1. Impact of the Öko-Institut Recommendations on an Avionics OEM :
Dave Hillman
Rockwell Collins
IPC Brussels June 2008

2. Impact of the Öko-Institut Recommendations on an Avionics OEM
Agenda:
High Performance Use Environment OEM Characterization
Visual Impact Example
Consequences of Material Changes on OEM
Impact of New RoHS Material Additions
Conclusions

3. Impact of the Öko-Institut Recommendations on an Avionics OEM
High Performance Electronic Products Characterization:
Life Critical & Flight Critical Applications
Extremely Stable Qualified Material Lists
Significant Use Life ~ Years Not Uncommon
Manufacturing Mode: High Mix/Low Volume
Design Cycle Mode: Deliberate and Long ~ 12 Months
Customer Certification
* Nothing is set in stone – and there is no guarantee that “legacy” products will have infinite exemption. exemption/exclusion
Graphic source: M. Kelly, SMTAI 2007, “Case Study: Qualification of a Lead-free Card Assembly & Test Process of a Server Complexity PCBA

4. Impact of the Öko-Institut Recommendations on an Avionics OEM

5. Impact of the Öko-Institut Recommendations on an Avionics OEM
(Graphic courtesy of L. Whiteman ACI)

6. Addresses issues that are:
AIA-AMC-GEIA Lead-free Electronics in Aerospace Project Working Group (LEAP WG)
Formed in 2004
AIA – Aerospace Industries Association
AMC – Avionics Maintenance Conference
GEIA – Government Electronics and Information Technology Association
Includes all stakeholders (market segments, supply chain, geographic regions)
~90 meeting attendees
10 active task groups
Addresses issues that are:
Unique to aerospace and military
Within control of aerospace and military
Copyright © 2006 Boeing. All rights reserved.
PPT cell courtesy of Lloyd Condra, Boeing

7. LEAP WG Actionable Deliverables
GEIA-STD , Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-free Solder
Used by aerospace electronic system “customers” to communicate requirements to aerospace electronic system “suppliers”
GEIA-STD , Standard for Mitigating the Effects of Tin Whiskers in Aerospace In High Performance Electronic Systems
GEIA-STD , Performance Testing for Aerospace and High Performance Electronic Interconnects Containing Lead-Free Solder and Finishes
Used by aerospace electronic system “suppliers” to develop reliability test methods and interpret results for input to analyses
GEIA-HB , Program Management / Systems Engineering Guidelines For Managing The Transition To Lead-Free Electronics
Used by program managers to address all issues related to lead-free electronics, e.g., logistics, warranty, design, production, contracts, procurement, etc.
GEIA-HB , Technical Guidelines for Aerospace and High Performance Electronic Systems Containing Lead-Free Solder and Finishes
Used by aerospace electronic system “suppliers” to select and use lead-free solder alloys, other materials, and processes. It may include specific solutions, lessons learned, test results and data, etc.
GEIA-HB , Rework and Repair Handbook for Aerospace and High Performance Electronic Systems Containing Heritage SnPb and Lead-Free Solder and Finishes
GEIA-HB , Impact of Lead Free Solder on Aerospace Electronic System Reliability and Safety Analysis
Used to determine, quantitatively if possible, impact of lead-free electronics on system safety and certification analyses, using results from tests performed per GEIA-STD
Copyright © 2006 Boeing. All rights reserved.
(Published)
(in ballot)
PPT cell courtesy of Lloyd Condra, Boeing

8. Impact of the Öko-Institut Recommendations on an Avionics OEM
Failure Phenomena Due to a Materials Change

9. Impact of the Öko-Institut Recommendations on an Avionics OEM
*Determining, quantitatively if possible, impact of material substitutions on system safety and certification is a significant task
200 thermal cycles: SnPb solder (left) and SAC solder (right)

10. Impact of the Öko-Institut Recommendations on an Avionics OEM
Material - Beryllium
Beryllium is a highly regulated and controlled material within aviation electronics market segment. Beryllium has extensive applications in electronic component construction and as metal alloy constituent. Metal alloys utilizing Beryllium as an alloy constituent have unique performance characteristics for which a substitute material may not exist.

11. Impact of the Öko-Institut Recommendations on an Avionics OEM
Material - Nickel
Nickel is widely used as substitution material for current RoHS prohibited materials: Cadmium and Hexavalent Chromium. Nickel has extensive applications in electronic component construction, plating, and as metal alloy constituent. The addition of Nickel to the current RoHS prohibited materials list would result in the requalification of another substitute material for Cadmium and Hexavalent Chromium, provided a substitute material exists.

12. Impact of the Öko-Institut Recommendations on an Avionics OEM
The Periodic Table is a Finite Material Set
Table Courtesy of Sargent Welch Scientific Co.

13. Impact of the Öko-Institut Recommendations on an Avionics OEM
The compact fluorescent light bulb is an example of controlled use of a hazardous material resulting in a better technology
Material substitutions require due diligence test/evaluation efforts to determine applicability for a industry use segment compatibility before a substitution can be accomplished

14. Impact of the Öko-Institut Recommendations on an Avionics OEM Conclusions:
The High Performance Use Environment Industry Segment is not a “stand alone” entity - material changes to the global industry supply base impact all industry use segments.
A critical parameter of material assessment is the balance of material elimination versus material restricted use
The implementation of new materials of High Performance Use Environment technologies is achievable if conducted in a measured, controlled, methodical manner.