Paul,
We have gone through the qualification process twice and will do so again
shortly as our equipment line up has changed.
The cost of running this qualification effort is around $8 - $10K when
everything is said and done.
The costs include using an off site laboratory to perform the tests that
have to be run in an environmental chamber. Even though we have this
equipment I wanted to have the test results from an unbiased source.
We are using organic water soluble fluxes in our solder paste and at the
wave solder machine. We only allow the use of organics at the bench top in
selected areas. Areas where cleaning occurs immediately after work is
performed.
We do not use organics in component tinning areas and areas where wires
are being soldered.
You may contact me off-line to get specifics.
We have had customers requesting to review our qualification data and they
have been satisfied. (Actually, I think they were surprised to find that
we actually did this qual testing "by the book".)
Your choices may limited to
- losing this customer
- asking your customer to fund, maybe partially, the qualification effort
- switching to L0 or L1 fluxes
- performing the qual test and using the results as good press for your
class 3 capability.
Many places that I've visited who claim to be class 3 compliant using
alternative materials seem to go into a song and dance routine when I ask
to see qualification data. In fact, some change their tune by stating that
they use RMA fluxes only for class 3 work.
Hope this helps.
Paul Baine <[log in to unmask]>
Sent by: TechNet <[log in to unmask]>
03/09/2007 01:17 PM
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[TN] Qualification Testing for H1 Flux
Hello all,
A recent Customer requires us to work to J-STD-001 Class 3 and
has been examining our process.
We are currently using Type OR (organic) flux with activity level H1.
Our Customer has pointed out that Para. 3.3 of J-STD-001D
requires that activity level LO or L1 fluxes be used. If we want to
continue to use H1 flux, then "data demonstrating compatibility
shall be available for review".
Appendix C of J-STD-001D details the tests needed for
demonstrating compatibility. Currently we do a ROSE test as part
of our process.
I talked to a solder flux manufacturer and they said that our
Customer would have to define the required tests if we want to
keep using OR H1 flux. They also said that various labs exist
which could do the required tests.
However, there is a Note in Appendix C which says:
"This testing is a 'site specific' qualification process to be done at
the manufacturer's location using production processes and
equipment whenever possible."
This note would suggest that we can't send samples out for test,
as the testing must be done at our facility.
It is also not clear whether the test is done on populated PCB
Assemblies or bare boards.
Something else that worries me is that, as per para. C-5.1, a
minimum of 10 samples are required, and as per para. C-6.2, "all
biased sites need to have the components removed...preferably by
cutting of leads." Does this mean that, if PCB Assemblies are
tested, that the components will be destroyed? Our contract with
our Customer is for low volume quantities, and losing 10
Assemblies is not an attractive option.
I would appreciate any help in clarifying exactly what we need to do
to qualify OR H1 flux. I find Appendix C of J-STD-001 confusing.
Please not we are also considering the option of changing our flux
to Type LO or L1 as per J-STD-001 Para 3.3
Best regards,
Paul Baine
Q.A. Manager
C-Tech Ltd.
PB/jstj
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