At Nufesa Labs, we offer advanced failure analysis services to detect and resolve defects in printed circuit board assemblies (PCBAs). In this article, we explore a practical case study to demonstrate how we tackle complex challenges.
But first, we would like to emphasize the importance of performing failure analysis.
Why is Failure Analysis Important?
Failure analysis is crucial to ensure that electronic products are not only functioning properly but also durable and reliable. It helps to identify both existing failures and potential future problems, reducing costs and improving customer satisfaction.
Case study: Failure Analysis in a 12-Layer PCB
1. Identifying the Issue: A 12-Layer PCB with Field Failure
A manufacturer reached out to us regarding a field failure in a 12-layer PCB. The first step was to collaborate with the client to pinpoint the issue, which turned out to be one of the BGAs assembled on the circuit.
2. Initial Inspection: X-Ray and Tomography
To confirm the defect’s location, we performed X-ray and tomography inspections. Initially, we found no anomalies in the BGA’s ball soldering or the die. However, we continued with a deeper investigation.
3. Digging Deeper: Suspecting a Stacked Via
Despite the initial results, we suspected the fault might not lie with the BGA, so we traced the signals. During this phase, we discovered a stacked via that appeared to be the source of the issue.
4. Metallographic Cut: Revealing the Cracks
Since the X-ray didn’t reveal the fault, we decided to perform a metallographic cut. This analysis allowed us to directly observe the internal structure of the PCB, where we identified cracks in several key points, explaining the field failure.
We tell you the whole process in this video:
How Nufesa Labs Approaches Failure Analysis
This process exemplifies how Nufesa Labs applies a combination of advanced methods to diagnose issues. From optical microscopy to more sophisticated techniques like SEM/EDX, we provide a comprehensive approach to not only detect visible defects but also identify potential failure points for the future.
Our service not only solves immediate problems but also offers recommendations to prevent future failures, ultimately improving our clients’ products’ reliability.
Conclusion
Failure analysis is crucial for ensuring that electronic products are reliable and meet quality expectations. At Nufesa Labs, we have the tools and expertise to identify the root causes of the most complex failures, contributing to the development of more robust and dependable products.
If you need detailed analysis for your own production, feel free to contact us and learn how we can help you improve your processes and products.