May 18, 2006 THE SWATCH GROUP IS GOING BACK TO LEAD SOLDER-PRECURSOR FOR THE ELECTRONICS WORLD?
Yes, folks, it's true. The major Swiss, major world watchmaker, with going-on $4B sales, one quarter of world watch production, diligently did the lead-free R&D for 2 years, went into lead-free production 13 months in advance of the RoHS deadline, and then disaster. Tin whiskers got them, shorting circuits both in the quartz crystal resonator and fine pitch electronic systems. Now the Swatch Group is applying for an exemption from RoHS so they can go back to lead. Between you and me, I'll bet that if we could get into one of their 180 factories we'd see good old 63-37-- that is, 37% lead-being used right now. The "Requested Exemption" came from the legal department, 16 pages in the English language edition, complete with tin whisker pictures. And you know that the Technical Adaption Committee, set up by the European parliament's Environmental Commission to shepherd the transition to lead-free, etc will advise granting the exemption. The Swatch Group even tentatively "offered" to consider using the 90% tin alloy which is allowed under RoHS.
The critical dimension at which tin whisker shorting became a production- line- stopping problem was 0.8mm, that is, 32 mils-it might as have been a meter in electronic interconnections these days. So the Swatch Group has given us a preview of what we will see en masse. For those who escape tin whiskers, lead-free solder has some other treats in store. There are Kirkendall voids-they cause open circuits as copper diffuses into tin without lead alloyed, leaving voids behind. There are Conductive Anodic Filaments, leakage paths in the PCB, a mechanism accelerated by the high processing temperatures of lead-free. Dongkai Shangguan of Flextronics has put a book together describing these lead-free solder problems and more: Lead-free Solder Interconnect Reliability (Hardcover) Dongkai Shangguan (Editor) Publisher : ASM International Copyright Year : 2005 Number of Pages : 350
The Requested Exemption from the Swatch Group has pictures of tin whiskers. They used 99.5Sn 0.5Cu, no Ag, so not the SAC alloy, which also contains silver. But the EU Commission dare not mandate them to use Ag. The tin-copper alloy is generally used for wave soldering and lead-free HASL. Besides they know Ag is a biocide. Mine silver and you usually get lots more lead. I think that the exemption will be granted for the following reasons.
1) It comes from the company's legal department and if the Swatch Group is forced to stop making watches...I don't think I have to go on, because that is almost the way they put it. 2) The Environmental Commission has a lot on its plate-constructive initiatives. Why risk egg on its face? Why fight in court or in the court of public opinion for an ecologically, environmentally damaging ban on lead in solder? Stavros Dimas, the Environmental Commissioner, has already acknowledged that lead-free will require greatly increased energy. 3) WEEE, Waste from Electrical and Electronic Equipment already mandates recycling populated printed circuit boards, somewhat as lead-acid batteries are recycled now. So the ban on electronic lead was always over-kill.In conclusion, I'd like to make 2 nominations for the Electronic Diogenes Award of 2006: 1) the Swatch Group and 2) John Burke of