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47.3.10.3.2 Thermocouple Contact. The thermocouple bead must be in intimate contact with the lead and pad combination of the solder joint to be measured. Therefore, the thermocouple bead must be inserted between the device lead and the circuit board bonding pad. It is good practice to tailor the size of the thermocouple wire and, thus, the bead, for the scale of the solder joint to be measured. Flattening the thermocouple bead also helps in positioning it between lead and pad. Flattening can be accomplished with smooth-jaw pliers, a smooth-jaw vise, or a hammer.After flattening the bead, check to ensure that it is neither cracked nor broken (see Fig. 47.12).

FIGURE 47.12 Checking the quality of the termocoupling: (a) A good thermocouple deployment. The bead is secured beneath a single lead and held in place with hightemperature solder. (b) The thermocouple is held in place by high-temperature solder but the solder has bridged to multiple leads. Temperature indicated will be that of the entire thermal mass of leads and solder rather than a single lead as in (a).

For BGAs and other area-array devices, it is necessary to drill a very small diameter hole through the board and into the BGA ball or column. This procedure is done with a very fine drill bit slightly larger than the BGA ball.The drill bit should be kept short (slightly longer than the board plus ball thickness) to avoid breaking the bit. It helps to drill the hole location before assembly and then redrill to remove solder for thermocouple insertion after reflow. An overly hot thermal profile can be used for assembly of the thermal profile board. Drilling into the ball at that time completes the path for thermocouple insertion. As long as the hole diameter is kept small, there is no need to add solder to retain the thermocouple within the BGA. If the hole is kept slightly larger than the thermocouple bead, the radiated air temperature within the hole and around the thermocouple bead should be the same as the ball temperature. A hightemperature adhesive or heat-resistant tape should be used to anchor thermocouple leads to

FIGURE 47.13 Thermocouple embedded into BGA ball. Leads are anchored to the board with a high-temperature adhesive or high-temperature tape.

the board to keep them in place and to prevent dislodging of the bead from its intended measurement target (see Fig. 47.13). Note that there is no need to seal the drilled hole into which thermocouple is inserted. It is a miniature blind hole largely filled with thermocouple wires.Air transfer within this hole will be negligible. 47.3.10.3.3 Thermocouple Size. Many factors can confound the solder-joint temperature measurement process, regardless of whether the thermocouple bead is properly deployed between lead and pad. Among these are the size of the bead and the thermal mass of the thermocouple assembly. In general, the use of finer-gauge thermocouples such as 30 to 36 American Wire Gauge (AWG) (see Table 47.1) is recommended. This will permit insertion between lead and pad even at very fine lead and pad pitches. Ideally the thermocouple bead will be completely within the solder joint to be measured.

TABLE 47.1 AWG versus Wire Diameter and Anticipated Thermocouple Bead Diameter Wire diameter (in.) 0.032 0.020 0.010 0.005 Wire diameter (mm) 0.81 0.51 0.25 0.127 Bead diameter (in.) 0.048 0.030 0.015 0.0075 Bead diameter (mm) 1.22 0.76 0.38 0.19

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Strive for the shortest possible length of thermocouple wire pair that is practical for the application. Long, large diameter wire may conduct heat away from the solder joint to be measured, altering its true heating nature. 47.3.10.3.4 Securing Thermocouples: Thermally Conductive Adhesives. If an adhesive is to be used to hold a thermocouple bead, its thermal conductivity must be taken into account. Most thermally conductive adhesives are not nearly as conductive as metal or solder. The best are filled with high thermal conductivity materials such as aluminum, boron nitride, or other

thermally conductive ceramics If the thermal conductivity is not high enough, a false thermocouple reading will result Thermally conductive adhesives are meant to be applied thinly and conductivity depends on bond-line thickness It is wise to baseline a conductive adhesive against a soldered thermocouple to ensure that it is not insulating and affecting measurement results Also ensure that it survives multiple reflow cycles and still maintains it thermal conductivity Were the adhesive to release the thermocouple bead during the process, then measurement data would be useless Many adhesives will not tolerate the high-temperature environment of soldering or the continuous thermal cycling encountered in trying to adjust a soldering profile This is especially true with the onset of Pb-free soldering and the higher soldering temperatures associated with the move away from lead-bearing alloys High-conductivity adhesives are also expensive 4731035 Securing Thermocouples: Adhesive Tapes.