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1 20002215 Sanders Road Northbrook, IL 60062-6135 Telephone: FAX: e-mail: All rights reserved under both international and Pan-Americancopyright conventions. Any copying, scanning or other repro-ductions of these materials without the prior written consentof the copyright holder is strictly prohibited and constitutesinfringement under the Copyright Law of the United 1-580984-54-1 IPC-DRM-53 1st printing 5mThisPromotional Sample (not for reproduction)has Low Resolution imagesto make downloads quickerIntroduction toElectronics Assembly 1 PageTable of Contents34555778101012121414151617192122 23252628 IntroductionComponentsInterconnectionsEl ectronics AssemblyIndustry OverviewElectrostatic DischargeAssembly ProcessesIncoming InspectionThrough-Hole AssemblyAutomatic InsertionManual InsertionWave SolderingHand SolderingSurface Mount AssemblySolder Paste ApplicationComponent PlacementReflow SolderingAdhesive ApplicationCleaningElectrical TestRework and RepairConformal CoatingFinal System AssemblyGLOSSARYP romotional SampleIntroduction toElectronics Assembly 2 Introduction toElectronics Assembly 3 IntroductionLook around.

2 Electronic prod-ucts are everywhere. They re inour homes, offices, schools,hospitals, airports, banks andstores. And year after year thereare innovations - products getbetter and better, they re easierto use and their value increasesas they do more for the same orlower computers are a per-fect example. Ten years agothey were priced high and ranslow. Now they re a lot fasterand you were to take the cover offan electronic product you d seecomponents and inside view of a typicalelectronic ATM machine is an electronic device we all laptop and cell phone atwork in the AssemblyPromotional SampleIntroduction toElectronics Assembly 4 Introduction toElectronics Assembly 5 InterconnectionsThe interconnections are thepathways where electricityflows between pathways are almostalways printed circuit boards, orprinted wiring boards.

3 These aresometimes referred to as PCBsor PWBs. The printed boards arebasically a pattern of electronicconductors that are formed onan insulating base material, AssemblyElectronics assembly is theprocess of attaching componentleads or terminations to thelands, or conductors, on the cir-cuit board, and then solderingthem to make both mechanicaland electrical circuit board assembliesare at the heart of our electron-ic products - allowing the prod-ucts to be both complex OverviewElectronics assembly is per-formed by Original EquipmentManufacturers (OEMs), and bymembers of the ElectronicsManufacturing Services Industry,also known as EMS are companies thatdesign and manufacture theirown electronic these companies do allor some of the electronicsA printed circuit board with no typical Electronics Assembly circuit board assembly isinserted into a metal are devices thatalter the flow of electricity.

4 Themajority of electronic compo-nents are semiconductors -meaning they have propertiesof both conductors and insula-tors. A conductor is ametal/material that carries elec-trical signals. An insulator is anymaterial that has a high resist-ance to the flow of and capacitors arecalled passive means the basic functionof these components does notchange when they receive a sig-nal. Resistors slow down, orresist the flow of current to pro-vide the proper store an electricalcharge for a period of time, thendischarge it over a longer orshorter period of time -depending on the requirementsof the , diodes and integrat-ed circuits, or ICs, are calledactive components.

5 That meansthe basic function of these com-ponents will change when theyreceive a signal. ICs can storeinformation, perform calcula-tions and move the informationaround. A microprocessor chipthat contains millions of transis-tors and diodes is an exampleof a very sophisticated References:IPC-CD-18 Component ID Training(CD)IPC-DRM-18 Component ID Desk Reference ManualComponents prior to assembly onto circuit IC in a capacitor and resistor of theThrough-hole SampleIntroduction toElectronics Assembly 6 Introduction toElectronics Assembly 7tronics industry as a wholeemploys more people than theaerospace, steel and automo-tive industries DischargeOne of the critical issues in elec-tronics assembly is control ofelectrostatic discharge, or occurs when static electric-ity from your body or a chargedsource comes in contact withand is discharged into an elec-tronic component.

6 this electric-ity can degrade or destroy theoperation of many types ofcomponents. There are a widevariety of materials and tech-niques to eliminate the build upand discharge of static References:IPC-VT-19 ESD Control (Video)IPC-CD-19 ESD Control (CD-ROM)Technical References:IPC-A-610 Acceptability of Electronic AssembliesAssembly ProcessesThere are two primary cate-gories of electronic compo-nents; through-hole and surfacemount. Through-hole compo-nents have leads that are insert-ed throughthe holes in the cir-cuit board. Surface mount com-ponents have leads or termina-tions that attach directly ontothe lands on the surface of theboard. A third category of com-ponents are those actuallyembedded in or on the surfaceAn ESD sensitive component getting ZAPPED by an operatornot wearing his grounding component board has through-hole componentson the left, and smaller surface mountcomponents on the work themselves.

7 Fora variety of reasons, there aretimes when OEMs send out allor some of their design andassembly to EMS providers are differentiatedfrom OEMs in that they don tproduce their own provide assembly andsometimes design the assembly processcan begin the components andcircuit boards must be pro-cured. Then these circuit boardsand components go throughspecific manufacturing process-es to create the solderedassemblies. After processing,the assemblies are tested. Theassembler, whether OEM orEMS provider, usually performsany rework and repair that sneeded. Occasionally, an EMSprovider also performs the finalsystem assembly, as well as sys-tem and reliability the OEM will haveassembly operations that notonly perform circuit boardassembly, test and systemassembly for their own prod-ucts, but also accept assemblywork from other OEMs.

8 Thatmakes the company both anOEM and an EMS recent years there has beensignificant growth in the EMSindustry. The industry plays adynamic role in today s informa-tion and entertainment-orient-ed world. It also provides manyjobs and enjoys exciting careeropportunities. In fact, the elec-Assembly design is a complex training session for insertion is sometimes done by SampleIntroduction toElectronics Assembly 8 Introduction toElectronics Assembly 9required. Incoming inspection isa method of verifying that orderrequirements have been includes the correct num-ber and type of products, thecondition of the products uponreceipt and the function ofthose companies use a systemof certified suppliers to mini-mize incoming inspection sometimes called dock to this system, the suppliertakes responsibility for the qual-ity of the materials being pur-chased by the customer by thor-oughly inspecting and testingthe circuit boards and compo-nents before they are means that when thematerials arrive on the loadingdock at the customer s facilities.

9 They can be left in the packag-ing; the associated paperworkchecked for part number andrevision level; and sent to thestockroom. There is no incom-ing inspection or testing neededfor verification of the more detailed incominginspection is required, there area number of characteristics thatmay be checked by example, a Sample of circuitboards may be checked forproper dimensions, hole pat-terns and sizes, solder maskand solderability, and shipment of electronic com-ponents could be checked forcount, condition, marking board dimensionsduring incoming References:IPC-VT-57 Stockroom Materials - Storage and Distribution (Video)IPC-CD-63 Bare Board Acceptability (CD)Technical References.

10 IPC/EIA J-STD-002 Solderability Tests for Component Leads, Terminations, Lugs, Terminals and WiresANSI/J-STD-003 Solderability Tests for Printed BoardsIPC-6011 Generic Performance Specification for Printed BoardsIPC-6012 Qualification and Performance Specification for Rigid Printed BoardsIPC-A-600 Acceptability of Printed BoardsIPC-DRM-18 Component Identification Desk Reference ManualVerifying components duringincoming a printed wiring board. Aprinted wiring board (PWB)with embedded components iscalled a printed circuit board(PCB). this reference manual will dis-cuss many of the through-holeand surface mount processesinvolved in electronics assem-bly.