Can Nano-Coatings Really Improve Stencil Performance? Tony Lentz FCT Assembly
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1 Can Nano-Coatings Really Improve Stencil Performance? Tony Lentz FCT Assembly
2 Outline/Agenda Introduction Claims & questions about coatings Experiment design Results of coating performance Return on investment Benefits and negative impact Q & A
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5 Properties of Nano-Coatings Hydrophobic Oleophobic Fluxophobic
6 Claims About Nano-Coatings Reduced underside cleaning Reduced bridging Improved solder paste release Improved yield
7 Questions About Nano-Coatings How to measure performance? How robust are the coatings? What is the return on investment? What are the hidden benefits? What are the negative impacts?
8 Test Procedure 1. Stencils made and nano-coated 2. Measured contact angle, abrasion and chemical resistance 3. Printed 20 boards with no cleaning 4. Measured solder paste volume 5. Inspected bridging areas 6. Inspected underside of stencils
9 Experiment Equipment and Materials Essemtec printer 20 mm/sec, 0.18 Kg/cm, 1.5 mm/sec ASC International SPI AP212 with VM150 sensor Solder paste No clean, lead free, SAC305 Type 3 Stencils, 304 SS (127 microns) thick Datum PhD
10 Experiment Equipment and Materials Test Board F1 Paste release in 6 BGAs Bridging in 2 areas Bridging 0.4 mm BGA arrays 0.5 mm BGA arrays Bridging
11 Experiment Equipment and Materials BGA areas 3 x 0.5 mm arrays, SAR 0.575, 252 pads/board 3 x 0.4 mm arrays, SAR 0.500, 1080 pads/board 0.5 mm BGA arrays SAR mm BGA arrays SAR 0.500
12 Experiment Equipment and Materials Bridging areas (2) 144 possible bridges per board Bridging Pitch: 8, 12, 16, 18, 20 mils
13 Experiment Surface Area Ratio Calculation 0.5 mm BGA arrays Stencil thickness = 5.0 mils (127 µm) Aperture = 11.5 mils (292 µm) square SAR = mm BGA arrays Aperture = 10.0 mils (254 µm) square SAR = 0.500
14 Experiment Stencil apertures 10.0 mil square SAR Pads on circuit board 8.0 mil round Printed paste
15 Coating Application Wipe on Coating B Coating C Spray coat and cure Coating A Coating D
16 Coating Chemistry Stencil Self Assembled Monolayer Coating B Coating C Polymer Cross Link Coating A Coating D
17 Coating Thickness Coating Thickness Uncoated 0 Coating A Coating B Coating C Coating D nm (1 2 microns) 2 4 nm 2 4 nm nm (2 4 microns)
18 Questions About Nano-Coatings How to measure performance? How robust are the coatings? What is the return on investment? What are the hidden benefits? What are the negative impacts?
19 Performance Measurement SURFACE FUNCTION Contact angle Underside cleaning Bridging APERTURE FUNCTION Solder paste release Transfer efficiency
20 How to Measure Contact Angle GONIOMETER
21 Surface Function - Contact Angle Hydrophobic Surface Hydrophilic Surface High Contact Angle Low Poor Adhesiveness Good Poor Wettability Good Low Surface Energy High
22 Surface Function Contact Angle Coating CA DI Water CA n-hexadecane Uncoated 54 9 Coating A Coating B* Coating C* Coating D *Inconsistent performance lot to lot
23 Performance Measurement SURFACE FUNCTION Contact angle Underside cleaning Bridging APERTURE FUNCTION Solder paste release Transfer efficiency
24 Surface Function Underside Cleaning
25 Surface Function Underside Cleaning Uncoated stencil Nano-coated stencil Coatings A, B, C, D After 20 prints with no underside cleaning
26 Surface Function Bridging Coating Bridging Profile Shape Uncoated 174 Deteriorates Coating A 0 Consistent Coating B 2 Consistent Coating C 0 Consistent Coating D 0 Consistent
27 Performance Measurement SURFACE FUNCTION Contact angle Underside cleaning Bridging APERTURE FUNCTION Solder paste release Transfer efficiency
28 Aperture Function Solder Paste Release Journal of SMT Volume 16 Issue 1, REAL TIME VISUALIZATION AND PREDICTION OF SOLDER PASTE FLOW IN THE CIRCUIT BOARD PRINT OPERATION. Dr. Gerald Pham-Van-Diep, Srinivasa Aravamudhan, and Frank Andres
29 Aperture Function Transfer Efficiency TE by Location for SAR 0.575
30 Aperture Function Transfer Efficiency TE by Location for SAR 0.500
31 Transfer Efficiency (%) Aperture Function Transfer Efficiency Average Transfer Efficiency SAR (0.5 mm BGA) U A B C D Coating Type
32 Transfer Efficiency (%) Aperture Function Transfer Efficiency Average Transfer Efficiency SAR (0.4 mm BGA) U A B C D Coating Type
33 Aperture Function Stencils After 20 Prints Coating A Coating B Coating D Uncoated
34 Questions About Nano-Coatings How to measure performance? How robust are the coatings? What is the return on investment? What are the hidden benefits? What are the negative impacts?
35 Robustness of Nano-Coatings ASTM D2486 Abrasion Tester
36 Abrasion Test Procedure 1. Coating scrubbed for 2000 cycles 2. Contact angle measured every 500 cycles with DI water 3. Testing repeated with chemicals added
37 Contact Angle (deg) Contact Angle (deg) Robustness Abrasion Abrasion - 100% Cotton Abrasion - Water D B C D B C Cycle Count Cycle Count
38 Contact Angle (deg) Contact Angle (deg) Robustness Abrasion with Chemicals Abrasion - IPA Abrasion - 25% Rosin Flux D 80 D 70 B 70 B Cycle Count Cycle Count
39 Questions About Nano-Coatings How to measure performance? How robust are the coatings? What is the return on investment? What are the hidden benefits? What are the negative impacts?
40 Return on Investment Cost of Printing Cycle time - productivity Cleaning material usage Waste of solder paste Yield loss Rework time and materials
41 Return on Investment Cycle Time Clean Every Print - Uncoated Stencil Typical for small SAR <0.55 Print 1 board every seconds Clean Every 20 Prints - Nano-Coating Print 1 board every seconds Doubles print productivity
42 Return on Investment Cleaning Material Usage Clean Every Print Uncoated Stencil Fabric usage = 3 inch x $0.04/in = $0.12 Solvent usage = 10 ml x $0.008/mL = $0.08 Total = $0.20 per circuit board Clean Every 20 Prints - Nano-Coating Total = $0.01 per circuit board
43 Return on Investment Uncoated Stencil Solder Paste Waste Solder paste is cleaned from stencil bottom 0.4 to 0.7 grams of paste cleaned from stencil Waste of $0.04 to $0.07 per board 70% 30% Transfer Efficiency Wasted Paste
44 Return on Investment Nano-Coated Stencil Solder Paste Waste Solder paste is NOT cleaned from stencil bottom No waste of solder paste, save $$$
45 Return on Investment Yield Loss Print Issues Account for the Majority of Defects Nano-coating yield improvements of 10 70% reported by Shea, Zubrick, and Whittier* Increased TE can improve these defects: insufficient solder, solder balling, graping If a circuit board costs $100, preventing scrap pays for most nano-coatings *SMTA 2011, USING SPI TO IMPROVE PRINT YIELDS. C. Shea, M. Zubrick, R. Whittier
46 Return on Investment Rework Time and Materials What is the Impact of Nano- Coatings on Rework? First pass yield improvement Eliminate rework and improve cycle time Save materials and labor cost
47 Return on Investment Item Cost Savings ($) Improved print cycle time 2 boards per minute instead of 1 Cleaning material savings Save $ per board Solder paste waste reduction Save $ per board Yield improvement Savings inestimable Save on rework costs Savings inestimable If Nano-coating costs $40 ROI is 150 to 180 boards
48 Questions About Nano-Coatings How to measure performance? How robust are the coatings? What is the return on investment? What are the hidden benefits? What are the negative impacts?
49 Hidden Benefits Benefits Underside cleaning improved Bridging improved Transfer efficiency increased Visible on the stencil Re-apply by the user Nano-Coatings Tested All coatings A, B, C, D All coatings A, B, C, D Coatings A and D Coatings A and D Coatings B and C
50 Questions About Nano-Coatings How to measure performance? How robust are the coatings? What is the return on investment? What are the hidden benefits? What are the negative impacts?
51 Negative Impact Negative Impacts Coating wears through abrasion Coating wear not visible Transfer efficiency decreased Nano-Coatings Coatings B and C Coatings B and C Coatings B and C
52 Conclusions Nano-coatings provide benefits, but coatings differ in performance. The cost of most coatings is negligible compared to the costs of cleaning materials, solder paste waste, defects, yield loss and rework. If you use a nano-coating, be sure to choose the right one.
53 Thank You for Your Attention! Any questions? Tony Lentz FCT Assembly
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