Harsh Use Environment Alloy Evaluation

This project proposes to evaluate lead free solders that may be suitable for harsher environmental and use conditions such as transportation, and defense applications.

Project stage: 
Project type: 

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Idea Information


Several new Lead Free alloys have been developed that may have better properties that may enable them perform better in harsh use environment. Performance data needs to be generated so that capabilities can be validated.



This project proposes to evaluate lead free solders that may be suitable for harsher environmental and use conditions such as transportation and defense applications. Some application environments are much more severe than in-plant networking and fixed environments. Many products have more stringent use cases which mandate greater and more frequent temperature cycling.


Definition Information

Goals / Benefits: 


  • This project will reduce costs for members by providing a way to share resources and the reuse of existing test vehicles.
  • It will provide comprehensive data on all of the new alloys selected by our members.
  • If a better alloy is available, it could improve the reliability of a number of our members’ products.
  • It will provide vibration test data and model for new better performing alloys for harsh use environment.


High level objectives: 


Proposed Project Deliverables:


iNEMI Collaboration




Phase 1

  • Development and design of a vibration test vehicle.
  • Modeling of test vehicle
  • Validation of test vehicle and model.

Phase 2

  • Vibration testing of 4 high thermal cycle performing alloys along with SAC 305 and Eutectic Sn/Pb controls.
  • Validation of Model performance with new alloy properties



 The initial work has been a collaboration with iNEMI using the existing “Common Alloy Test Vehicle” to gather initial data on 15 alloys with SAC305 and SAC105 controls and 4 different temperature cycles . HDP will share resources and results.

The HDP members are also interested in how these alloys will perform in vibration testing. Vibration testing is an area that HDP projects have not addressed in the past. The team has been gathering information on how to test new alloys and focus on failures within the solder joint and not component leads or PWB pads. The approach will be to design a test vehicle and validate test method and test vehicle in the first phase. This activity is very complex because position of components on board can impact the performance.

Key Participants: 
DFr solutions