Expired PCBs may seem harmless in storage, but they pose significant risks that can lead to costly failures and rework. Over time, surface oxidation renders solder pads unsolderable, while absorbed moisture during storage can expand during soldering, causing internal delamination. The core materials, such as FR4, deteriorate over time, developing microcracks that compromise the board’s structural integrity. Environmental factors like temperature swings, air pollutants, and cleaning agents accelerate the aging process, attacking protective coatings and weakening layer bonds. These thermal stresses can result in via failures and broken connections, jeopardizing reliability.
In addition to physical degradation, electrical issues emerge as expired PCBs develop microscopic conductive paths, leading to undetectable short circuits. The solder mask also loses its insulating properties over time, exposing circuits to failure risks. Even automated assembly processes aren’t immune; warped surfaces and degraded reference points cause pick-and-place machines to falter, reducing placement accuracy. Understanding these risks emphasizes the importance of monitoring PCB shelf life and maintaining proper storage conditions to ensure product quality and prevent avoidable complications.
source: https://www.myemssolutions.com/uncovering-the-hazards-of-using-an-expired-pcb/
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