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It is necessary to clearly define the terms repair and rework: Repair, which is also referred to as touch-up, describes the single-step procedure of applying flux, solder, and heat to a previously formed joint in order to improve it. Besides meeting acceptance criteria, improving the fillet geometry may also be required to bring the interconnection into a geometry window that is commensurate with long-term reliability predictions. The benefits of repair operations have long been debated. On the one hand, optimizing the fillet geometry or hole fill will improve solder-joint consistency in order to accommodate long-term reliability prediction criteria. However, the opposing viewpoint is that the added reflow temperature cycle degrades the reliability of the other solder-joint structures, such as solder mask adhesion, the bond between Cu features and laminate, as well as damage to the laminate material itself. It is likely that any repair-induced degradation will increase with a lesser quality of the circuit board. Therefore, particular consideration should be given to the use of repair steps on consumer electronics circuit boards, which are typically made of lower quality materials. Fortunately, repair steps would be most likely used on high-reliability electronics (military, space, and satellite applications), which typically use higher-quality circuit board materials and construction. A rework procedure is typically performed to replace a defective component on the circuit board. Therefore, the rework procedure has the following multiple steps: 1. Remove the previous solder joints in order to release the defective component from the circuit board. 2. Dress the circuit board solder pads by removing any excess solder while the latter is molten.

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3 Clean the circuit board of solder metal (spatter or balls) and flux residue 4 Place the new component on the circuit board site Solder is supplied to the joint area by preplaced paste or preform as well as by solder wire (in a hand-soldering process) Flux must also be added to the joint area when using preform or when hand soldering with a wire, unless the latter is flux-cored 5 Apply the heat source in order to re-create the joints 6 Clean the circuit board of solder metal (spatter or balls) and flux residue The obvious distinction between the repair and rework processes is the number of heating cycles to which the printed circuit board is exposed in the latter case There is one heating cycle in a repair operation that requires melting of the solder, whereas there is a minimum of three such cycles in a rework procedure.

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The circuit board laminate material, solder mask, and adhesion of the Cu conductor to the laminate must be sufficiently robust against degradation caused by these heating cycles Poor thermal stability can result in manufacturing defects that reduce production yields, or aging defects that jeopardize the long-term reliability of the product once it reaches service Often, preheating of the circuit board is used to reduce thermal shock and thermal gradients that may potentially damage the laminate material, vias, Cu pads, etc Also, the replacement component must have adequate thermal stability to accommodate the typically faster heating and cooling rates of the more abbreviated rework timetemperature profile vis- -vis the original assembly process A second distinction made between repair and rework procedures is the heating methodology A repair operation addresses one solder joint at a time Therefore, heating is localized to a relatively small area.

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On the other hand, in a rework procedure, the heat is supplied to the site in a more de-localized manner because of the need to de-solder multiple joints at one time Similarly, in the re-soldering of a multiple I/O component, it is preferred to make all of the joints at one time in order to minimize the rework time The heat source may be a hot-bar placed across a row of gull-wing leads or hot air that envelops the entire component site; for example, such a heat source might be used for the rework of a BGA package The de-localized heat flow raises concerns regarding thermal damage For example, with respect to the component in question, there is potential thermal damage to the package material and internal components (eg, the Si die) and interfaces.

Also, there is possible heat damage to the Cu bond pads as well as hole and via structures in the underlying circuit board Beyond the immediate component, there is the potential risk of remelting nearby solder joints or thermal damage to the neighboring component packages, particularly on very densely populated circuit boards Thermal damage to nearby components can arise from any one or any combination of the three heat transfer modes: radiation (hot-bar or soldering iron), convection (hot air), or conduction (through holes or along other conductor features) During process development, strategically placed thermocouples should be used to determine the temperature rise of the reworkable component as well as those of neighboring structures prior to implementing a repair or rework procedure A third distinction between repair and rework is product time frame.

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Repair steps are typically performed on circuit boards that have been inspected immediately following the assembly process, prior to shipment to the customer However, rework is not limited only to being performed immediately following a post-assembly inspection (visual or in-circuit testing) Rework activities can also be performed on electronics assemblies well after the products have entered service The rework may be performed to replace a broken device or to upgrade the functionality of a legacy systemAlthough the nominal process steps are similar in the latter case, there are complicating factors that must be addressed in the process The electronics must be taken apart to the level of the component or daughter-board in need of repairThe removal of potting material and conformal coatings must not damage the other components or their solder joints.

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