Peter,
We have research papers here at Rockwell from 1990, stemming from an
incident we lovingly call "The Great Post Coat Massacre of 1990", which
show conclusively that conformal coating mascarading as an underfill is a
REALLY bad idea.  Unfortunately, I cannot release that paper to the public.
Since you cure from the outside in, underfilling a component with conformal
coating means you will have entrapped solvent in the centermost portion of
the component.  Bad karma there.  You do not get a uniform material that is
uniformly cured throughout the bulk, as you do with an underfill.

Doug Pauls
Rockwell Collins

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