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In an equivalent electronic flow loop, absence of the transmission lines reduces the natural period to the vicinity of 2 sec. Noise, however, becomes more prominent. Noise means disturbances, either periodic or random, occurring at frequencies too high for control action. Figure 3.3 is a record of noise in an electronic flow loop. Turbulence in the stream and vibration from pumps are the chief sources of this noise. Even in pneumatic systems, flow noise is invariably present in sufficient magnitude to prevent the use of derivative. Phase lead is useful, but unfortunately the increase in high-frequency gain which accompanies it actually explodes the loop into instability.

Taking the transform of Eq. (11.8) gives the transfer function for the second reactor: l/(l + k2V/F) (11.9) C2(s) = Cl(S) 72.7 + 1 To obtain some numerical results, we shall assume the following data to apply to the system: Molecular weight of A = 100 lb/lb mole PA = 0.8 lb mole/ft3 QS = 0.1 lb mole A/ft3 F = 100 cfm ms = 1.0 lb mole/min

TABLE 32.2 Advantages and Disadvantages of HASL HASL Advantages Inexpensive relative to other finish options Cu/Sn solderjoint Widely available Reworkable HASL disadvantages Not flat Paste misprints Poor fine-pitch assembly Thick intermetallics May contain Pb Thermal damage to board Solder bridging Plugged PTHs

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Failure Modes HASL involves a delicate balance between sufficient solder coverage and excess solder. Inadequate solder results in exposed copper intermetallics and reduced shelf-life. Excess solder (which is more common) forms bridging among fine-pitch features. If the solder is not removed sufficiently from through holes, pin components do not place at automated assembly. A chief failure mode is due to HASL s lack of flatness. At assembly, stencils do not gasket well to the board surface, so paste misprints and skips can be problematic. Assemblers find difficulty stenciling paste on HASL finished PCBs using technology below 0.5 mm pitch. Positioning a HASL board (see Fig. 32.2) in the fixture for stenciling can be challenging if the PCB dimensions changed during HASL thermal steps.

k2 = 3 min-

(a) HASL equipment (b) surface scanning electron micrograph (SEM).

32.4 ELECTROLESS NICKEL IMMERSION GOLD (ENIG)

v = 300 ft3 Substituting these constants into the parameters of the problem yields the following values: 71 = 2 min 72 = 1 min CL = 0.0733 lb mole Alft3 c2s = 0.0244 lb mole Alft3 m,/pA = 1.25 cfm

Chemically, gold is the ideal element for the external coating of PCBs Gold does not form an oxide, so it is virtually unaffected by temperature and storage conditions that might reduce the shelf-life of other finishes In addition, gold dissolves nearly instantaneously into solder, promoting superior wettability Gold is limited, however, in other ways Gold embrittles solderjoints when present in excess of about 3 percent by weight, so gold coatings of 03 mm maximum thicknesses should be used in soldering Gold dissolves very quickly into copper as well To prevent the mixing of gold with copper, and the eventual solderability problems caused by oxidized copper at the PCB surface, a layer of nickel is deposited to separate the metals ENIG does not rely on electrolytic plating with outside power; in practice, nickel is deposited as a phosphorous-reduced electroless nickel 324.

1 Chemistry ENIG deposition is dependent on the electromotive series of elements Gold readily deposits directly on copper as an immersion bath, but as stated previously, a barrier of nickel is needed In common practice, 3 to 5 mm of nickel is used in ENIG, with a thin gold coating of 005 to 015 mm (typically) to prevent nickel oxidation Nickel does not deposit directly on copper without prior catalysis Palladium or ruthenium metal forms an immersion deposit on copper as the catalysis or activation step of ENIG Catalysis baths employ the immersion (galvanic displacement) chemical mechanism As with all finishes, extra steps are required before the deposition of catalyst, Ni, and Au All commercial ENIG processes rely on a cleaner and microetch prior to catalysis in order to remove trace residues from the solder mask and tin strip processes before final finish.

Assume that the control valve selected for the process has the following characteristics: The flow of A through the valve varies linearly from zero to 2 cfm as the valve-top pressure varies from 3 to 15 psig. The time constant 7, of the valve is so small compared with the other time constants in the system that its dynamics can be neglected. From the data given, the valve sensitivity is computed as

Microetch is normally based on peroxide, persulfate, or monopersulfate systems 3242 Fabrication Process Table 323 shows the process flow for ENIG surface finish..

TABLE 32.3 Process Flow for ENIG Time (min.)

K, zz -

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