The outsourcing trend within the electronics industry continues to accelerate as OEMs focus their limited resources on core
competencies that enhance shareholder value. This outsourcing trend is driving OEM Design and NPI Supply Chains to
become increasing horizontal,triggering them to recognize that their ability to leverage their supply base is a critical element
in their business model. These companies have recognized the need to craft a design and NPI supply chain that leverages
their internal strengths with the core competencies of their supply base. This paper presents the key characteristics of a
successful OEM/EMS NPI collaboration,including the creation of a NPI process framework. The key elements of this NPI
process framework include:
• OEM/EMS process alignment - developing a common NPI process language
• Alignment on business models,core competencies,technology roadmaps that create a "win-win" partnership
• Early engagement (concept/feasibility phases of the OEM NPI process)
• OEM/EMS executive sponsorship
• Discipline and accountability around:
• Conducting reviews
• Overall project management
• Communication plans
• Product collaboration tools and data standards
• Design for X that encompasses the complete design and supply chain (e.g.,assembly,test,reliability,safety,cost,
logistics,environment,etc).
The paper addresses the benefits and challenges of establishing and implementing a collaborative OEM/EMS NPI process
framework. Case studies of successful implementations / lessons learned will be provided.

With the ban of CFC’s,various cleaning processes have emerged and have been established as viable
alternatives1,2,3. Several cleaning processes such as ultrasonic and spray in air batch and in-line have become
firmly established. Each equipment type typically has its advantages and disadvantages,which will obviously be
of different significance to the end-user.
This in-depth study sets out to determine,which mechanical agitation cleaning system might demonstrate the
best cleaning results with regard to cleaning performance. To address the most currently available technologies:
ultrasonic,pressurized spray-in-air,spray-under-immersion,and centrifugal cleaning systems were taken as a
representative basis.
In order to guarantee meaningful results,the most demanding application was chosen: the cleaning under large
surface components. A significant conclusion of the study is that the cleaning chemistry is significantly more
important than the equipment technology used.

The evaluation of a new solvent blend to clean printed wire boards is reported. Ethyl nonafluorobutyl ether (HFE-
7200) provides the fluid dynamics to build engineered cleaning fluids that exhibit superior cleaning on a wide range
of flux technologies. Environmentally engineered solvent substitutes for CFCs have done an adequate job on rosin
based flux technology but have exhibited poor cleaning efficacy on many of the low solids flux technologies. As
such,not in kind aqueous and semi-aqueous cleaning fluids have found favor in the market.
Trends and changes in technology drive the development of electronic materials. As microelectronics converges
with surface mount technology,cleaning fluids must exhibit high solvency,low surface tension and superior wetting
properties. New innovations in engineered cleaning fluids are required to satisfy the diverse technologies facing
industry today.
Properties including solvency,viscosity,surface tension,ozone depletion potential,global warming potential and
flash point are reported and compared to commercially available cleaning solvents. Fluids engineered with ethyl
nonafluorobutyl ether have similar physical properties compared to other commercially available cleaning solvents,
and have favorable environmental,safety and health properties.
The results indicate that newly engineered solvent blends containing ethyl nonafluorobutyl ether can be used to
safely and effectively clean printed wire boards containing advanced packages. Solvent cleaning processes using
cost of ownership will be presented. Performance data will be reported on leading flux technologies. Information
needed to support the manufacturing,environmental,safety and health improvement efforts of the electronic
assembly industry will likewise be reported.

To meet today’s environmental demands,new VOC-free and low-VOC cleaning agents have been formulated that exhibit
outstanding cleaning performance for a variety of flux residues. The new cleaning agents were tested for defluxing watersoluble,
no-clean,and RMA residues from tin/lead and lead-free solders. Cleanliness was assessed by visual inspection and
ionic contamination measurements. Currently-available aqueous defluxers were included in the test matrix,and the
cleanliness data was used as a baseline.

As technologies evolve with the onset of smaller and smaller components,different flux residues,and the no-lead
solders,manufacturing companies are asking questions regarding what they need to consider for the future to
effectively clean and dry circuit board assemblies. The physical obstacles encountered in the cleaning process are
described in detail herein. This abstract will provide examples of the components and the technologies used to
achieve acceptable cleanliness and drying while using No-Lead solder,water-soluble and no clean fluxes,and
evolving component packages.

A novel liquid halide-free PK-002,epoxy flux,is reported for SnAgCu soldering,where the thermally cured flux
residue is designed to provide an interference-free service performance,in addition to the low cost advantage of a
no-clean process. epoxy flux exhibits a slightly lower flux activity than conventional fluxes. However,soldering
wetting for flip chip assembly process is outstanding. Presumably this is due to the lower flux viscosity of epoxy
flux which allows a higher flux volume to be picked up at flip chip flux dipping step. At ribbon connector assembly,
the peel strength of epoxy flux is the highest,attributable to the combined effect of solder bond strength and epoxy
adhesion. The flux residue of epoxy flux is virtually fully cured when processed through a simulated hot-bar
soldering cycle,as evidenced by DSC and solvent cleaning test. BGA solder bumping and BGA assembly are
accomplished satisfactorily. The voiding content in the solder bumps and BGA joints made with epoxy flux is lower
than all conventional fluxes tested,mainly attributable to the negligible outgassing rate of epoxy flux at soldering
temperature.

Applying underfill materials to the bottom of components prior to shipping to the 2nd level end-user is very desirable
in that it would eliminate the underfill process from the end-users assembly line. The overall value to the end-user is
tremendous. It eliminates the need for special equipment to process underfill materials,allows more flexibility
during the product design phase and minimizes employee exposure to wet chemicals.
This paper will examine the key application and process challenges associated with implementing the use of
package-applied underfill. Included in this will be the challenges of physically putting the underfill on the
components at the 1st level component suppliers as well as the effects on 2nd level assembly operations,such as
component placement,reflow (effect on interconnect) and reliability performance.

A simple and cost effective method has been developed in order to test adhesion of components to a circuit board
via a reflow encapsulant. Originally,a mechanical shock test similar to current methods was used that involved
physically dropping the test board from a given height and orientation. However,the majority of the reflow
encapsulant materials tested were able to withstand numerous drops without any signs of failure. A standard die
shear test did not provide the mechanical shock that the board would experience when being physically dropped. For
those reasons,a guillotine type of device was constructed which provided the opportunity to reproducibly deliver a
force to any desired area of the test vehicle. The "blade" of the device was fitted with a known mass,which is easily
varied. The test vehicle used in this test contained three types of components; two BGA's (225I/O,15x15 Ball
Matrix,Full Array,1.5mm Pitch),three CSP's (48I/O,10x10 Ball matrix,Perimeter Array,1.0mm pitch),and one
quartz slide (12mm x 12mm). Several failure types have been observed and noted. Electrical continuity was used as
a failure mode where applicable. Another mode of failure was observed as cracking/delamination around the fillet of
the BGA's and CSP's,and underneath the quartz test dies. The final failure mode noted was where the components
were entirely broken off of the circuit board. The details of the testing apparatus will be presented along with the
results on materials with differing abilities to survive the test cycle.

In this work,we have evaluated the use of underfill to enhance the reliability of small BGAs in the automotive
thermal cycling environment. Best parameters for underfilling of BGAs were developed during a processing study,
and then a set of test boards was assembled with several 15 and 17 mm body size BGA components from two
different vendors,and four different underfill encapsulants. Larger 23 mm BGAs (non-underfilled) have also been
included in the test matrix as a control/reference. The assembled test vehicles have been subjected to 6000 thermal
cycles over the range -40 to 125 oC,and the daisy-chain resistances of the various components were monitored
throughout the testing. Logged failures have been statistically analyzed using two parameter Weibull models. The
analysis results have allowed the board level reliabilities of the examined BGA components to be compared and
ranked,and the reliability enhancements achieved with various underfills to be accessed. Detailed failure analyses
have also been performed to find the locations of solder joint fatigue crack growth,and to identify other failure
modes occurring in underfilled parts. Finally,heat transfer studies have also shown that use of underfill can
significantly reduce the junction to case thermal resistance of the BGAs.

It is stated that some degree of voiding is acceptable and inevitable when soldering electronic components,and
specifically BGAs. There have been many publications which discuss this phenomena,the reasons for,how to
detect,what is and isn’t acceptable,reliability etc. this paper looks from a practical approach,in a production
environment as to the causes,minimisation,detection and measurement of voiding,and some discussion on it’s
impact on reliability.
A void is defined as a “bubble” of air entrapped within a solder joint. Due to surface tension effects this is
generally spherical in shape. There can also be single void,or multiple voids within any joint; the significance
of these is also discussed.