The Tin-Whisker Menace
An anonymous reader writes "Fortune has an article about how the recent environmental push to completely eliminate lead from electronic components and wiring may eventually lead to the next Y2K problem of slowly-growing tin whiskers short-circuiting equipment.""
This probem is one of the reasons we use lead in solder, it's only reappearing now that the EU is pushing for all new electronics sold to be lead-free. Frankly, I'd like to see everyone keep using lead and just stop selling to europe. That'll teach 'em.
how hard would it be to put -everything- on chip?
I mean, yeah, stuff remains modular. One module, one chip. A motherboard consisting of a central "motherboard chip" (containing both bridges, IDE circuitry, bus drivers, all the "integrated hardware" etc), plus slots for all the rest of the hardware, single-chip graphics card, single-chip RAM dice, etc. Just reduce the role of PCB to a board where slots are being located and connected to the central chip, no more batteries of capacitors, network of resistors, hundreds of small chips... Just load everything into one (even big) IC, add some radiator/cooler, and get rid of space and soldering problems.
45 5F E1 04 22 CA 29 C4 93 3F 95 05 2B 79 2A B2
All other factors aside, the reason that Y2K would have been the problem that some alleged is that all the failures would happen at the same time. If something fails, even something major like a powerplant, it's a problem not a catastrophe. It would only be a catastrophe if lots of tem, or worse yet all of them, failed at the same time.
So supposing this problem is as stated, it'll just lead to higher failure rates of electronics. That's not a catastrophe, just something we'll have to deal with, either by changing the methods used or simply by increasing the rate at which we replace devices.
Where is the problem in making a final layer of paint finish on the tin circuitry?
Lead on the cirquit boards is a huge sleeping environmental problem and those who are tempted to shout 'tree higger' now might want to inform themselves on the potential lead hazards first.
-silence
Dyslectics of the world, untie!
Obviously to fix the problem we need some amalgamation of courage and heart in electronic form pronto. Is there any engineers here whose work includes hiding behind curtains and appearing to his co-workers in giant green mask form?
... you lot just slashdotted NASA.
"The page cannot be displayed. There are too many people accessing the Web site at this time."
If construction was anything like programming, an incorrectly fitted lock would bring down the entire building...
Same story as 6 month ago Zinc Whiskers Cripple Colorado's Computers. There's a PDF there that explains it all as well. They are pretty little whiskers, that can only be observed if examined very closely in the right environment.
Then again, this problem doesn't work out so bad for the hardware manufacturers, now does it?
Jerry
http://www.syslog.org/
I quote from a most informative pdf (get it here):
"A tin whisker is a single crystal of tin that grows spontaneously from a surface a pure tin. They are typically only a few microns (?m) in diameter but can grow to lengths of more than 10 mm (though lengths on the order of 1 mm are far more common) [NIST Website, 2002]. Tin whisker growth is spontaneous, not relying on external influences of current or electrolytic action, more commonly associated with mechanisms like "dendritic" growth, conductive filament formation and electromigration. While early studies believed that tin recrystallization (which occurs at 50 deg C) played some role in whisker formation, recent studies have reported as much, if not greater, propensity for whisker formation at temperatures as low as room temperature [NASA Web Site, 2002].(....)Conventional wisdom attributes tin whiskering to internal stresses in the pure tin layer, with a primary source being the compressive stresses caused by electroplating. However, tin whiskers have also been reported from surfaces where tin has been applied by methods other than electroplating. In the presence of compressive stress, whiskers are extruded over time, as a stress release mechanism. Many factors may contribute to the stress in the plating, including intermetallic formation, thermal expansion mismatches, corrosion of the substrate, and externally applied forces such as bending, lead forming and application of pressure. Defects such as scratches and nicks have been reported to magnify the effects by causing local stress concentrations and possibly providing openings in any protective surface oxide layers. In fact, these external factors may cause whiskering in samples that may otherwise be resistant to the phenomenon. For example, tin whiskers have been observed to form on tin finished surfaces that had been exposed to hot oil dip to fuse the tin (a known mitigating process) [Cunningham and Donahue, 1990]. Adding a trace amount of another element (i.e. Pb or Bi) has been shown to reduce the tendency of plating to grow whiskers."
----- One learns to itch where one can scratch.
</drawl>
woof.
This is just a government conspiracy to bypass tin-foil hats! Everyone knows that it's the 2% lead content which actually blocks the mind-control rays....
Oh man, this song could be sooo big!
Tin Whiiiiiiiiiskers
They cancelled IT Class
Tin Whiiiiiiiiiskers
They come from Satan's ass..
Hairs of the Devil, items of no good repute
If the grow to a certain lenght, the PC's can't compute!
Tin Whiiiiiiiiiskers
(guitar solo)
(reprise)
The issue with tin whiskers is that they are so small and invasive. Next to this problem however nanotechnology will make it look trivial.
The small particles being produced with nanotechnology concepts will enable it to invade and affect the body in ways that connot possibly be handeled by todays technology or our immune systems.
I'm all for technology but we need some protections before a company starts spewing these waste/production nanoparticles off into the enviroment in order to save in producing costs for that lastest flat screen tv using carbon nanotubes.
When I worked in the E-Warfare division of (deleted) we ran into this issue whenever we used brass prototype packages to house circuits. The cause of the whisker growth (in brass) was the repeated temperature cycling (TC) of the package. Apparently in the presence of the TC, the tin in the brass preferentially crystalized out of the brass in whisker form and pushed out of the sides. Kinda neat, actually, except for the occasional power supply short. We found that a solid nickel-plate or copper-plate fixed the problem nicely.
Cloned foods give the statement "We had that last week!" a whole new meaning.
All other factors aside, the reason that Y2K would have been the problem that some alleged is that all the failures would happen at the same time. If something fails, even something major like a powerplant, it's a problem not a catastrophe. It would only be a catastrophe if lots of tem, or worse yet all of them, failed at the same time.
Tin Whiskers are less like Y2K, more like Mad Cow -- an insidious, slow-growing disease that consumes our neural infrastructure.
-kgj
-kgj
The lead in solder accounts for a very, VERY tiny percentage of the lead we use and dispose of. It's a really stupid thing to be targeting since there are much bigger problems. It's like worrying about a basket of dirty laundry when your entire floor is covered in garbage. You aren't fixing a problem worth solving.
Now these tin whiskers aside, this sucks for people who like ot do electronics work at home. The only solder blends that are easy to work with contain lead. A 63/37 Sn/Pb or 62/36/2 Sn/Pb/Ag blend is what you need for a low melting point and nice, clean, easy application. The non-lead solders are much harder to work with since they need much higher temperatures. Easy to burn out a component if you aren't careful.
Now compare the amount of lead I use to make an electronic device (like 25-30% of a tube the size of my pinky, that's less than 40% lead and wound such as to use less than 30% of the space in the tube) to a lead-acid car battery, which all cars have and are replaced about once every 5 years.
The no lead in circuts is a wonderful example of environmentalists going after a non issue and fucking things up for people. Yes, lead is a problem, it can contaminate water tables and lead poisoning is NASTY. However the small amount of lead used on PCBs is NOT the problem, and getting rid of it just creats MORE waste by creating electronics that die faster.
because there is a lifetime for every component, it would be reasonable to expect a reasonably static rate of growth of tin wiskers, and it will therefore prolly take a set amount of time for them to grow between components and short (at least in particular types of products.
Forinstance if AMD started manufacturing the AMD64 3200+ and got the substitues wrong, they would all start failing at rougly the same time, taking down all computers that are built using them.
It's not such a date of failure but the inference is they will prolly all fail at similar times
I've always bought tins of whiskers for tiddles, should I switch to another brand - He's never been too keen on kit-e-cat. How will this affect my cat ?
...
Nick
Electronic Music Made Using Linux http://soundcloud.com/polyp
A "leaky capacitor" can be identified by the foreign material seeming stuck to it on the outside of the capacitor, almost like glue, but not sticky. A less extreme sympton of a bad capacitor is a bulge in the sides or top. Really big capacitors (used in high power electrical applications)or older (20+ years,maybe?)capacitors actually have liquid inside, so the sign of leakage might be a stain on the circuit board or chassis.
A capacitor can be identified by the letters "uF" (which stands for "micro-Farads", which capacitors are measured in) after a number. They tend to be either cylendrical, with the leads coming out of the bottom circular base, or "plate shaped", with the leads coming out of the edge.
Granted, much of the increase is due to better medical care, but much of it's due to knowing things about hygene and the like that we didn't know back then. At one point, plates and the like had lots of lead in them, and people ingested lots of lead from this and it caused them to live shorter lives.
But now that I know about the tin whiskers, I want lead in my electronic circuits! I wonder which is worse for the environment -- a stereo with no lead that gets thrown in the landfill after breaking after 10 years, or a stereo with some lead in it that lasts 20 years before breaking and getting thrown away ...
Dead board. I've seen a few ibms and no-name boards with these. Most of the affected capacitors seem to have an x on the top of them. They split apart at the seams and ooze all over the board.
I'm not anti-social, I'm anti-idiot.
Top ten list of critique openers most likely to get you prematurely killed by an engineer
10. I wonder...
9. I was just thinking...
8. That's great, but what I was really looking for was...
7. You know what would be really cool...
6. Was it supposed to do that?...
5. I'm sure it'll look better by the time you've finished...
4. Would it be possible to...
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2. Did someone tell you to do it this way?...
1. How hard would it be to...
My best friend owns one of the top plumbing outfits around here. He routinely does the more difficult jobs in Pebble Beach and Big Sur. He also does the bread and butter work in the less expensive areas where cost is the paramount consideration. Years ago, he won a bid on an apartment complex in Marina, a town next to the old Fort Ord land.
To save costs he picked up some plastic pipe from an outfit he had never dealt with but was offering him a really good price on the pipe. Long story short, the pipes started failing about 6 months after the apartments had been occupied - they were all splitting wherever the stress was greatest. The pipe company went tits up as the problem was popping up all around the country. My friend was adequately insured so he didn't lose money replacing the bum pipes but it did cost him as he couldn't take any new work during the time his men were tearing out old pipes. This happened about 12-14 years ago just about the time plastic plumbing was beginning to come on strong.
My friend's experience with the bum pipes circulated and set plastic plumbing back a few years around here. The development didn't want the grief the apartment house owner in Marina had had and so the developer specified metal pipe instead. It is ironic that their schedule got bit by the lead solder but then it's not the first time that a solution to one problem raised another.
Hey there, there's a HUGE difference between pipes made out of lead and a bit of solder with lead in it.
Lead isn't a death-sentence, it can be safely used. I've been drinking from lead pipes and living in lead-painted walls my whole life and never shown elevated levels. My dad is a lead inspector and he says that virtually all the lead poisoning cases are caused by lead paint dust and chips, kids get the dust on their hands and toys and it ends up in their blood.
This sort of demonizing really pisses me off, some of the best materials we had for common uses has been outlawed because of irresponsible use and disposal. Asbestos insulation, lead solder, and asbestos brake pads are all superior at what they do. Hell, my heating bill (gas, in Boston) is about 30% of most of my coworkers because my house is jacketed in asbestos, and as long as I don't fsck with it it's perfectly safe.
Ever notice how often you have to replace brake pads these days? Or how much rusty dust they drop on your rims? That wasn't a problem with asbestos brake pads, they were awesome. I'm still looking to see if I can get my hands on some from overseas (I'll replace them myself or tell my mechanic before he services them).
Lead solder is a dream to work with compared to other materials, it's cheaper, and it lasts much longer. Outlawing it because people illegally dispose lead-containing stuff in landfills is moronic at best.
"Sometimes, I think Trent just needs a cup of hot chocolate and a blankie." -Tori Amos on Nine Inch Nails
So I guess its time to go stock up on lead-tin solder before they pull them off the shelves.
I really do with they'd go after other products with lead, batteries and such, before they go after our electronics. Its not like little kids are licking their parents' spool of solder!
Cast iron is better for hot water applications. Ask any HVAC guy or pipefitter. And if you have a pump in the system, don't even think about PVC. A single deadheading will shatter the pipes, and there's a risk of shattering the pipes every time you start or stop the pump, due to the inertia of the water circulating in the system.
There are far more dangerous materials in common usage out there, but treated with proper respect they can be used. Bismuth is significantly more toxic than lead, as is cadmium,
I cringe everytime I think of how many Ni-Cd rechargeable batteries get thrown into landfills all over the place, including arid environments where life depends upon the availability of quality groundwater.
I dunno if this is the case everywhere, but my local public waste handling facility has an amnesty day, where you can bring in all those crusty old cans of solvents, paints, pesticides, household cleaners for free. This helps to mitigate the problem of people tossing dangerous chemicals into household trash and not get the proper treatment such chemicals deserve. Or the auxiliary problem of illegal dumping because "taking that stuff to the dump is expensive, dammit!"
"Provided by the management for your protection."