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This amplifies the need for effective high-impedance testing of high-reliability product types as a means of preventing latent field failures Note that the nature of board materials is such that they can absorb moisture relatively easily, and they do so over time Thus even a fairly dry contamination providing a very weak electrical path may eventually result in sufficient metal migration during product operation to cause a serious field failure 36414 RF Impedance Fault Many circuits produced today are required to operate at very wide bandwidths Examples include fast microprocessors, fast general digital circuits, RF amplifiers in wireless devices, etc Just as we must use a proper type of cable to connect a television antenna to a TV receiver, it is important for specific RF characteristics to be maintained in interconnections between components of fast electronic circuits on printed wiring boards.

One parameter commonly specified and measured is the RF transmission line impedance of the signal traces This parameter is strongly affected by the materials used in fabricating the board, the trace thickness and width, and the spacing from ground planes and adjacent signals A common method of measuring RF impedance is to employ TDR The TDR measurement provides a statement of RF impedance as a function of distance along the trace (Distance and time are related here, as the electric signal flows through the board at velocities approaching the speed of light) TDR testing is often performed on a test coupon attached to the product during manufacture and subsequently disconnected TDR testing on actual product traces is also done on selected traces, but is complicated by the need for a trace length of several inches, uninterrupted by branches or other constructions.

Common values for RF impedance on circuit boards range from the low tens of ohms to several hundred ohms RF impedance should not be confused with ordinary direct current (DC) resistance and cannot be measured with common ohmmeters, even though the same unit of measure the ohm is used RF parameters of interconnections can also be characterized in the frequency domain using instruments referred to as network analyzers, but this method is not common in bare board testing Requirements for RF impedance testing are more commonly applied as signal frequencies exceed 100 MHz 36415 Hi-Pot Faults Hi-pot or high potential voltage breakdown testing is often confused with isolation testing The tests are very similar, and, to the extent that high voltage is.

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Time and temperature depend on the mass and solder materials During reflow, the assembly is briefly brought to the temperature sufficient to reflow the solder After reflow, a gradual cooling should be used to prevent thermal shock Gradual cooling produces a finer grain structure and fatigue-resistant solder joint During reflow process, care must be exercised to prevent the formation of oxides that degrade subsequent processes A nitrogen-with-flux or hydrogen-flux-free reflow process has been used to control oxide formation There is a trend in the industry toward smaller area-array packages with lead-free bump sizes in the range of 10 15 mm Metal bumps, including gold, copper, and nickel, are lead-free wafer bumping33 In addition, gold and copper have a greater mechanical shear strength compared to lead solders.

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This helps to relieve residual stresses caused by the mismatch of the CTE between the chip and printed-circuit board materials, and hence strengthens the bump connections34 Gold stud bumps are formed by a modified wire bonder that uses thermosonic energy (150 200 C) to first attach a gold bondwire to the die bond pads and then shear the top of the gold wire without leaving a tail35 To achieve a uniform bump height, the gold studs may be flattened or coined by pressing any remaining wire tail to the ball or shearing it off This yields a planar, flat-top gold bump that does not require any coining in a single-step process Copper is another candidate material for wafer bumping Compared to gold, copper costs less but has a good electrical and heat-dissipating performance due to its low electrical resistivity and high thermal conductivity.