To my mother, Shu-shuen Chang, for her care and encouragement To my wife, Shen-chwen Lee, for her understandingand full support Reflow Soldering Processes and Troubleshooting: SMT, BGA, CSP and Flip Chip Technologies Ning-Cheng Lee BOSTON OXFORD AUCKLAND JOHANNESBURG MELBOURNE NEWDELHI Copyright2002byNewnes,animprintofButterworth-Heinemann Allrightsreserved. Nopartofthispublicationmaybereproduced,storedinaretrieval system,ortransmittedinanyformorbyanymeans,electronic,mechanical, photocopying,recording,orotherwise,withoutthepriorwrittenpermission ofthepublisher. Recognizingtheimportanceofpreservingwhathasbeenwritten, Butterworth-Heinemannprintsitsbooksonacid-freepaper wheneverpossible. Butterworth-HeinemannsupportstheeffortsofAmericanForests andtheGlobalReLeafprograminitscompaignforthebetterment oftrees,forests,andourenvironment. 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Solvents ...............................................................3....2....4.. .R..h..e..o..l.o..g..i.c..a..l. additives ...................................................................................3....3.. .S...o..ld..e..r. powder ..............................................................................................3....3....1.. .A...t.omization .........................................................3....3....2.. .P..a..r.t.i.c..l.e.. .s..iz..e.. .a..nd shape 3.4 Solde..r.. .p..a..s.t.e.. .c..o..m...p..o..s..i.t.i.o..n.. .a..n..d.. .m...a..n..u..facturing ............................................................3....5.. .S..o..l.d..e..r. .p..a..s..t.e.. .rheology ..............................................................................3....5....1.. .R...h..e..o..l.o..gy basics ................3....5....2.. .S..o..l.d..e..r. .p..a..s..t.e.. .v..i.s..c.o..s..i.t.y.. .m...e..a..surement ...................3....6.. .S...o..ld..e..r.. .p..a..s.t.e.. .r..h..e..o..lo..g..y.. .r.e..q..u.irement .........................3....6....1.. .E..f.f.e..c..t. .o..f. .c..o..m...p..o..s..i.t.io..n.. .o..n.. rheology ..............................................................................................3....7.. .C..o..nclusion ......4.. .S..u..r..f.a..c..e.. .M...o..u..n..t.. .A..s..s..e..m...b...l.y.. .P..r.o..cesses ..........................................................4....1.. .S..o..l.d..e..r. .p..a..s..t.e.. .m. aterials ............................................4....1....1.. .P..a..s..t.e.. .h..a..n..d..l.i.n..g.. .a..n..d storage ..............................................................................4....1....2.. .P...a..s..t.e.. .d.eposition ...............................................4....2.. .P..r..in..t.e..r.. .le..v..e..l. .c..o..n..s..ideration ..............................................................................................................4....2...1 Stencil ..................................................................................................4....2....2.. .S..queegee ...............................4....2....3.. .P..r.i.n..t.i.n..g.. .a..n..d.. .i.n..s..p..e..c.t.i.o..n. process ..................................................................................4....3.. .P..i.c..k.-..a..nd-place ............................................................................................................4....4 Reflow .....................................................................................4....4....1.. .I.n..f.r.a..r.ed reflow .....................................................................4....4....2.. .V..a..p..o..r.. .p..h..a.se reflow ...................................................4....4....3.. .F..o..r.c..e..d.. .c..o..n..v..e..c..t.ion reflow .....................................................4....4....4.. .I.n..-.l.i.n..e..-.c..o..n..d..u..c..t.ion reflow ......................................................................................4....4....5.. .H...o..t.-.b.ar reflow ............................................................................................4....4....6.. .L..a..s.er reflow .4....5.. .E...f.f.e..c.t. .o..f. .r..e..f.lo..w... .a..t.m...o..s..p..h..e..r.e.. .o..n.. .s.oldering ..........................4....6.. .S..p..e..c..i.a..l. .s..o..ld..e..r..in..g.. .c..o..n..s..i.d.erations .....................................................................................4....6....1.. .S..t.e..p.. .soldering ..................................................................................4....6....2.. .R...e..f.l.o..w.-alloying .........................................................................................4....6....3.. .P..a..s..te-in-hole ...........................................................4....7.. .S...o..l.d..e..r. .j.o..in..t. .i.n..spection .....................................................................................................4....8.. .C. leaning ...............................................................................4....9.. .I.n..-.c..i.r.c..u..it-testing 4.10 Princ..i.p..l.e.. .o..f. .t.r.o..u..b..l.e..s.h..o..o..t.i.n..g.. .r.e..f.l.o..w... .s.oldering .........................................................................................4....1..1.. .C..o..n.clusion ..........................5.. .S..M...T.. .P...r.o..b...l.e..m...s.. .P..r..i.o..r. .t.o... Reflow ................................................................................5....1.. .F..l.u..x.. .s.e..paration .......................................................................................................5....2.. .Crusting .............................................................................5....3.. .P...a..s.t.e.. .h..a.rdening .................................................................................5....4.. .P..o..o..r.. .s.t.encil life ...................5....5.. .P...o..o..r. .p..a..s..t.e.. .r.e..l.e..a..s.e.. .f.r..o..m... .s.q.ueegee ..................................................................5....6.. .P..o..o..r.. .p..r.i.n..t. .t.hickness ............................................................................................................5....7 Smear ..........................................................................................5....8.. .I.n..s.u..fficiency ..............................................................................5....9.. .N..e..e..d..l.e.. .clogging .........................................................................................................5....1..0 Slump .................................................................................................5....1..1.. .L.ow tack ............................................................................5....1..2.. .S...h..o..r.t. .t.a.ck time ..........................................................................................5....1..3.. .C..o..nclusion ............................6.. .S...M...T.. .P..r..o..b..l.e..m...s.. .D...u..r.i.n...g.. Reflow ................................................................................................6....1.. .C..o.ld joints ..............................................................................................6....2.. .N..o..nwetting ..................................................................................................6....3.. .D..ewetting ....................................................................................................6....4.. .L.eaching .......................................................................................6....5.. .I.n..t.e..r.m. etallics ..........................................................................................................6....5....1. General ....................................................................................................................6...5.2 Gold ........................................................................................6....6.. .T..o..m...bstoning ......................................................................................................6....7.. .Skewing ........................................................................................................6....8.. Wicking .......................................................................................................6....9.. .Bridging ......................................................................................................6....1..0. Voiding ..................................................................................................6....1..1.. .Opening ...................................................................................................6....1..1....1.. Pillowing ..............................................................................6....1..1....2.. .O...t.h..e..r. .openings .............................................................................................6....1..1....3.. .F..illet lifting ...........................................................................6....1..1....4.. .P..r.o..j.e..c..t.ed solder ..................................................................................6....1..2.. .S..o..l.d..e.r balling .............................................................................6....1..3.. .S...o..l.d..e..r. beading .............................................................................................6....1..4.. .S...pattering ..........................................................................................6....1..5.. .C..o..nclusion 7 SMT... .P..r.o...b..l.e..m...s.. .A...t. .t.h..e.. .P...o..s..t.-. .r..e..f.l.o..w. Stage .....................................................................................7....1.. .W....h..i.t.e. residue ..............................................................................7....2.. .C..h..a..r.r..e..d. residue ...............................................................7....3.. .P...o..o..r. .p..r.o..b..i.n..g. contact ...................................................................7....3....1.. .F..l.u..x. .r..e..s.i.d..u..e content ..................................................................7....3....2.. .T...o..p..-.s..id..e.. .f.l.u.x spread ........................................................7....3....3.. .B..o..t.t.o..m...-..s.i.d..e.. .f.l.u.x spread .........................................................................7....3....4.. .R..e..s..i.d..u..e.. .hardness .....................................................................7....3....5.. .R...e..f.lo..w... .a..t.m. osphere ........................................................................................7....3....6.. .M...e..t.a.l content ...............................7....3....7.. .S..o..f.t.-.r.e..s..i.d..u..e.. .v..e..r.s..u..s.. .lo..w. -residue ..........................7....3....8.. .S..o..f.t.-..r.e..s..id..u..e.. .v..e..r.s..u..s.. .R...M...A residue ..........................7....3....9.. .M...u..l.t.i.p..l.e.. .c..y.c..l.e..s.. .p..r.o..b..i.n..g.. .testability 7.4 Surface insulation resistance or electrochem.ic..a..l. .m...i.g..r.a..t.i.o.n failure ....................7....4....1.. .S...u..r.f.a..c..e.. .i.n..s.u..l.a..t.i.o..n.. .r.e..s..i.s..t.a..nce (SIR) ...............................7....4....2.. .E..l.e..c..t.r.o..c..h..e..m...i.c..a..l .m...i.g..r.a..tion (EM) .................7....4....3.. .E..f.f.e..c..t. .o..f. .f.l.u..x.. .c.h..e..m...i.s..t.r.y.. .o..n.. .IR values .................................7....4....4.. .E..f.f.e..c..t. .o..f. .s..o..l.d..e..r.i.n..g.. .t.e..m.perature ...........7....4....5.. .E..f.f.e..c..t. .o..f. .c..le..a..n..l.i.n..e..s..s.. .o..f. .in..c..o..m..ing parts 7....4....6.. .E...f.f.e..c.t. .o..f. .c..o..n..f.o..r.m...a..l. .c..o..a..t.i.n..g../.e..n..c..a.psulation 7.4.7 Effect of inte..r.a..c..t.io..n.. .b..e..t.w...e..e..n.. .f.l.u..x.. .a..n..d.. .s.o..l.der mask 7.4.8 Effect of interaction between solder paste flux res..i.d..u..e.. .a..n..d.. .wave flux 7.5 Delamination/voiding/non-curing of conformal coatin..g../. .e..n..c..a..psulants ...........................................................................................................7....5....1 Voiding .........................................................................................7....5....2.. .D...e..la.mination ..........................................................................7....5....3.. .I.n..c..o..m...p..l.e.te curing ..............................................................................................7....6.. .C..o..nclusion 8 Solde.r. .B...u..m...p..i.n...g.. .f.o..r.. .A..r..e..a.. .A..r..r.a..y.. .P..a..ckages .....................................................................................8....1.. .S...o..ld..e..r criteria 8.1.1 Alloys used in flip. .c..h..i.p.. .s.o..l.d..e..r. .b..u..m...p..i.n..g.. .a..n..d.. .soldering 8.1.2 Alloys used in BGA and CSP s.o..ld..e..r.. .b..u..m...p..in..g.. .a..n..d.. .soldering ...........................................................................8....1....3.. .L..e..a..d..-.f.r.e..e solders .............................8....2.. .S...o..ld..e..r.. .b..u..m...p..in..g.. .a..n..d.. .c..h..allenges ..............................................................................8....2....1.. .B...u..il.d..-.u..p. process .....................................8....2....2.. .L..i.q..u..id.. .s..o..l.d..e..r. .t.r.a..n..s..f.e..r process .................................8....2....3.. .S..o..l.i.d.. .s.o..l.d..e..r. .t.r..a..n..s.f.e..r.. .p.rocesses .............................................................8....2....4.. .S..o..l.d..e..r. .p..a..s..t.e.. bumping ..............................................................................................8....3.. .C...o.nclusion ...9.. .B...G...A.. .a..n...d.. .C..S...P.. .A...s..s..e..m...b..l.y.. .a..n..d... .Rework .......................................................................9....1.. .A...s..s.e..m...b..l.y.. process .............................9....1....1.. .G...e..n..e..r.a..l. .s..t.e..n..c.i.l. .d..e..s..i.g..n.. guideline ................................................................9....1....2.. .B...G...A../.C...S..P.. .p..lacement .............................................................................................................9....1...3 Reflow ...................................................................................................9....1....4.. .I.nspection .........................................................................................................9....2.. Rework ..........................................................................................9....2....1... .P..r.o..cess flow .................................................................................................9....2....2.. .P..re-baking ...................................................................9....2....3.. .C..o..m...p..o..n..e..n..t removal ..........................................................................9....2....4.. .R...e..f.lo..w... .e..quipment .................................................................................9....2....5.. .S..i.t.e.. .p..r.eparation ...............................................................9....2....6.. .S..o..l.d..e..r. .r.e..p..l.e..nishment ....................................................9....2....7.. .P...la..c..e..m...e..n..t. .o..f. .c..o.mponent .....................................................9....2....8.. .R...e..f.lo..w... .o..f. .B..G...A... and CSP 9.3 C.h..a..l.le..n..g..e..s.. .a..t. .a..s..s..e..m...b..l.y. .a..n..d.. .r.e..w...o..r.k stages ......................................................................9....3....1.. .S...t.a..r.v..e..d.. .s.o.lder joint .....................................................................9....3....2.. .P..o..o..r.. .s.e..l.f.-.a.lignment ...........................................................................................9....3....3.. .P..o..o.r wetting ...........................................................................................................9....3....4 Voiding .........................................................................................................9....3....5. Bridging ..................................................................................................................9....3.6 Open ......................................................................9....3....7.. .U...n..e..v..e..n.. .jo..int height ..................................................................................9....3....8.. .S..o..l.d..e..r. webbing ........................................................................................9....3....9.. .S...o..ld..er balling ............................................9....3....1..0.. .P..o..p..c..o..r.n.. .a..n..d.. .d..e..l.a.mination ..............................................................................................9....4.. .C...o.nclusion ............................1..0.. .F..l.i.p.. .C...h..i.p.. .R...e..f.l.o..w... .A..t..t.a..chment .............................................................1..0....1.. .F...li.p.. .c..h..i.p.. .a..t.t.achment .....................1..0....1....1.. .C..o..n..v..e..n..t.i.o..n..a..l. .f.l.ip.. .c..h..i.p.. .a..t.tachment ..............................................................................................1..0....1....2.. .S..nap cure ..............................................................................................1..0....1....3.. .E..poxy flux ......................................................................................................1..0....1....4. No-flow ................................................................................................................1..0...1.5 SMT .....................................................................1..0....1....6.. .F..l.u..x..l.e..s.s.. .s.oldering 10.1.7 Wafer-applied underfill 10.1.8 Wafer level compres.s..i.v.e..-..f.lo..w... underfill .....................................................................................................................(..WLCFU) 10.2 Prob..l.e..m...s.. .d..u..r.i.n..g.. .f.li.p.. .c..h..i.p.. .r.e..f.l.o..w.. .a..t.t.a..chment ...................................................................................1..0....2....1.. .M...i.s..a..lignment .......................................................................................1..0....2....2.. .P..o..o.r wetting ..................................................................................1..0....2....3.. .S..o..l.d..e.r voiding ............................................................................1..0....2....4.. .U...n..d..e..r.f.ill voiding ....................................................................................................1..0....2....5.. Bridging ..............................................................................................................1..0....2.6 Open ..................................................................................1..0....2....7.. .U..n..d..e..rfill crack .....................................................................................1..0....2....8.. .D..e..l.a.mination ........................................................................1..0....2....9.. .F..i.l.l.e..r. .s..e..gregation ....................................................1..0....2....1..0.. .I.n..s..u..f.f.i.c..ie..n..t. .u..n.derfilling .........................................................................................1..0....3.. .C...o..nclusion 11 Optimizing a Reflow Profile Via Defect Mechan..i.s..m....s.. .A..nalysis ....................................................................................1..1....1.. .F..l.u..x.. reaction 11.1.1 Time/temperature req..u..i.r.e..m...e..n..t. .f.o..r.. .t.h..e.. .f.lu..x..i.n..g. reaction 11.1.2 Fluxing contrib.u..t.io..n.. .b..e..l.o..w... .t.h..e.. .m...e..l.t.in..g.. .t.e..m..perature ....................................................................1..1....2.. .P...e..a..k. .t.e..m...perature ..........................................1..1....2....1.. .C...o..l.d.. .j.o..in..t. .a..n..d.. .p..o..o.r wetting 11.2....2.. .C..h..a..r.r..in..g..,. .d..e..l.a..m...i.n..a..t.i.o..n..,. .a..n..d.. .i.n..t.e..rmetallics ..................................................................................................1..1....2....3.. .Leaching ..................................................................................1..1....3.. .C..o..o..l.i.ng stage .....................................................................................1..1....3....1.. .I.n..t.e..rmetallics ...............................................................................................1..1....3....2.. .G.rain size ...............1..1....3....3.. .I.n..t.e..r.n..a..l. .s..t.r.e..s..s.-..c.o..m...p..o..n..e..n..t. cracking .............................................................1..1....3....4.. .D...e..f.o..r.m...a..t.io..n. of joints 1.1....3....5.. .I.n..t.e..r.n..a..l. .s.t.r..e..s.s.. .s..o..l.d..e..r. .o..r. .p..a..d.. .d..e..tachment .................................................................................1..1....4.. .H...e..a..t.i.ng stage ........................................................1..1....4....1.. .S..l.u..m...p..i.n..g.. .a..n..d. bridging ...............................................................................1..1....4....2.. .S..o..l.d..e..r beading ......................................................................................................1..1....4....3. Wicking ............................................1..1....4....4.. .T..o..m...b..s..t.o..n..i.n..g.. .a..n..d. skewing ....................................................................................1..1....4....5.. .S..o..l.d..er balling .......................................................................................1..1....4....6.. .P..o..o.r wetting .......................................................................................................1..1....4....7 Voiding ..........................................................................................................1..1....4...8 Opens .......................................................1..1....5.. .T...im...i.n..g.. .c..o..n..s..i.d.erations ..............................................................................1..1....5....1.. .R...a..m...p..-up stage ....................................................................................1..1....5....2.. .S..o..a..k.ing zone .......................1..1....5....3.. .O...n..s.e..t. .t.e..m...p..e..r..a..t.u..r.e.. .o..f. .s..pike zone ........................................................1..1....6.. .O..p..t.i.m...i.z..a..t.i.o..n.. .of profile .................1..1....6....1.. .S..u..m...m...a..r.y.. .o..f. .d..e..s..i.r.e..d.. .p..r.o..f.i.le feature .......................1..1....6....2.. .E..n..g..i.n..e..e..r.i.n..g.. .t.h..e.. .o..p..t.i.m...iz..ed profile ....1..1....7.. .C...o..m...p..a..r.i.s.o..n.. .w...i.t.h.. .c..o..n..v.e..n..t.i.o..n..a..l profiles ............................................................1..1....7....1.. .C...o..n..v..e..n..t.i.o..n..al profiles .............1..1....7....2.. .B..a..c..k..g..r.o..u..n..d.. .o..f. .c..o..n..v..e..n..t.i.o..n..al profiles .....................1..1....7....3.. .A..p..p..r.o..a..c..h.. .o..f. .c..o..n..v..e..n..t.i.o..n..al profiles ...........1..1....7....4.. .C..o..m...p..r.o..m...i.s..e.. .o..f. .c..o..n..v..e..n..t.io..n..a.l profiles ........................1..1....7....5.. .E...a..r.l.ie..r.. .m...a..s.s.. .r.e..f.l.o..w... .t.e..c..hnologies 1..1....7....6.. .F...o..r.c..e..d.. .a..ir.. .c.o..n..v..e..c..t.i.o..n.. .r.e..f.l.o..w.. .t.e..chnology 11.7.7 Defect potential ass.o..c..i.a..t.e..d.. .w..i.t.h.. .c..o..n..v..e..n..t.i.o..n..al profiles ...........................................................................................1..1....8.. .D...is.cussion 11.8....1.. .P..r.o..f.i.l.e..s.. .f.o..r. .l.o..w.. .t.e..m...p..e..r.a..t.u..r..e.. .s.o..l.d..er pastes 11.8.2.. .P...r.o..f.i.le..s.. .f.o..r. .h..i.g..h.. .t.e..m...p..e..r.a..t.u..r.e.. .s..o..l.d..er pastes ..........................................1..1....8....3.. .L..i.m...i.t.e..d.. .o..x..id..a..t.i.o..n.. .tolerance 11.8.4 Unevenly d..is..t.r.i.b..u..t.e..d.. .h..i.g..h.. .t.h..e..r.m...a..l. .m...a..s..s. systems .......................................1..1....8....5.. .N..i.t.r.o..g..e..n.. .r..e..f.lo..w... .a..t.m. osphere .........................................................................................1..1....8....6.. .A...ir. flow rate ....................................1..1....8....7.. .A...d..j.u..s.t.m...e..n..t. .o..f. .o..p..t.i.m..al profile ............1..1....9.. .I.m...p..l.e..m...e..n..t.i.n..g.. .li.n..e..a..r. .r..a..m...p..-.u.p profile ......................................................................................1..1....1..0.. .C..o..nclusion ..........................................................1..2.. .L..e..a..d..-.f..r.e..e.. .S..o..ldering ...............................................................................1..2....1.. .I.n..i.t.i.a..l. .activities .........................................................................1..2....2.. .R...e..c..e..n..t. .activities .................................1..2....3.. .I.m...p..a..c..t. .o..f. .J..a..p..a..n..e..s..e.. .activities 12.4 US reactions.................................................................................................. ..........................1..2....5.. .W...h..a..t. .i.s.. .l.e..a..d..-.f.r.e..e.. .i.n..t.e..r.c.onnect? ..........................................1..2....6.. .C...r.i.t.e..r.i.a.. .o..f. .le..a..d..-..f.r.e.e solder .......................................................1..2....7.. .V..i.a..b..l.e.. .l.e..a..d..-.f.r.e.e alloys ....................................................................................1..2....7....1.. .S..n..9..6..5/Ag3.5 ...................................................................................1..2....7....2.. .S..n..9..9..3/Cu0.7 .................................................................................................1..2....7....3.. .Sn/Ag/Cu ..........................................................................................1..2....7....4.. .S..n../Ag/Cu/X ............................................................................................1..2....7....5.. .S...n/Ag/Bi/X ............................................................................................................1..2....7..6 Sn/Sb .....................................................................................................1..2....7....7. Sn/Zn/X ..............................................................................................................1..2....7.8 Sn/Bi ...............................................................................................................1..2.8 Cost ....................................................................................1..2....9.. .P..C...B.. finishes .................................................................................1..2....1..0.. .C...o..m..ponents ...................................................................1..2....1..1.. .T...h..e..r.m...a..l. damage ........................................................................1..2....1..2.. .O...t.h..e..r. .p.roblems ...................................................................1..2....1..3.. .C...o..n..s..o..r.t.i.a activity ......................................................1..2....1..4.. .O..p..i.n..i.o..n..s.. .o..f. .c.onsortia ......................................1..2....1..5.. .T..h..e.. .s..e..l.e..c.t.i.o..n..s.. .o..f. .pioneers ..............................................................................1..2....1..6.. .P...o..s.s..ible path ..................................................................1..2....1..7.. .I.s.. .l.e..a..d..-.f.r.ee safe? ........................1..2....1..8.. .S..u..m...m...a..r.y.. .o..f. .l.e..a..d..-.f.r.e..e.. .adoption ........1..2....1..9.. .T..r.o..u..b..l.e..s..h..o..o..t.i.n..g.. .le..a..d..-..f.r.e..e.. .s.oldering ...................1..2....1..9....1.. .C..o..m...p..a..t.i.b..i.l.it.y.. .w...i.t.h.. .r.e..f.l.o..w. process .........................................................................................1..2....1..9....2.. .F..illet lifting ......................................1..2....1..9....3.. .C...o..n..d..u..c..t.iv..e.. .a..n..o..d..e. filament ............................................................................1..2....1..9....4.. .G...r.a..i.n..y surface 12.19.5 Sn../.P..b../.B...i .t.e..r..n..a..r.y.. .lo..w... .m...e..l.t.in...g. .e..u...t.e.c..tic phase ......................................................................................1..2....2..0.. .C..o..nclusion ................................................................................................................. Index