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Solder
joint cracking is normally found after some form of environmental
testing, hopefully not found at all. In manufacture it can only
be caused by flexture of the board after soldering. Areas which
should be checked for the possible causes of flexture are in circuit
test, break out of multi panels, tight reflow or wave solder fixtures
and, of course, just poor handling.
An
interesting often forgotten, cause of open joints is wave solder
topside board temperature. Not exactly a cracked joint but the visual
appearance is the same. When the board goes through the wave topside
joints reflow. As with even the best systems boards flex leaving
some joints open. It can also happen during second side reflow if
only some joints become molten.
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