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Instead, the press-fit pin is anchored solely by the mechanical interference between connector lead and the PTH barrel of the PWB. Oxides on the surface of the press-fit pin and mating PTH barrel are broken loose by the high frictional forces associated with the press-fit assembly operation, so nobility of materials, oxide build-ups, and material shelf-life are less critical considerations than in soldering. If conditions are proper in terms of sizing and materials, the press-fit process results in a gas-tight contact between the connector pin and the PTH barrel wall. The notion of a gas-tight seal as the product of a proper press-fit is crucial to connection reliability. If an electrical contact is to be reliable, the interface between the two mating surfaces must remain chemically and mechanically stable. The gas-tight, smeared, metal-to-metal contact attained during the press-fit operation mitigates oxidation of either contact (PTH barrel or pressfit pin) and prevents fretting corrosion, which is a common failure mechanism for mechanically mated contacts, especially those subjected to vibration. Press-fit interconnection is considered at least as reliable as a soldered connection and there is no solder joint to degrade or crack with time.
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SURFACE FINISHES AND EFFECTS
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Surface finish of the PWB s PTH has a significant effect on the force required to seat a pressfit connector. Changes in surface finish and PTH finish quality can have a profound effect on pressing force and reliability.
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Tribology Every material has frictional (tribologic) properties. Some are naturally lubricating, such as Sn-Pb alloys, and others are notably nonslippery, such as tin or copper. Copper is one of the least slippery of the surface finishes and typically requires more pressing force than Sn-Pb or gold finishes for a comparably sized hole. Tin s crystalline structure is also rather resistant to sliding. In some cases, extra attention to PTH finished hole size (FHS) is required. The PWB vendor should be alerted to the fact that holes are being placed in the board for press-fit, so FHS and surface finish conditions are appropriate for the press-fit component. In some cases, for some materials such as copper, the holes could be specified for the upper end of its FHS as expressed by the connector vendor to aid in insertion. FHS should be just that: the hole size after surface finish is applied. If tribologic forces are too great, then the PTH barrel can be pushed out of the board or otherwise damaged. Trial boards and pressing parameters should always be assessed before full manufacturing commences. Only very small changes or imperfections can interfere with the typically high yields of press-fit connections. As previously mentioned, recently the European Union exempted press-fit connectors from its RoHS legislation, allowing the use of Sn-Pb coatings on compliant tails. The Pb adds a small amount of lubricity, allowing for easier pressing into notably difficult surface finishes such as organic solderability preservative (OSP) copper.
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PTH Barrel Finish Barrel finish can have a profound impact on the press-fit operation. If a PTH barrel is too thin or poorly sized for the compliant pin, the pin may pierce the barrel wall or break internal connections to it. OSP-copper finish since it is a watery, thin topical coating adds no appreciable thickness to the PTH lands or barrel, so its control in high-aspect-ratio holes is not an issue in terms of press-fitting. Electroless/immersion surface finishes are generally thin and self-limiting in thickness, and as with OSP-copper, there no appreciable change in PTH hole diameter adding little impact to the press-fit process. At the other end of the spectrum are hot air solder leveling (HASL) and electroplated finishes, which may add significant material to PTH barrel walls and annular rings. Too thick a HASL coating can lead to PTH barrel diameter reduction. During pressing, the press-fit pins may be overcompressed, causing them to yield and collapse beneath the connector rather
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