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Key Role in Lead-Free Book

Co-edited by a Delphi technologist, a book highlights "green" processing for successful electronics manufacturing.

Delphi is taking a leadership role in its lead-free and product development activities. These activities include a plan to assist the electronics industry and Delphi's customers in migrating to lead-free solder to meet new environmental requirements. But converting from lead to lead-free in the manufacture of electronic assemblies is not simply switching the solder composition. Major factors include selecting a lead-free solder able to withstand the demanding thermal cycling and vibration environment of a vehicle, and identifying and adapting all of the necessary design, manufacturing process and component changes. To help provide a quality lead-free solder solution, Delphi has actively participated in a six-year study to develop a solution that will help "get the lead out" of electronic assembly boards. This participation also highlights Delphi's ongoing commitment to help vehicle manufacturers increase the "green" rating of vehicles.

This focus on "green" solder is apparent with the recent publication of a book on lead-free electronics, co-edited by Richard D. Parker, lead technologist for Advanced Assembly Technology, Delphi Electronics & Safety. Released in October 2007, Lead-Free Electronics: iNEMI Projects Lead to Successful Manufacturing explains the challenges of developing an alternative to lead solder and includes topics such as solder material properties, lead-free rework, and reliability testing.

"We are especially proud to have Rich as one of the co-editors of this new book," said Bob Schumacher, director of Advanced Product & Business Development, Delphi Electronics & Safety. "His work on lead-free solder is a pivotal piece of our vision to keep our products and processes focused on being environmentally friendly."

Prologue

Delphi began an internal search for an alternative solder in the early 1990s. Since then, Delphi has played a key role in addressing many obstacles, including how to modify the circuit boards, components, and process materials to tolerate exposure to high processing temperatures that are necessitated by the new lead-free solder alloys.

In 1999, Delphi recognized an opportunity to help the world standardize on an industry-wide lead-free solder alloy composition, which is vital to maintaining the reliability of electronic assemblies. Delphi specialists, including Parker, have been active since the inception of International Electronics Manufacturing Initiative (iNEMI), a consortium of industry experts from manufacturing and supply companies, associations, government agencies, and universities. According to an iNEMI overview, it is the "only corporate membership organization focused exclusively on electronics manufacturing technology."

"Rich has been a valuable contributor to iNEMI's lead-free initiatives," said Jim McElroy, CEO of iNEMI. "He was not only instrumental in the publication of this book, but also in the work described in the book. His leadership and vision have been—and continue to be—integral to iNEMI's successes in this area. This would not be possible without the management support and sponsorship of Delphi Electronics & Safety."

Parker has been active in iNEMI from the beginning and currently chairs its Tin Whisker Project, Phase II. This team is identifying the root causes of these electrically conductive, crystalline structures of tin that can grow from surfaces where tin (especially electroplated tin) is used as a final finish. Tin whiskers can cause an electronic system to short-circuit, so Delphi's experienced engineers are actively focusing on minimizing the risk of system failures by identifying root causes.

When asked about the challenge of co-editing a book, Parker remarked that the most difficult aspect was collecting all of his iNEMI colleagues' contributions in time to meet the publication date. "All of us have full-time jobs in addition to our participation in iNEMI," he said. "So getting information ready for the book, while high on our list of priorities, was difficult.

"Overall, the rewards made the challenges worthwhile. It is such a pleasure working with brilliant people from so many companies and organizations. I toss out ideas and challenges, and enjoy the scientific discussions that ensue. This camaraderie has resulted in many friendships."

Postscript

The release of the lead-free electronics book doesn't signal the end of Delphi's affiliation with iNEMI nor its interest in helping manufacturers provide more environmentally friendly vehicles.

"iNEMI has many projects on its plate and as vehicle electronics continues to evolve, I'm convinced that Delphi will continue to play an active role in the initiative," said Schumacher. "The solder used in electronic assembly boards may seem like such a small part of the overall vehicle, but each step toward a greener vehicle becomes a significant step toward a better environment for all. Delphi is determined to help the electronics and vehicle industries get to where they need to be."