Soldering of electronic products-printed
Soldering of electronic products
One of the major uses of this method is soldering of electronic assemblies. There are two main types of profiles used today: The Ramp-Soak-Spike (RSS) and the Ramp to Spike (RTS). In modern systems, quality management practices in manufacturing industries have produced automatic process algorithms such as PWI, where soldering ovens come preloaded with extensive electronics and programmable inputs to define and refine process specifications. By using algorithms such as PWI, engineers can calibrate and customize parameters to achieve minimum process variance and a near zero defect rate.
In soldering, a thermal profile is a complex set of time-temperature values for a variety of process dimensions such as slope, soak, TAL, and peak. Solder paste contains a mix of metal, flux, and solvents that aid in the phase change of the paste from semi-solid, to liquid to vapor; and the metal from solid to liquid. For an effective soldering process, soldering must be carried out under carefully calibrated conditions in a reflow oven. Convection Reflow Oven Detailed Description
There are two main profile types used today in soldering:
The Ramp-Soak-Spike (RSS)
Ramp to Spike (RTS)
Ramp is defined as the rate of change in temperature over time, expressed in degrees per second. The most commonly used process limit is 4 °C/s, though many component and solder paste manufacturers specify the value as 2 °C/s. Many components have a specification where the rise in temperature should not exceed a specified temperature per second, such as 2 °C/s. Rapid evaporation of the flux contained in the solder paste can lead to defects, such as lead lift, tombstoning, and solder balls. Additionally, rapid heat can lead to steam generation within the component if the moisture content is high, resulting in the formation of microcracks.
In the soak segment of the profile, the solder paste approaches a phase change. The amount of energy introduced to both the component and the PCB approaches equilibrium. In this stage, most of the flux evaporates out of the solder paste. The duration of the soak varies for different pastes. The mass of the PCB is another factor that must be considered for the soak duration. An over-rapid heat transfer can cause solder splattering and the production of solder balls, bridging and other defects. If the heat transfer is too slow, the flux concentration may remain high and result in cold solder joints, voids and incomplete reflow.
After the soak segment, the profile enters the ramp-to-peak segment of the profile, which is a given temperature range and time exceeding the melting temperature of the alloy. Successful profiles range in temperature up to 30 °C higher than liquidus, which is approximately 183 °C for eutectic and approximately 217 °C for lead-free.
The final area of this profile is the cooling section. A typical specification for the cool down is usually less than −6 °C/s (falling slope).