Detection of Counterfeit Components

Harold "Woody" Hewett
Electro-Comp Services, Inc.
Clearwater, FL, USA

In this paper I will discuss the different methods and equipment used to detect counterfeit electronic parts, specifically integrated circuits as well as demonstrate some of the "red flags" that help to identify a part as being suspected counterfeit. We will begin with the initial receipt of the parts and the examination of the outer packaging, the basic visual inspection of the parts, the visual inspection and documentation at high magnification, permanency marking, blacktop test, scrape test, XRF (RoHS), decapsulation, X-ray, basic electrical testing, C-sam, full function testing and limited function testing.

As technology changed and parts became smaller, used less power and were more susceptible to static discharge and moisture, most manufacturers and distributors put ESD and MSL compliant processes in place. There is no evidence that the counterfeit parts that are in the market today have been handled with such scrutiny, quite the opposite. The methods used to store the circuit boards and to remove the parts from the circuit boards are less than desirable. We have all seen instances where there are piles of circuit boards laying on the ground outside. We have also seen the uncontrolled heat source that is used to remove the parts from the circuit board.

The act of sanding the parts also puts physical stress on the parts. With these issues in mind, it is imperative that processes be put into place to detect counterfeit parts before they go into manufacturing. AS5553 has addressed this as well as risk mitigation but until there is not a market place for the counterfeit parts there will be counterfeiting. A complete, diligent incoming inspection process will cut down the number of incidences where a counterfeit part is used in production.

That being said, there are a few things that are important when performing the inspections:
1) Known good device-this is the most desirable tool for determining the authenticity of a part.
2) Training-the personnel performing the inspection must be properly trained and retrained as needed
3) Experience-there is no substitute for experience. The more an individual sees the more he can learn from.
4) Tools-having the correct tools for the job is always important
5) Documentation-all observations should be documented and easily accessible.
6) Review-since it is not necessarily just one item that indicates a part as being counterfeit it is important that all observations and documents be review.
7) The inspection process must be dynamic-as we discover new methods to identify counterfeit parts the counterfeiters change what they do. We must be willing and able to change.

An additional counterfeit detection method, effective for various retail items today, is moving to the PCB space and even individual electronic components: RFID chips can be embedded in (high value) integrated circuits and used to validate their authenticity. By providing the means of assigning a serial number to individual components - serial number that can be read wirelessly from a distance of a few mms in an automated fashion - these tiny RFID chips enable assembly lines to validate that only authentic components are used in a PCB build.

These electronic serial numbers, unlike markings of most sorts, are indelible and cannot be duplicated. By providing a unique, positive identification of individual chips, they can detect not only counterfeits but also diversion or other fraudulent schemes in the supply chain.