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flux, solder-preform flux, and flux-cored solder. It is not the intent of this standard to exclude any acceptable flux or soldering aid material; however, these materials must produce the desired electrical and metallurgical interconnection. J-STD-005, Requirements for Soldering Paste. This standard prescribes general requirements for the characterization and testing of the solderpastes used to make high-quality electronic interconnections. J-STD-006, Requirements for Electronic Grade Solder Alloys and Fluxed and Non-Fluxed Solid Solders for Electronic Soldering Applications. This standard prescribes the nomenclature, requirements, and test methods for electronic grade solder alloys; for fluxed and non-fluxed bar, ribbon, and powder solders, for electronic soldering applications; and for special electronic grade solders. Other Standards. There are many standards that comprise the necessary content for successful production practices that lead to acceptability. Each represents an element of the foundation that supports a complete and successful production effort. One example is moisture susceptibility and the procedures to ensure that the components are not damaged by popcorning during reflow. J-STD-020 and J-STD-033 provide classification and control for moisture-sensitive components. Others, such as IPC-CC-830, Qualification and Performance of Electrical Insulating Compound for Printed Wiring Assemblies, deal with material acceptability of conformal coating. Each of the elements is important and should be considered as a package for overall acceptability. Many of the material specifications reference test methods. Rather than include the actual test method with the publication of the specification, the IPC posts them on its web site, where they can be easily accessed and kept current without extensive revision of the various reference standards. This prevents possible conflict with outdated procedures. Criteria for the acceptance levels, however, are provided by reference standards such as J-STD-001, J-STD-004, and so on. IPC-A-610, Acceptability of Electronic Assemblies . Many companies use IPC-A-610, Acceptability of Electronic Assemblies, as the standalone workmanship standard for their products. J-STD-001 establishes the requirements for soldering processes, whereas IPC-A-610 depicts the pictorial acceptability criteria for production, including soldering as identified in the J-STD-001 document. IPC-A-610 also addresses additional, broad criteria to define handling and mechanical workmanship requirements, among others. A large percentage of the acceptability criteria defined in this chapter is that which is illustrated in the IPC-A-610 standard. The popularity of IPC-A-610 is apparent considering that it is available in many different languages and used throughout the world as the acceptance reference of choice for electronics. The IPC-A-610 standard describes the acceptability criteria for quality electronic assemblies. It does not define process requirements, although the methods used must produce a completed solder joint conforming to the acceptability requirements as defined. Consistent with other IPC standards, the IPC-A-610 document details the acceptance criteria for each of three classes. The three classes of product allow flexible application of the conditions for which the standard provides acceptance criteria. The customer should provide the inspector with the intended class for acceptability before the product is considered for acceptance. The three classes are 1, 2, and 3 and are the equivalents of the definitions provided by J-STD-001. In addition, this standard discusses and visually illustrates degrees of compliance, such as Target, Acceptable, Defect, and Process Indicator, for each condition relative to the three classes of product. The importance of the condition varies with the expected performance of the class based on the preceding class criteria. Acceptance definitions are summarized as:
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Target This condition is close to perfect or preferred; however, this desirable condition is not always achievable and may not be necessary to ensure reliability of the assembly in its
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service environment. Although this condition is not a requirement for performance based on the standard, it is provided to illustrate to users the desired condition that the creators of the criteria thought they should strive to achieve. Acceptable This condition, although not necessarily perfect, will maintain the integrity and reliability of the assembly in its service environment. Defect This condition may be insufficient to ensure the form, fit, or function of the assembly in its end-use environment. Defect conditions need to be dispositioned by the manufacturer based on design, service, and customer requirements. Disposition may be to rework, repair, scrap, or use as is. Repairing or using the assembly as is may require customer concurrence. A defect for Class 1 automatically implies a defect for Class 2 and 3. A defect for Class 2 implies a defect for Class 3. Process indicator A process indicator is a condition (not a defect) that identifies a characteristic that does not affect the form, fit, or function of a product. Such condition is a result of material, design, and/or operator- or machine-related causes that create a condition that neither fully meets the acceptance criteria nor is a defect.
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As established by the predecessor military standards, process indicators are not intended to be reworked or even dispositioned, and they can be included in product delivery without correction of the product. They are, however, not desirable and indicate the relative success of the process and materials; if the process or materials could lead to defect conditions, the process may need to be adjusted or corrected for future production. Process indicators should be monitored as part of the process control system. Should the number of process indicators indicate abnormal variation in the process or identify an undesirable trend, the process should be analyzed. This analysis may result in action to reduce the variation and improve yields before there is a defect trend that may require rework or scrap or, worst of all, result in customer dissatisfaction.
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Workmanship Manuals Many companies use a workmanship document of some sort to describe what the operations should achieve during production. IPC-A-610 is used frequently by manufacturing and also quality personnel to determine acceptable quality levels of their product. Some companies have also developed very good workmanship manuals for their own use, especially to cover unique or uncommon design requirements. If a need exists to develop a unique workmanship manual, then this manual should reflect the intended contract requirements. It is certainly desirable to use a manual already in existence since it can become extremely costly to develop your own, and because customer review is unnecessary since the customer should already be aware of the common requirements definition. If minor changes are necessary to standard performance due to process, product or material limitations, they can often be addressed as a contractual waiver, addition, or exception to the standard definition.
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