Hi George,

Those little young-un's can be a handful huh? I'm sure you're doing your
job as all grandparents do and spoiling him to death (GRIN). Glad you're
enjoying him!

So I just want to give a little more information about the board. The was
returned to us conformal coated, so what you may have mistaken as flux
residues is actually conformal coating. The board finish is actually Sn/Pb
HASL. We assemble the SMT with a Sn62/Pb36/Ag2 water soluble paste and is
cleaned in a DI inline cleaner after reflow. The through-hole is stuffed
and wave soldered, again using a water soluble flux. It is again cleaned in
the inline cleaner. The board is inspected at the end of the reflow oven,
and after wave solder, as well as going through AOI. Any touch-up that is
done requires that the board go through the inline cleaner again, so I'm
confident that the board is clean when we ship it to our customer.
Unfortunately we don't electrically test the assembly, the test set-up is a
custom deal that our customer doesn't want to part with, so they do the
electrical test and conformal coat the assemblies.

The red arrows were placed by our customer, and the probe marks that you
see in the solder joints were done by what I assume were their test
technicians with a DMM to isolate the fault. What isn't readily apparent in
the photos is a slight darkening around the via, and you can see that the
via looks like it blew a solder ball out that you see on the annular pad If
you look carefully in the photos you can see tiny solderballs down inside
the via, and if you you look at the via pad surface and compare the other
via pad surfaces in the photo, you can see that the arrowed via did
over-heat.

The other assembly came to us with several IC's on the board with lifted
pins which I assume were done trying to track down where the short was.
This board also had a blown tantalum capacitor (which I didn't post a photo
of), but the capacitor was installed with the correct polarity as you could
still see the polarity stripe on the cap and see that it was installed
correctly. So that was evidence in itself that voltage came from the wrong
direction to that cap...

So I've been reading everything I can find about CAF, and trying to
understand the problem better. I think that probably that's what is
happening given that it's taking time for the failures to occur.

Steve

On Fri, Apr 8, 2016 at 5:34 PM, George Wenger <[log in to unmask]>
wrote:

> Hi Steve,
> I haven't been on TN for some time (my 3 year old grandson has been taking
> up much of my time).  Greg Munie had forwarded your TN post and Dave
> Hillman's reply and I sent an email repl to Greg that he suggested I post
> on TN so here it is:
>
> From: "Greg Munie" <[log in to unmask]>
> To: [log in to unmask]
> Sent: Friday, April 8, 2016 12:39:07 PM
> Subject: FW: [TN] Recommendations for Failure Analysis / Root Cause of
> PCBA Failure...
>
>
>
> Dis looks like a job for George . .
>
> From: [log in to unmask] [mailto:[log in to unmask]]
> Sent: Friday, April 08, 2016 3:20 PM
> To: Greg Munie <[log in to unmask]>
> Subject: Re: [TN] Recommendations for Failure Analysis / Root Cause of
> PCBA Failure...
>
>
>
> Dis would be a job for George if George still worked in a Lab like he had
> in Lucent or Andrew but doesn't have that now.  I believe that Dave Hillman
> is correct that with two PCBAs with shorts there are many labs that could
> most likely find the root cause for the failure.  I didn't see Steve's
> resopnse to David's question about if Steve believes the problem to be an
> internal short.  I know what I would do if I were doing the failure
> analysis and the first thing would be to ask Steve many more questions
> about the PCBA and when the failures are detected before I did any physical
> analysis of the two PCBAs because the analysis is destructive and if you
> don't find the root cuse you're out of luck
>
> After reading Steve's email and looking at the two photos a couple of
> things come to mind.  The short could be an internal PCB short or it could
> be an external PCBA short.  From the photograph the surface finish on the
> PCB appears to be ENIG and it also appears that there isn't a cleaning
> process done after PCBA solder assembly process.  My first questions would
> be what solder paste is used for the assembly?, Is the PCBA a double side
> surface mount reflow assembly?, is there a wave soldering assembly
> performed and if there is what flux is used?  I'd also ask for PCB layer
> drawings and an electrical circuit diagram.  I would do a high resolution
> scan of the top and bottom sides of both of the failed PCBAs and inspect
> both failed assemblies in detail under a microscope. Before doing any
> cleaning of the PCBAs or cross sections of the area that is shorted I would
> systematically begin removing surface mount components that are soldered
> across the 12V power. I'd carefully examine the bottom of each removed
> component and the PCB surface from which it was removed for any debris,
> dendrites, or shorts and also measure the removed component to see if it is
> shorted as well as re-measure the via to see if the PCBA is still shorted.
> An alternative to doing doing a component by compnent analysis is to do an
> agressive cleaning and drying process on the PCBA and then measure the via
> to see if the short is still present.  The clening process I would us is to
> do ultrasonic cleaning in a terpine cleaner like EC-7 followed b ultrasonic
> cleaning in IPA to remove any terpine residue and then do a long (4 to 8
> hour) bake at 100C to drive off any moisture that might be traped under
> components or in component flexure cracks and then check the via to see if
> it is still shorted.  If it isn't then the problem is an external short
> rather than an internal PCB short.
>
>
>
> Since the failures are occuring after 111 to 472 days field exposure I
> believe there is a strong possibility that the shorts are external and are
> occuring under or within components rather than internal to the PCB.
>
>
>
> If the cleaning and component removal doesn't eleminate the short than I
> would do careful transmission xray imaging around the via that is shorted.
> Actually I would do this x-ray imaging of the shorted via before doing the
> cleaning and componet removal just to have the images.  The x-rays may not
> be able to see if there is a short but I would still do them.  If the
> x-rays son't show anything and the via is still shorted I think I would
> begin a very slow and careful lapsectioning of the via and examine each of
> the PCB layers for shorts as the laping progresses through the PCB.
>
>
>
> Sorry for the long winded answer but I hope it helps Steve find the root
> cause for his problem.  Feel free to share my response with Steve or Dave
> or any lab Steve might work with.  I haven't made any recommendations for
> an external lab because there are so many.  There are deffinately some labs
> out there that I wouldn't use because I'm not sure they really have the
> capabilityy and all they want is your money.  The one lab I've actually
> never used but I know their capability and would certainly reccomend is
> George Westby's Universal Instruments Lab in binghamton, NY.  Although the
> are really good the one drawback is they are expensive.  I think their
> minimum is $1000.
>
> Regards,
>
>
>
> George
>
>
>
> George M. Wenger
> Failure Signature & Characterization Lab LLC
> 609 Cokesbury Road, High Bridge, NJ 08829
> (908) 638-8771 (Home) (732)-309-8964 (Cell)
> [log in to unmask]
>


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