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When Removing Hazardous Substances from Electronic Components Makes Sense Technically and Economically
November 9, 2006 |Estimated reading time: 5 minutes
I first became aware of E-Certa in March of 2006. The idea of converting Pb-bearing parts to RoHS compliance was intriguing. Later, when I saw that a number of companies were applying for RoHS exemptions based on lifetime buys of Pb-containing parts, I thought that was odd given the E-Certa solution. This was clearly a case of "adaptation to scientific and technical progress" that was being ignored by the industry. This interview with Joel Deutsch explains the conversion process and how it can solve the lifetime buy dilemma.
RoHSwell.com: How exactly can E-Certa convert a non-compliant component to meet RoHS compliance standards?
Joel Deutsch: First, the electronic component's external leads are processed back to their original pre-plated condition using New Way technology's patent pending procedure. Then, the leads are re-coated in a qualified alternative solder, using a robotic hot solder dip technique. This process mitigates the RoHS restricted substances contained in the component to a compliant level. Finally, XRF testing is used to confirm the compliant status of the component. This process has been researched and verified through destructive icp/ms testing.
RoHSwell: What steps are involved?
Joel: When products to be converted are received, they are tested to determine their original elemental content by use of a Fischer XRF XAN machine. We document and file the test results. Then, the product moves into the physical conversion process. Upon completion of the process, the now compliant components are brought back into the XRF testing lab for confirmation and documentation. The test results are sent to a client-password-protected area of E-Certa's website for easy access should the client be audited by governing parties. Finally, a material declarations document is delivered to the client to meet due diligence requirements set forth by the EU RoHS Directive.
RoHSwell: What can be done to ease the end of life availability concerns for Pb-containing components?
Joel: With E-Certa's robotic hot solder dip technique, the conversion from no lead to tin/lead solder is a viable option. Requirements for this service from RoHS exempted industries-such as medical, military/aerospace, and network infrastructure-are mounting, stemming from problems with discontinued parts, long-lead times, price premium parts, and Pb free replacements with higher percentages of tin. Managers in these industries are concerned with temperature compatibility issues in the soldering environment and the risk of tin whiskering. When these companies need to get their parts converted from Pb free to Pb, material content confirmation is critical to them.
RoHSwell: What implications does your process have for tin-whisker mitigation?
Joel: Our conversion process employs techniques found to reduce the occurrence of tin whiskers that have been researched by groups such as iNEMI. In the iNEMI document "Recommendations on Lead-Free Finishes for Components used for High Reliability Products" version 3, researchers state that "Hot dipping with SnAg4 or SnAgCu is generally an effective mitigation practice." Also found in the iNEMI research is that "Annealing/heat treating (150 degrees C for 1 hour) of matte tin-plated copper alloy lead frames has shown promise as a tin whisker mitigation technique." However, they state that the data is still not at a level to which the User Group is ready to provide this technique with a blanket endorsement. These are currently the most applicable tin whisker mitigation techniques being researched and used today. E-Certa applies both of these practices in our conversion process to address tin whisker mitigation. We are continually monitoring research to mitigate and manage the risk of tin whiskering.
RoHSwell: Another point of interest is the economics. When is conversion cost effective? When is replacement financially prudent?
Joel: One answer is a simple formula, and the other is a business necessity. The formula to use is as follows: If you have already purchased $X worth of components you cannot use (because they either are Pb or Pb-free), and the replacement cost is $Y, then component conversion makes economic sense when Y is greater than X plus the conversion costs. In many cases, however, the compelling reasons to convert components owe to solving acute business problems such as lack of availability of the desired parts owing to "end of life" or allocation.
RoHSwell: You emphasize the importance not only of E-Certa's post-conversion chemical testing, but also your testing of in-coming components. Why is that so critical?
Joel: For example, manufacturers are getting certificates of compliance that say "these components are RoHS compliant," but it is not rare that upon initial screening we discover that the parts are non compliant. Given that E-Certa is already conducting front and back testing for the conversion process, we also test components (with our high-end XRF system) to address companies' concern about whether the materials are indeed as promised. (E Certa goes a step further-with its delidding service--to identify counterfeit components, in which the chip does not match the package.)
Once, a client shipped to us components it bought from a vendor, because the client heard reports of intermittent errors after these components were assembled onto printed-circuit boards. The client wondered if the components were counterfeit. First, to test the client's theory, we performed our delidding service--a destructive process in which the lid is removed and the chip inside is examined with a high-power metallurgical microscope. The brand and codes on the chip indeed matched those on the exterior package; the components were legitimate after all. So then we tested the component with our desktop XRF system, and solved the mystery: Some of the components had 1998 date codes, and these worked well; the others had 2001 date codes, and these components failed owing to measurably different amounts of Pb on the leads! The client was experiencing wetting/solderability issues because of different material content: 30,000 parts per million Pb in the 1998 components, and barely 1,000 ppm in the 2001 versions.
RoHSwell: How do you feel that the RoHS and other green directives will aid in improving our environment?
Joel: If manufacturers take all the responsible actions necessary to achieve compliance, this would have to include a prudent plan for existing inventories left in the supply chain both on manufacturing and distributor shelves. With the ability to apply physical conversion applications to reused and recycled components, removal of banned substances can now, and should be, reduced to compliant levels before product at end of life is dumped into landfills or polluted into the air by refinery methods. Given the WEEE and RoHS directives and JEITA guidelines, along with their amendments and exemptions, clearly there is an increasing need for manufacturers to have an environmental plan in place. The clear choice presented by all these initiatives is to re-manufacture, repair, reuse, and recycle.by Ray Franklinwww.RoHSwell.com