DEVELOPMENT OF LEAD FREE

SOLDER ALLOY

DEPARTMENT OF METALLURGICAL AND

MATERIALS ENGINEERING

Supervisor
Presented By Dr. Mukesh Raushan Kumar
Anju Kaushal Assistant Professor
OUTLINE
 INTRODUCTION

 Conventional Sn-Pb solders were removed from electronic assemblies in accordance with
EU law enacted in 2006 regarding the Restriction of Hazardous Substances (RoHS).
 The use of lead-bearing solders in vehicle electronics continued after this ban was lifted,
and in 2014 the automobile sector was officially prohibited from using lead.
 Lead has historically been a key metal in the solder alloy, helping to dilute tin to increase
wettability and flow factor.
 LEAD-FREE SOLDERING- WHY?
 There's a danger that lead soldering will no longer be allowed in electronics
assembly due to the WEEE directive in Europe and equivalent laws in Japan.
 Trade barriers are established between a nation that forbids lead from
electronics and anybody who is unable to provide lead-free electronics
solutions. Of course, this might also occur within specific industries or
businesses.
 Electronic goods made with lead-free solder alloys are already being produced
by several businesses and marketed as such. Fears of falling behind in the
marketing race have resulted from this
LEAD SOLDER VS. LEAD-FREE
SOLDER
Pb Consumption

 Worldwide Pb Consumption: 5 M tons

 Primary uses;
• Electric batteries (80 %)
• Ammunition – Electronic applications (less than 1 %)
• Electronic Applications
 Board assemblies (~40K tons) –
• HASL (surface finish)
• Sn-37Pb
 Components (~10K tons) –– Sn-10Pb, Sn-37Pb, 97Pb-3Sn
 Recent Development
 Europe
• Legislation banning Pb in electronics proposed by WEEE* pushed to 2007
• Product take-back proposed
 Asia
• No legislation pending
• Japanese companies driving “Green” consumer products by 2003
 US
• No legislation on horizon
• Renewed interest by electronic industry
• EIA, IPC, NEMI demonstrated technical initiatives
• Push back of WEEE date + lack of other legislation has taken immediate pressure off
drive to implement (NEMI, Jan. 2002)
 WHAT IS LEAD SOLDER?

Lead solder, which is a metal alloy with tin (Sn) and lead (Pb) as its base
components, is also known as Sn Pb solder. This type of solder was previously
preferred for the following reasons:
• Cooling: Lead solder cools more slowly than alternative metals. As a result,
there is less chance of the joint breaking.
• Wet joints: This kind of solder works well for creating a good electrical
connection between printed circuit board pads and leads in wetting joints.
• Melting point: Lead solder has a set melting point, unlike many metal alloys that
have a melting range. As a result, developing automated PCB assembly
procedures is made simpler. Additionally, because its melting point is lower than
that of other alternatives, it is easier to reach the temperature and less likely to
harm electronics.
 WHAT IS LEAD FREE SOLDER?
 They are easy to work with, flow well and form strong bonds with other
metals.
 The proportion of metals in lead-free solder formulations varies. Tin, copper,
silver, nickel, and zinc are examples of components.
 Tin-copper, with a melting point of 217°C, is the most widely used lead-free
combination.
Different characteristics such as –
 The melting point of lead-free solder is higher than that of lead alternatives.
 In addition, compared to lead soldering, this kind produces stronger and harder
joints when joining metals.
 Applications

.
Electronics Manufacturing
Printed circuit boards (PCBs), semiconductors, connectors, and other electronic components
are manufactured using lead-free solder on a large scale.
Automotive Industry
: In the automotive industry, lead-free solder is used in the manufacturing of electronic parts,
sensors, and control units.
Medical Devices:
To ensure that these products meet safety standards and regulations, the medical
industry uses lead-free solder in the manufacturing process.
Consumer electronics
In order to comply with environmental regulations and satisfy customers who care about the
environment, products like laptops, smartphones, and home appliances are progressively using
lead-free solder
 Advantages

1. Environmental Benefits: By using lead-free solder alloys, environmental pollution and health
risks related to lead exposure during production, use, and disposal are reduced.

2. Adherence to Regulations: Adhering to environmental regulations and standards through the

use of lead-free solder promotes compliance and corporate responsibility.

3. Enhanced Reliability: The mechanical and thermal properties of lead-free solder are frequently
better, which enhances the overall reliability of electronic components.

4. Consumer Trust: Lead-free soldered products attract environmentally conscious buyers,

improving a business's standing and viability in the marketplace.
 Disadvantages
1. Higher Melting Temperatures: Compared to conventional lead-based solder, lead-free solder usually
has higher melting temperatures. This could present problems for the manufacturing process.

2. Tin Whiskers: The formation of crystalline structures known as "tin whiskers" on the surface of lead-
free solder joints is a cause for concern as they have the potential to short circuit electronic components.

3. Cost Considerations: Because alternative materials can be more expensive than traditional solder, lead-
free solder alloys may have an effect on production costs.

4. Solder Joint Brittleness: A higher degree of brittleness can be seen in certain lead-free solder alloys,
which could have an adverse effect on the mechanical characteristics of solder joints and possibly raise
reliability concerns..
Environmental impacts of lead-free solder alloys

Reduction in Toxicity Water and Soil E-Waste

• The main advantage of Contamination: Management:
lead-free solder for the • When conventional • Lead-free solder is
environment is that lead lead-based solder is essential for managing
usage is eliminated or disposed of electronic waste (e-
drastically reduced incorrectly, lead can waste), which has an
seep into the water and adverse effect on the
soil, ecosystem. environment. When it
comes to electronic
devices.
Energy Consumption:
• While lead-free solder may have
higher melting temperatures,
which can impact energy
consumption during the
manufacturing process, the
overall environmental impact is
often considered favorable due
to the elimination of toxic lead
and the benefits to human health
and ecosystem.
Compliance with
Regulations:
• Many countries and regions
have implemented strict
regulations regarding the use
of hazardous substances in
electronic products. Lead-free
solder is often mandated to
comply with regulations such
as the (RoHS) directive,
promoting environmentally
responsible manufacturing
practices.
Long-Term
Environmental
Health:
• The reduced use of
lead in solder alloys
contributes to the
long-term
environmental health
of ecosystems and
organisms. Lead has
been associated with
adverse effects on
wildlife, and the
shift to lead-free
Literature Review