Dec 15 2005
The electronics industry is facing a major challenge: with a few exceptions, components being introduced to the market must be lead free as of next July. A recently-established technology and competence center helps in the transition.
In July 2006, two EU directives will become effective: “Restriction of Hazardous Substances in Electrical and Electronic Equipment (RoHS)” – known in industry parlance as the “lead-free directive” – and “Waste from Electrical and Electronic Equipment (WEEE)”. Both restrict the use of certain hazardous materials in electrical and electronic devices, measures that will present virtually all affected companies with substantial challenges and force them to implement processes for adapting to the changes.
“First they will have to decide which systems are best suited to which products,” explains Thomas Ahrens of the Fraunhofer Institute for Silicon Technology ISIT. “Then they will have to review the solder heat resistance of all components on a product-specific basis, because lead-free processes generally work with higher processing temperatures than those that employ lead. To put it plainly, many components will be damaged by the higher temperatures.” This ultimately alters long-term product performance, making re-qualification necessary. Opportunities for cost reduction should be identified and analyzed at an early stage, and staff will need to be trained.
At the competence center recently opened in Itzehoe north of Hamburg, interested companies can train their employees for lead-free manufacturing processes. The equipment available on the training line encompasses all relevant soldering technology steps: application of soldering paste and bonding agent, SMD mounting, wave and reflow soldering in the convection and vapor phases, and selective soldering using miniwaves and lasers. Circuit board assemblies ranging in width from three to 30 centimeters can be manufactured on this line.
“Our services are geared towards contract manufacturers, especially SMEs,” says Ahrens, who initiated the competence center. “These companies in particular need help in their decision-making before investing in new, expensive equipment.” Producers that manufacture their own products, on the other hand, often lack the capability to operate a lead-free line simultaneously with one that uses lead.
The competence center will remain relevant for industry even after 2006, since there will still be a need for training and quality assessment after the switch to lead-free soldering. In particular, companies will further optimize the technology with respect to process tolerances, quality and reliability, and cost reduction measures. Some areas such as automobile electronics will still be excepted from the directives, however – at least for the time being.