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provide information as to the specific gravity-per-flux target and also recommend an appropriate thinning formulation. The flux reservoir should be emptied, cleaned thoroughly, and refilled with a fresh charge of flux periodically. Sometimes the flux develops a residue that changes the flux s surface tension characteristics, clogs nozzles, or dispenses pores in foaming systems. In addition, flux may become contaminated with debris conveyed by the PCB to be soldered, which may impact assembly quality. Since the PTH relies on a minute capillary to be filled first by flux and ultimately by solder from the solder-wave process, any small particulates entrained in the flux or the solder may impede PTH barrel fill. Also, while the flux reservoir is empty, it is a good idea to inspect it to ensure that the materials of construction are holding up to the rigors of system operation and prolonged contact with fluxing agents that may prove corrosive in the long term. An inspection of the materials of construction for the entire system should be made prior to committing to the purchase of a wave-soldering machine. Unfamiliar or untested materials should be avoided unless there is sufficient literature, test results, or customer experience to ensure compatibility with fluxes that will be used in that system.

Preheating Preheating the PWB and components serves three purposes in the wave-soldering process:

Helps the board and components reach a temperature sufficient for the flux to activate and clean surfaces to be joined in preparation for wave soldering Lessens thermal differentials and decreases the likelihood of components cracking due to thermal shock when impacted by the intense heat of the molten solder wave Allows the board to ramp quickly to solder-melting and -wetting temperatures when it comes in contact with the solder wave

A component s resident time in the solder wave is 10 to 30 times shorter than for a comparable solder joint formed during reflow oven soldering, so everything in wave soldering has to happen very rapidly On the other hand, heating time-temperature ramps must be observed in accordance with the component manufacturer s specifications Components and PWB bonding pads must be fluxed sufficiently to allow adequate solder-joint formation, yet there must be enough flux left on the circuit board after preheating to protect the newly fluxed surfaces until the assembly reaches the solder wave Just as in the reflow soldering oven, there are multiple solder-wave preheater styles, but only two are in prevalent use: radiant preheaters (direct and indirect IR) and forced-air convective preheaters Both are effective and both have their advantages In fact, the best configuration is a combination of the two.

Some wave-soldering machines can be equipped with both top and bottom preheaters This can be advantageous for thermally massive boards 4744 The Wave Numerous solder-wave configurations are available Rather than provide a detailed discussion of each, this section offers a basic overview of the elements of the process in relation to the waveAs previously mentioned, the molten solder is pumped to form a standing waveThis is accomplished by a spinning impeller on the bottom or side of the solder reservoir Once the solder is molten, the impeller motor is activated and the solder wells up between baffles and nozzle that reside within the solder reservoirA combination of impeller speed and baffles-and-nozzle configuration dictates overall standing-wave characteristics The nozzles and baffles are generally adjustable, as are impeller speed, molten solder temperature, board introduction angle, and board conveyor velocity.

These, along with preheater settings, define the profile parameters or process variables that must be tamed to accomplish high-yield wave soldering..

Since the solder is a molten, turbulent liquid, theoretically it can make intimate contact with the underside of the circuit board Therefore, thermal uniformity is generally not difficult to control as long as the wave contact area along the width of the PWB s underside is uniform Since the solder is in contact with the underside of the PWB and since the underside of the PWB is coated with flux, the molten solder has the opportunity to wet to PWB lands and component leads As the process progresses, the solder wicks between the pin and barrel After leaving the wave, the board cools rapidly, liquid solder solidifies, and solder joints result 4745 Wave-Soldering Accessories Solder-wave manufacturers have devised a number of options that may be helpful to the process Some of these have extended wave-soldering capability to allow finer-pitch soldering or have permitted wave soldering of thicker PWBs.

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