What Causes a Cleanliness Failure in Electronics?
Cleanliness failures in electronics occur when unwanted contaminants are left behind during manufacturing or enter the system from the environment where the device operates. These failures can compromise performance and reliability, and understanding their root causes is the first step in preventing them.
1. Residual Flux
One of the most frequent culprits behind cleanliness issues is residual flux—a substance used during soldering to clean and prepare metal surfaces. If not fully removed after soldering, it can remain on the PCB and lead to problems over time.
- Moisture Absorption: Residual flux can absorb moisture from the surrounding environment. That moisture, in turn, can lead to corrosion and/or electrochemical migration, which may cause short circuits.
- Ion Contamination: Many flux residues are ionic in nature. These ions can reduce surface insulation resistance (SIR) and corrode PCB pads and traces, undermining the long-term reliability of the assembly.
2. Particulate Contamination
Particulate matter, such as dust, fibers, or small debris, can settle on assemblies during or after production. Even small particles can pose a threat, particularly on densely populated boards.
- Electrical Shorts: Conductive particles can form unintended electrical paths, causing shorts and device failure.
- Corrosion: Even non-conductive particles may become problematic if they retain moisture or interact with other contaminants, contributing to corrosion.
3. Chemical Contaminants
Chemical residues may be left behind from cleaning agents, adhesives, conformal coatings, or other processing materials. These chemicals can degrade over time and negatively affect electronic assemblies.
- Material Degradation: Some chemicals react with metals, plastics, or solder joints, gradually weakening these materials and shortening the product's useful life.
- Outgassing and Condensation: Chemical contaminants may outgas in use, and the vapor can condense on sensitive components, creating new paths for failure.
How Magnalytix Helps Prevent Cleanliness Failures
At Magnalytix, we focus on identifying and solving the cleanliness issues that threaten electronic reliability. Our work is guided by decades of experience from the leadership of experts like Dr. Mike Bixenman and is backed by testing methods designed to identify risks and help you avoid them.
1. Cleanliness Testing That Sees the Bigger Picture
We use proven techniques such as:
- Surface Insulation Resistance (SIR) Testing
- Ion Chromatography (IC)
- C3 Testing (Cleanliness, Coating, and Contamination)
These tools allow us to detect where and how cleanliness failures are likely to occur in your assemblies.
2. In-Depth Consultation Backed by Experience
We don't just hand you a test result. Instead, we explain what the data means and work with you to identify potential root causes of the problem. Whether it's an ineffective cleaning process, improper material selection, or an issue with environmental controls, we bring the experience needed to help you correct it at the source.
3. Targeted, Practical Solutions
Our strength lies in connecting specific problems to specific actions. Instead of just identifying the presence of contaminants, we examine the circumstances that created them. Based on that analysis, we may recommend changes to your soldering process, adjustments to your cleaning protocol, or improvements to environmental controls—whatever will most directly address the issue.
Conclusion
Cleanliness problems are a major reliability risk for electronic systems, but they are preventable. By identifying the sources—whether residual flux, particulates, or chemical contaminants—you can take meaningful steps to prevent failures.
At Magnalytix, we provide the tools to detect these risks and the insight to help you solve them. Our testing methods, combined with more than 30 years of experience, allow us to deliver solutions that support long-term reliability.
If you'd like to learn more about how to prevent cleanliness failures in your electronics, contact us. We're here to help you build systems that last.