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board surfaces; damaged traces or lands; fractured solder joints; and missing surface-mount technology (SMT) components. Physical damage caused by handling can ruin assemblies and cause a high scrap rate of components or assemblies. Scrap is costly and must be avoided to achieve an efficient and high-quality operation. Well-maintained handling equipment is also very important in preventing physical damage. One good example is conveyor systems. PCBAs can be caught in conveyors and damaged beyond rework or repair capability and, unless the area of operation is staffed, the conveyor system can damage many assemblies in a very short period of time. Care must be taken during assembly and acceptability processes to ensure product integrity at all times. The following guidelines provide general guidance:
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Keep workstations clean and neat. There must not be any eating, drinking, or use of tobacco products in the work area. Minimize the handling of electronic assemblies and components to prevent damage. When gloves are used, they need to be changed as frequently as necessary to prevent contamination from dirty gloves. Solderable surfaces are not to be handled with bare hands or fingers. Body oils and salts reduce solderability and promote corrosion and dendritic growth. They can also cause poor adhesion of subsequent coatings or encapsulant. Do not use hand creams or lotions containing silicone, because they can cause solderability and conformal coating adhesion problems. Never stack electronic assemblies, because physical damage may occur. Special racks need to be provided in assembly areas for temporary storage. Always assume the items are ESDS even if they are not marked. Personnel must be trained and follow appropriate ESD practices and procedures. Never transport ESDS devices unless proper packaging is applied.
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Most electronic assembly designs include a small percentage of mechanical assembly that requires hardware of various types. Some of the more common component types and the acceptability criteria associated with each are discussed in the following sections.
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Component Types 52.3.1.1 Threaded Fasteners. Hardware stack-up for all threaded fasteners must be identified on engineering documentation. The stack-up can be critical, depending on the types of material used for both the hardware and the PCB. Any missing hardware must be found or replaced.Any damage to hardware that prevents it from accomplishing what it was designed to do is unacceptable. A good example of this is any screw or nut that has been stripped, crossthreaded, or damaged to the point that a screw or nut driver is no longer able to tighten or loosen the part (see Fig. 52.3). A minimum of 11/2 threads should extend beyond the threaded hardware unless the hardware could interfere with other components. The maximum extension of threaded hardware is 3 mm plus 11/2 threads for hardware up to 25 mm long and 6.3 mm plus 11/2 threads for hardware greater than 25 mm long.
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ACCEPTABILITY OF PRINTED CIRCUIT BOARD ASSEMBLIES
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FIGURE 52.3 Hardware mounting for threaded fasteners (1) Lock washer (2) Flat washer (3) Nonconductive material (base laminate) (4) Metal (not conductive pattern or foil). (IPC)
Threaded fasteners should be tight to the specified torque on engineering documentation. If torque is not specified on engineering documentation, a generic torque table should be available for use in the assembly environment. Such a table is sometimes included in a workmanship manual. 52.3.1.2 Mounting Clips. Uninsulated metallic components, clips, or holding devices must be insulated from underlying circuitry. Minimum electrical spacing between land and uninsulated component body must not be violated (see Fig. 52.4). The clip or holding device must make contact with the component sides on both ends of the component. The component must be mounted with its center of gravity within the confines of the clip or holding device. The end of the component may be flush or extend beyond the end of the clip or holding device if the center of gravity is within the confines of the clip or holding device (see Fig. 52.5). 52.3.1.3 Terminals. Terminals that are to be soldered to a land may be mounted such that they can be turned by hand, but should be stable in the z-axis. Terminals may be bent if the top edge does not extend beyond the base and no other mechanical damage such as fractures or breakage to the terminal or the solder joint have occurred (see Fig. 52.6). Common terminals utilized are turret, bifurcated, hooked, and pierced or perforated terminals. See Fig. 52.7 for an example of a damaged turret terminal and a cross section of an assembled board. 52.3.1.4 Swaged Hardware, Flared Flange. The shank extending beyond the land surface is swaged to create an inverted cone, uniform in spread and concentric to the hole. The flange should not be split, cracked, or otherwise damaged to the extent that mechanical strength is compromised or allows contaminating materials to be entrapped in the rivet or funnel (see Fig. 52.8).
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