently address thevolume needed.

• Unique Cookson Electronicsaperture designs such as reversetaper, Micro Pocket and Micro Maximprove deposit volume.

• We are your stencil and printingknowledge source offering seminarsand publications on stencil designand printing technology to helpyou stay on the cutting edge.


Early Engagement in the NewProduct Introduction Process Helps Us Get Your Stencil Right the First Time

• ALPHA® stencil design expertise and printing knowledge allow us tounderstand your print and designrequirements and engage early withyou on new product introductionwork.

• ALPHA® stencil design experts can support you and makerecommendations that will enableyou to design stencils that can help achieve first time right printdeposits.

• ALPHA® can turn around anaccurate stencil for you “First-Time-Right” in a timely manner utilizingour global locations, stencilmanufacturing expertise, and theadvanced technology services.

• ALPHA® Global Technical Serviceand Support Team helps implementour stencils in the field and trouble-shoot if necessary, helping youachieve high yield, reduced defectimplementations.

ALPHA® CUT Laser Cut StencilsHelp Us Get Your Stencil Right the First Time

• ALPHA® CUT Laser Cut Stencilsprovide the highly repeatable,accurate printing performance you require for your challengingnew product introductions andproduction requirements. WithALPHA® CUT you get:

• Best-in-Class positional accuracyproven in process capability studiesand machine mapping and a widerange of options, including:- Stepped area(s) for optimized

paste volume deposition- Variety of surface finishes- High quality stainless steel or

hard solid nickel material- Range of material thicknesses- Framed or frameless format

(including TETRA & TETRA-VG)- Global manufacturing and quality

systems to ensure reliability andquality

- Local operations (11 global sites)ensures fast turnaround

• We also offer ALPHA® FORMelectroformed stencils forapplications requiring printingperformance down to micro-electronic levels – even below 0.4 mm pitch.

ALPHA® Stencils

• Leading technology products• Continuity of supply ensured through multiple manufacturing sites • Delivered lowest cost of ownership

ALPHA® CUT Laser Cut Stencil


ALPHA FORM™: ElectroformedStencils Help Us Get Your StencilRight First Time

• ALPHA FORM electro-formedstencils are for applications requiringsuperior printing performance downto microelectronic levels – evenbelow 0.4 mm pitch.

• They offer outstanding pasterelease properties and can be produced to custom thicknesses,accommodating stepped design features.

• These long life stencils enable veryhigh print yields and a positiveunderside gasket effect reduces theneed for under stencil cleaning.

ALPHA ETCH™: ChemicallyEtched Stencils Help Us Get YourStencil Right First Time

• Accurate yet economical stencilfoils, ideal for a variety of standardpitch printing applications.

• They permit high aperture countswithout cost penalties and canaccommodate multi level printingrequirements for small and largecomponents.

ALPHA® Stencils

ALPHA® Stencil ProductsALPHA FORM Electroform Stencils• For Board Assembly.

The industry's WINNING combination of High Transfer Efficiency and Low Paste deposit variability.

• For Wafer Bumping. Cost effective way to provide high aperture count WITH high accuracy and great stencil durability.

ALPHA CUT Lasercut Stencils The preferred cost effective way to provide high accuracy aperture placement combined with good pastetransfer efficiency down to 16 mil pitch.

ALPHA ETCH Chemically Etched Stencils Chemical Etching remains the ONLY wayto produce multi level stencils for printing boards with large and small components.

ALPHA TETRA Frame System The FIRST and the BEST high tension,high-accuracy frameless stencil system.

ALPHA® Stencil Services & SolutionsALPHA DIMENSIONS Stencil Engineering The one system that systematically and automatically applies aperture modifications.

Cookson Stencil Design RulesProvide scientifically sized and shaped apertures to handle any printing situationregardless of complexity.

PCB ScalingWhen the PROBLEM is the accuracy of the PWB, the SOLUTION is to scale thestencil to match the board.

Global Commonality Program Whether it is made in the Americas, Europe or Asia, Cookson’s worldwide stencilfabrication sites manufacture the same high quality product every time everywhere.

Area Ratio Rules Provide stencil users a flag to potential aperture design violations prior to actualfabrication.

Steps & Stepless StepsAn in-depth understanding of the plating process coupled with precise control of theelectroform plating bath allows skilled technicians to vary stencil thickness withaperture size to provide the most robust printing situation possible.

Unique Aperture Designs Including Reverse Taper Years of studying the underlying science of stencil printing has allowed Cookson todesign a family of “High Transfer” apertures, which allow the user to maximize pastedeposition in the most marginal printing situations.

Product and Service Portfolio


How we support “First-Time-Right”NPI Stencils

• By engaging early in the designprocess, we can help reduce thecycle time and produce the stencilright the first time.

• Our design rule recommendationsrepresent our collective knowledge of the printing process and canhelp get the right paste volume in the desired location.

• Automated application of customerand OEM/Product-specific designrules through our patentedDIMENSIONS® system reduces the possibility of CAD errors andimproves first time right service.

• Our DIMENSIONS® system allowsfor pre-programmed automaticapplication of existing design rulesand continuous addition of newdesign rules. This enables thecustomer to systematically utilizeone set of design rules globally.

• The PCB manufacturing process can result in variability of the padlocations. Our PCB scaling servicecan optimize the stencil to bettercorrect for board stretch. Scaling of stencil design to correspondingPCB thus reduces defects andrework, and improves first passyield in the NPI process.

• Stepped stencils and uniqueaperture designs allow singlestencils designed for broad rangeof deposit volumes to provide theright paste volume where needed.

Fast Turnaround of ALPHA® CUT Stencil Orders Help Us Get Your Stencil Right the First Time

ALPHA® Stencils are manufactured at 12 Cookson Electronics sites globally,and are available with delivery options to suite your specific needs, includingthe use of shipping services to meet your specified delivery dates.

Global Stencil Manufacturing Locations

Americas:

Boynton Beach, FLPhone: [email protected]

Buffalo Grove, ILPhone: [email protected]

Johnson City, NYPhone: [email protected]

San Jose, CAPhone: [email protected]

Sao Paulo, BrazilPhone: [email protected]

Monterrey, MexicoPhone: [email protected]

Europe:

Cholet, FrancePhone: [email protected]

East Kilbride, ScotlandPhone: +44 (0) [email protected]

Budapest, HungaryPhone: +36 [email protected]

Turnhout, BelgiumPhone: [email protected]

Woking, UKPhone: +44 (0) [email protected]

Asia-Pacific:

SingaporePhone: [email protected]


www.alpha.cooksonelectronics.com

Global Headquarters109 Corporate BoulevardSouth Plainfield, NJ 07080USATel: +1-800-367-5460

European HeadquartersForsyth Road, SheerwaterWoking, Surrey GU21 5RZUKTel: +44 (0) 1483 758400

Asia/Pacific1/F, Block A, 21 Tung Yuen StreetYau Tong Bay, KowloonHong KongTel: 852-3190-3100

©2008 Cookson ElectronicsIssued 7/08SM978

Documents

Solder Paste Wave Solder Flux Preforms Cleaners Stencils Wave Solder …/media/Files... · 2012. 3. 9. · • High reliability. • Low oxides, low drossing. • Solder bar, chunks,