Hi Sam,
It is common that it is the leads of leaded SM components that fail in
vibration testing. While it is possible that there are problems with the
leads (too severe bending, wrong material choice), it is more likely that the
vibration test was too severe. 
Problems with Ni/Au can be either related to inadequate wetting (oxidation of
NI before Au coating or Au porous, inadequate reflow process) or the result
of gold 'embrittlement'--actually 'weakening' due to excess amount od Sn/Au
intermetallic compounds (Au layer too thick).

Werner Engelmaier
Engelmaier Associates, Inc.
Electronic Packaging, Interconnection and Reliability Consulting
23 Gunther Street
Mendham, NJ  07945  USA
Phone & Fax: 973-543-2747
E-mail: [log in to unmask]

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