1. Dave Hillman, Tina Berthiaume, Preston Schaaf Rockwell Collins PERM 23
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Dave Hillman, Tina Berthiaume, Preston Schaaf
Rockwell Collins
PERM 23

2. Agenda Background IPC Committee Task Plan Test Materials Test Vehicle
Metallographic Sectioning Plan
Conformal Coating Measurements
Results To Date
Looking At “Future”

3. Background
Graphic Courtesy of CALCE Consortia

4. Background
Graphic Courtesy of CALCE Consortia

5. Background
Graphic Courtesy of CALCE Consortia

6. Background
Graphic Courtesy of CALCE Consortia

7. Background
Graphic Courtesy of PERM group

8. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
IPC-JSTD-001E Subcommittee Task Team:
Conformal Coating Material & Application “State of the Industry” Assessment
The goal of the project is to document the current “State of the Industry” of conformal coating application on printed wiring assemblies.
The project will look at the major conformal coating types (i.e. AR, ER, UR, SR, XY) and method of application (i.e. spray, dip, brush).
The project will not evaluate individual companies or specific conformal coating products – plan is to do a “blind” task activity. Study will produce baseline data on what thickness/coverage the industry is/can achieve with conformal coating materials.

9. Conformal Coating Types: AR = acrylic ER = epoxy UR = urethane
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Conformal Coating Types:
AR = acrylic
ER = epoxy
UR = urethane
SR = silicone
XY = paralyene
Application Method:
Machine or Manual
Spray
Dip
Brush
Other
Application Volunteers to collect and retain detailed documentation of application method –NO IP will be disclosed. Sufficient baseline application process details have been disclosed for every application method.
Test Vehicle

10. Task Group coating/application tasks complete:
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Current Status:
Task Group coating/application tasks complete:
~12 volunteer conformal coating facilities utilized
~ 95 individual test vehicles processed
5 Conformal Coating materials covered (AR, ER, UR, SR, XY)
Task Group application methodologies covered:
Manual Spray
Automated Spray (stream)
Automated Spray (atomized)
Dipped
Brushed
Vapor Deposition (on XY only)
Reviewed Every 6 Months: APEX Conference and IPC Committee meeting at SMTA Fall Conference

11. Manual Spray: AR = 1, UR = 3, SR=3
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Project “Statistics”
Application Method:
Manual Spray: AR = 1, UR = 3, SR=3
Automated Spray: AR = 4, UR = 6, SR = 3, ER = 2
Vapor Deposited: XY = 1
Dip Deposition: AR =1
Manual Brush: AR=1
Manual Syringe/Automated Spray: AR =1
Cure Method:
Thermal UV
Air/Thermal/UV combinations
General:
3 Different Automated Spray Systems, Multiple Spray Angle/Pass Combinations

12. Processing: Photodocumentation
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Processing: Photodocumentation

13. Processing: Photodocumentation
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Processing: Photodocumentation

14. Processing: Photodocumentation
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Processing: Photodocumentation

15. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Components Being Assessed: 25 per TV and 3 TV per Coating/Application Set

16. Will “cap coat” gold layer for metallographic section purposes
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Coating Coverage and Thickness Assessment Method: Metallographic Cross-sectioning
Details:
Will gold sputter to define conformal coating outer edge before potting
Will “cap coat” gold layer for metallographic section purposes
Will cross-section from two angles
Straight On
Profile
Lots of Photographs with general assessment before cross-section (photos, flat thickness measurement)
Task Group Metallographic Process Document Available on IPC Kavi Site

17. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Careful Removal From Test Vehicle (Gold Sputtering/Protective Cap Layer)

18. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Photo documentation of cross sections from two angles:

19. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

20. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

21. Measurements: Standards Calibrated Metallographic Scope
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Measurements: Standards Calibrated Metallographic Scope

22. Measurements: Maximum, Minimum, and Top of Component Examples
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Measurements: Maximum, Minimum, and Top of Component Examples

23. Example Application Details:
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Example Application Details: SR
Manually Sprayed with Binks Model 2001 conventional gun at angle (approximately 45 degree) with applications at every 90 degrees (the boards are rotated to receive the angle spray from 4 sides to prevent shadowing). UR
Asymtek C740 equipment, SC300 atomizing head, 0.26 mm nozzle, 10 Degree flute, 10 psi fluid pressure, 30 psi atomizing pressure, 4 passes per path direction procedure. ER
Atomized Spray Coating, 10 passes each in X & Y axis, IR Profile followed by Batch Cure 45 min, mils.

24. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

25. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

26. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

27. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

28. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

29. IPC Conformal Coating Material & Application “State of the Industry” Assessment Project

30. Multiple Opportunities for Comparison: Application Method
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Multiple Opportunities for Comparison:
Application Method
Manual Spray: AR = 1, UR = 3, SR=3
Automated Spray: AR = 4, UR = 6, SR = 3, ER = 2
Vapor Deposited: XY = 1
Dip Deposition: AR =1
Manual Brush: AR = 1
Manual Syringe/Automated Spray: AR =1
Final Report anticipated to address thin coating areas and potentially “critical coating” areas similar to “critical solderability” areas

31. Opportunities for Data Collaboration with Current Studies:
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
Opportunities for Data Collaboration with Current Studies:
NPL Conformal Coating Study
13 Companies
32 Conformal Coating “products/formulations”
49,152 Individual Leads
ONE Component with ONE Failure after 12 Months
Controls (uncoated) Failed after 1 Month
NASA Urethane Study
13+ Years, 3 mils Thick Has No Whisker Protrusion
Lockheed Martin Test (Woody/Fox Set)
10+ Years, 3 mils Thick Has No Whisker Protrusion

32. If You Want Access to the Committee Activities:
IPC Conformal Coating Material & Application “State of the Industry” Assessment Project
If You Want Access to the Committee Activities:
Contact Teresa Rowe =
Committee = 522 arr J-STD-001 Conformal Coating Material & Application Industry Assessment
Kavi site = committee document depository

33. Questions ???
Graphic Source: Iowa State University Ag Extension Office 2012 PPT “Having A Bad Day”