ESA UNCLASSIFIED – For Official Use Update on the ESA Lead Free Control Plan (LFCP) Working Group Barrie Dunn May 2011

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 2 ESA UNCLASSIFIED – For Official Use Main Objective of the Working Group is to publish a Lead-free Control Plan (LFCP) that can be used by the Space Industry in order to: ensure that spacecraft electrical systems and related hardware comply with the contractual requirements of ECSS standards, and, assess the inherent risks with Pb-free As of May 2011, the Plan is about 60% complete Intention is to publish it as an ESA STR document (not a Standard, but a good practice document, parts of which could be formalised in the future as requirements) Main Objective of the Working Group

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 3 ESA UNCLASSIFIED – For Official Use To exchange, share information, return of experience concerning Lead-Free To identify the issues and problems to be solved regarding the concerns expressed by the CTB members To define recommendations for solutions and answers to these concerns The scope includes: EEE components and COTS devices Connectors PCBs Solder Peripheral hardware : clamps, screws, pins, wires, electronic housings Secondary Objectives :

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 4 ESA UNCLASSIFIED – For Official Use Chapter Titles for LFCP Introduction (Chapter 1) Problems associated with Lead-free (processes at higher temperatures, materials with different mech props, solderability, inspection criteria, whiskers, rework/repair, mixing of alloys, traceability, black pad, etc.) (Chapter2) ESA Requirements (Chapter 3) Definition of Pure Tin (Chapter 4) Assessment of Suppliers LFCPs (Chapter 5) Methods for detecting Tin and Lead (Chapter 6) Method for Re-processing component terminations (Chapter 7) Mitigation strategies for the avoidance of failures due to tin whiskers (Chapter 8) Illustrations of problem situations (Annex 1) Check List (for in-house awareness and auditing purposes) (Annex 2)

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 5 ESA UNCLASSIFIED – For Official Use Restriction of the use of certain hazardous substances in electrical and electronic equipment ***I This Directive does not apply to: a)equipment which is necessary for the protection of the essential interests of the security of Member States, including arms, munitions and war material intended for specifically military purposes; b) equipment designed to be sent into space; c)equipment which is specifically designed and to be installed as part of another type of equipment that is excluded or does not fall within the scope of this Directive, which can fulfil its function only if it is part of that equipment, and which can be replaced only by the same specifically designed equipment ; d)large-scale stationary industrial tools; e)large-scale fixed installations; f)means of transport for persons or goods, excluding electric two-wheel vehicles which are not type-approved. A7-0196/2010 P7_TA-ROV(2010)0431

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 6 ESA UNCLASSIFIED – For Official Use Lead-free Control Plan Working Group –Flow Diagram for Plan (suggestion): 1. Procurement to define lead-free requirements 2. Incoming Inspection of components, pcbs, terminal posts, connectors Using: visual, swab (red means lead), XRF, SEM-EDAX,etc. 3. Lead-free parts may need reprocessing de-tin, pre-tin with solder, etc. per ECSS-Q-STD Impossible to reprocess then a Risk Assessment is needed 5. Risk Assessment will include consideration of mitigation possibilities involving: tin composition, tin thickness, substrate material, heat treatment history, track/line spacing distance, conformal coating, environment exposure (life, temperature, cycles, etc.)

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 7 ESA UNCLASSIFIED – For Official Use Lead-free Control Plan Working Group

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 8 ESA UNCLASSIFIED – For Official Use

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 9 ESA UNCLASSIFIED – For Official Use

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 10 ESA UNCLASSIFIED – For Official Use

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 11 ESA UNCLASSIFIED – For Official Use

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 12 ESA UNCLASSIFIED – For Official Use Cross section 3

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 13 ESA UNCLASSIFIED – For Official Use APPENDIX 2 of LFCP: CHECK LIST FOR CONTROLLING THE AVOIDANCE OF LEAD-FREE MATERIALS AND COMPONENTS No. YesNoComments 1Is there a Materials and Processes manager to supervise lead- free policies and forbidden materials per ECSS-Q-70B. Do Declared Materials, Components, Processes and Mechanical Parts Lists exist. Does the supplier have a Lead-Free Control Plan (LFCP). Is one individual responsible for documenting and operating the tasks specified in the LFCP (comment on named individual).

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 14 ESA UNCLASSIFIED – For Official Use Technical Tasks for WG members: Understand EU Directives Risks and Limitations with Lead-free such as: tin whiskers, solder joint reliability, copper dissolution, cross contamination, higher processing temperatures (most of these have been researched with answers available and some have been identified for small studies by ESA) Components and other items delivered per ECSS requirements must be without pure tin – inspection methods Provide recommendations for reworking pure tin components Identify other small studies where information is missing (such as the SPUR tin chemical stripping study) Present WG Members are from: ESA (Chair), CNES, Astrium, THALES Group, SEA Ltd UK NEW MEMBERS ARE WELCOME 1.Technical Tasks for WG members:

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 15 ESA UNCLASSIFIED – For Official Use Link between LFCP & PSWG ad hoc WG on Pb free incoming inspection test ESCC SCSB CTB PSWG ECSS Technical Authority Discipline focal point Ad hoc WG on Pb free incoming inspection test Lead Free Control Plan ECSS-Q-ST (COTS) RNC-CNES-Q-ST (COTS) Astrium, TAS, others procedures Cooperation on Q-60 discipline

ESA Presentation | Barrie Dunn | May 2011 | TEC-Q | Slide 16 ESA UNCLASSIFIED – For Official Use LFCP WG Next Meetings will be in the form of small workshops at THALES, Toulouse 15 th June 2011 Re-processing of component terminations based on existing Thales and Astrium experiences and novel ideas from industry 22 nd September 2011: Risk Assessment and Mitigation associated with lead-free and whisker growths based on existing computer programmes and novel ideas from industry INPUTS from both Workshops will be used for the LFCP Chapters 6, 7 and 8 All Component and Materials specialists are invited to attend, contact: or