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protective finishes (Au, Sn, Sn-Pb, etc) very much like those used on traditional components to support the soldering process 40252 Insertion Equipment Because the demand for through-hole circuit boards has remained strong, insertion equipment capabilities have steadily improved Brushless servomotors and state-of-the-art motion controllers and sensors have replaced most pneumatic drive assemblies and bulky (and slow) mechanical switches and relays, respectively Some equipment options include the capability to test parts electrically prior to insertion At insertion rates of up to 40,000 components per hour (CPH), defect rates are a couple of hundred parts per million or lower for the common axial and radial leaded packages Interchangeable tooling has allowed the automated insertion of many odd-form components, as well The change to Pb-free solders does not have a direct impact on insertion equipment technology 402.

6 Automated Soldering and Wave Soldering The most commonly used process for the soldering of through-hole and mixed (through-hole and surface-mount) circuit boards is wave soldering The wave-soldering process is shown schematically in Fig 407 The populated (or stuffed ) circuit board is secured to a conveyor belt The conveyor belt carries the board through the fluxer, then the preheat stage, and lastly on to the molten solder wave Interestingly, one of the most critical steps in the wave-soldering process is the application of the flux Manual fluxing has given way to more precise, automated equipment in order to improve yields The advantage is better control of the quantity of flux on the circuit board as it enters the wave because the flux controls both the entry and exit geometries of the molten solder wave, which in turn are instrumental toward minimizing skips, bridges, or icicle defects.

PUB SetMotorPower dira[BRK..DIR]~~ repeat case pulselen 300..1500: outa[DIR]~ MotPwr:=1500-pulselen 1501..3000: outa[DIR]~~ MotPwr:=pulselen-1500

Flux can be applied by spraying techniques or by passing the circuit board through the foam or suds of the flux The latter technique is provided by the foam fluxer..

FIGURE 40.9 Photograph of the dual-wave configuration. (Courtesy of Vitronics-Soltec.)

After the fluxing step, the circuit board passes through the preheat stage, which is comprised of a set of radiant heaters As the circuit board is heated, this step evaporates volatiles from the flux coating (which if not adequately removed can lead to voids and blow holes) and activates the chemical reactions between the flux and oxides on the component lead or termination and the circuit board conductor The solder wave is created by pumping molten alloy upward through a nozzle, where it exits to a certain height and then falls back into the bathThe solder bath temperature is 260 C for eutectic Sn-Pb solderThe printed circuit board is carried by the conveyor so that is passes over the surface of the wave.

The bottom side of the circuit board contacts the wave, allowing the molten solder to wet the exposed pads as well as to flow upward through the holes by capillary action The speed of the conveyor and the take-off angle that is, the angle at which the circuit board approaches the wave are critical parameters for minimizing wave-soldering defects Another critical parameter of wave soldering is the wave geometry The schematic diagram in Fig 408 shows the commonly used dual wave The first wave is turbulent so as to counteract the surface tension of the molten solder, thereby literally forcing the molten solder into confined geometries in order to initiate the wetting process The second wave is smooth or laminar.

9:

The laminar wave is located at the exit point because its geometry reduces the propensity for bridges and icicle defects to form as the molten solder retracts itself from the circuit board The photograph in Fig 409 shows a circuit board entering the turbulent wave of a dual-wave soldering system A variation of wave soldering is the so-called selective soldering process Instead of using a long wave to accommodate.

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the dimensions of an entire circuit board, a small fountain is created of molten solder The reduced geometry allows for the soldering of individual components or several components on only selected areas of the circuit boardA manual operation is used to apply flux and preheat the circuit board prior to the actual soldering process The change to Pb-free solders has affected the wave-soldering process Fortunately, the 260 C bath temperature used with eutectic Sn-Pb solder has proven to be adequate for most applications using the 993Sn-07Cu (wt percent) and Sn-Ag-Cu alloys Some users have preferred to raise the pot temperature to 260 to 270 C The elements Ni and Ge have been added to the Pb-free solders in order to provide the shiny fillets that inspectors are accustomed to observing with Sn-Pb solders.