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May 17, 2012
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February 2, 2011
Conformal Coating Over No-Clean Flux

We have a new project and need to apply conformal coating to one circuit board assembly. We have not applied conformal coating before.

Is it normally acceptable to apply conformal coating directly over circuit board assembled using no-clean flux?



D. L.

Experts Comments

Coating over no-clean flux residues is a standard practice, but as with any engineering question, the answer is it depends...

On the type of coating chemistry you are using and the specific nature of the flux residue. Some coatings are more tolerant of flux residues, especially those with very high solvent contents.

Others such as water-based materials are very sensitive to flux residues, with specific defects including dewetting (the coating won't completely coat the residue -- it will pull back away from the residue), poor adhesion, CTE mismatch between the coating and flux residue causing cracking during thermal cycles/shock, or more insidious cases of electrochemical corrosion...

This last defect/failure mode is generally believed to be caused by the coating interacting with the residue to liberate the excess activators from their resin matrix which during high humidity conditions can lead to the formation of corrosion products.

First point of call, I'd check in with your coating and flux suppliers to see if they have any experience or data regarding the 'compatibility' of the materials. This data whilst useful to you, is unlikely to replicate your exact process (thermal profiles etc) so you would want to make an internal evaluation (flux/coating suppliers should be able to help you verify your process) to ensure you are not solving one problem and inadvertently causing another.

Aside from the flux residues, general cleanliness of the assembly (residues from handling, bare board fab etc) and the cure conditions of the solder mask will have a big impact on the overall level of reliability you achieve.

This is why cleaning would generally be considered the defacto standard for high reliability applications, but even cleaning has its own pitfalls beyond the scope of your question.

I hope this helps for now, please don’t hesitate to contact us if we can assist you in any way.

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Phil Kinner
European Sales Manager
PVA Inc
Phil Kinner is European Sales Manager of PVA, Inc.

It should not have any issues.

If the coating of selection is not adhering most likely it will be a harmful excess of no clean residue that is not supposed to be there in any case.

A standard average no clean flux residue is normally acceptable.

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Wayne Wagner
President
Krayden Inc.
Wayne Wagner has over 25 years in the conformal coating industry and is the president of Krayden Inc., a leading distributor of engineered materials.

Many people do this the feasibility of doing so depend on both the conformal coating and the flux. There are two main areas of concern, one is inhibition of cure of the coating which is typically limited to thermal cure silicones.

The other is adhesion to the flux reside, poor adhesion to the flux residue can allow pooling of moisture under the coating, this is difficult to predict and will need to be tested.

Neil Poole
Senior Applications Chemist
Henkel Electronics
Dr. Poole is a Senior Applications Chemist in Henkel Technologies, electronics assembly materials application engineering group. He is responsible for all of Henkel's assembly products including soldering products, underfills, PCB protection materials, and thermally conductive adhesives.

I would not recommend that any coating be applied over any surface, without that surface being cleaned to remove possible contamination. The adhesion of the conformal coating is directly proportional to the adhesive forces between the coated layer and the coated surface.

ANY particulate or chemical contamination, even at microscopic or trace levels, will weaken these forces, which, in turn, will weaken the continuity and effectiveness of the conformal coating. It is possible that delamination can occur in these weakened areas, depending on the environmental stresses the board will experience.

As an experienced coatings chemist, my recommendation is to CLEAN the board before conformal coating. "No-clean" flux is more of a marketing catch-all phrase than a practical reality, for high performance requirements

Jim Williams
Chairman
Polyonics, Inc.
Jim Willimas is a PhD Chemist in Polymers and Materials Science. He specialize in printing, cleaning, inks, and coatings used in electronics manufacturng operations. Williams has more than 30 years experience.

The short answer is yes.

The majority of circuit boards that are coated are no clean.

However it is a good idea to get the combination of no clean flux and coating compatibility tested. Most coating suppliers offer this service.

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Chris Palin
European Manager
HumiSeal
Chris Palin is currently managing European sales and support for HumiSeal Conformal Coatings. His expertise is in test & reliability, solder technology, power die attach and conformal coating.
Additional Comments
Reader Comments

This question has been asked for a very long time. The answers seem to always be the same. I guess both answers are correct. The IPC used to state they were incompatible and removed the statement some years ago.

My experence tells me nothing has changed in the coating or the no-clean. The fact is that the coating needs to cover the metals on the circuit assemblies non of which has been tested with metals with flux polymers left behind.

I don't believe UL has tested this with the coating manufactures.

Ed Branco


  1. Where will this be used, exclusively outdoors (near the coast with high salt content or inland where there is just rain or snow) or will it be exposed for short term periods of high humidity?
  2. What type of material, acrylic, urethane, epoxy, silicone etc are you considering?
  3. How will the coated electronics be oriented? Flat or vertical?

Like Phil from Humiseal, I generally always clean the boards, even when no clean was used. I know coating houses that wash these (no clean) boards in alcohol before they coat them.

Urethanes, epoxy, and silicones are better water barriers but difficult to repair. Acrylics (like some of the Humiseals, are easy to repair but are hydroscopic, meaning that in climates where the humidity is constantly high, moisture will migrate to the surface of the board and depending on the distance between differential voltages (and the amount), dendrites can grow and ultimately short.

Also the question about flat or vertical is important. I had boards fail (they were used outside all the time), they were vertical and because of the location of power and ground, when the moisture migrated through the acrylic and started to react with the no clean flux residues, gravity actually helped the dendrites grow and caused the boards to short (thousands eventually failed).

We fixed the problem by relocating the components and re-orientating them while thinking about the voltage differentials. We also buried power and ground to the inner layers.

J. F.

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