Tin Pest

As a follow-on to writing Robust Electronic Design Reference Book, Volumes I and II in 2003, in late 2004 I started seriously researching:

• lead-free electronics.
• the RoHS Directive.
• the WEEE Directive, and their ilk.

Fifteen years later, the 26,000+ documents that I have collected on these subjects take up half of my office and have overflowed into my living room, filling three bookcases and 10 file cabinets.

My Bibliography for Designing Lead-Free, RoHS-Compliant, and WEEE-Compliant Electronics contains all of the references to this mass of material. But at 6.9MB and 1,870+ pages length, the full Bibliography tends to choke many editors and some browsers.

A serious unintended consequence of the RoHS Directive-- mainly due to its ban on the use of lead in electronics-- has been a horrendous reduction in the quality, reliability, and longevity of electronic products produced since early 2006, versus equivalent tin/lead- based electronics that were manufactured from about 1950 through 2005. My gut feel from attending the Surface Mount Technology Association (SMTA) International Conference in October 2012 was that the out-of-box quality of lead-free electronics was finally approaching the quality we had for tin/lead-based electronics in 2005. But the reliability and longevity of lead-free electronics still suck in comparison to tin/lead-based electronics.

The much higher processing temperatures and poorer wetting of lead-free solders versus tin/lead- based solders have increased the number and severity of almost all of the kinds of manufacturing defects that we used to see in production. And all of the material changes forced on us by the RoHS Directive have made RoHS-compliant electronics susceptible to serious new failure modes:

• Tin pest.
• Tin whiskers.
• Conductive anodic filaments (CAF).
• Creep corrosion.
• Kirkendall voids.
• Copper dissolution.
• Head on pillow.
• Pad cratering.
• Foil cracks.
• Non-wet opens.

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I would like to thank David Hillman for contributing to this study.

We'd like to thank all of the clients who chose dBi to test their products from 1995 to 2013. Below is a brief summary of our accomplishments during the 18 years we were in business.

From 1995 to 2001, under Don Bush's ownership and operation, dBi:

• Did the official approval testing of 141 products developed by 20 client companies.
• Did the official FCC/ Industry Canada (IC) Verification and Declaration of Conformity (DoC) testing of 92 products.
• Did the official FCC/IC Certification testing of 15 products.
• Did the official CE Marking testing of 100 products.

From 2002 to 2013, under John Barnes' ownership and operation, dBi:

• Tested 389 products and 2 testers developed by 44 client companies.
• Did the official approval testing of 357 products and 2 testers, getting all but 5 of them to meet all of the FCC, Industry Canada (IC), CE Marking, C-Tick, and Regulatory Compliance Mark (RCM) standards and requirements for their desired market areas.
• Did the official FCC/IC Verification and Declaration of Conformity (DoC) testing of 296 products.
• Did the official FCC/IC Certification testing of 24 products.
• Did the official CE Marking testing of 271 products and 2 testers.
• Did the official e-Mark testing of 3 products.
• Did the official Australia/New Zealand Verification testing of 170 products.
• Co-sponsored John's writing the Robust Electronic Design Reference Book, Volumes I and II.
• Served as an expert witness on electronics in three lawsuits.

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Last revised February 5, 2021