Today modern electronics cannot survive without PCBs, and we all know it. The reason is that PCBs act as a fundamental block for the fine performance of electronics and consumer appliances. The best part about these PCBs is their wide range of categories that serve specific appliances based on their features.
As we already know that electronics cannot survive without PCBs. Due to this reason, we need to carefully inspect them to check their longevity and durability on all counts. One way to do this is to go for the PCB X-ray inspection method. Over the years, this method has been one of the most reliable PCB inspection techniques that most producers follow.
We are going to dig deeper into this process in this post. So let’s get started!
Defining PCB X-Ray Inspection
We can define PCB X-ray inspection as a method in which we use X-rays to check the PCBs deeply. If we talk about the scope of X-rays and their usage in different industries, the list will go too long for discussion.
However, from aerospace to medical, X-rays are important for crucial applications. Now for the PCB industry, this method comes in handy through which products can detect small to big defects and technical issues in the PCBs.
The X-rays go through the PCB structure. When this happens, we get multiple images of PCBs from different angles, including the PCB parts present inside. This eventually leads to a full inspection of PCBs not only on the surface level but reaches the internal parts as well.
PCB X-Ray Inspection in Electronics Industry
Now we need to understand why only X-rays have become a reliable inspection method in the PCB and electronics industry. In this section, you will learn about some major benefits of relying on X-ray machines. So let’s check them out below without further ado!
- Component placement: It is a crucial part of the PCB production process. Over time, PCB components are undergoing miniaturization, and layers are shrinking, which makes component placement more challenging. Due to this reason, X-rays can easily reach congested areas in the process of inspection to find out defects successfully.
- Component size: The PCB component size is getting smaller. Therefore, it becomes important to critically inspect these sensitive components through an effective method.
- SMT: This method also comes in handy for SMT, in which we produce small packages. It leads to more dense circuit boards with tightly packed components that demand intense inspection.
Today, there will be hardly any producer that does not manufacture less dense PCBs. The general manufacturing trend is small and dense PCBs.
Due to this reason, the components do not have many spaces in the setup, which makes them get close to each other. In this case, a challenge arises for the producers to cope with the inspection of tightly packed PCB components. X-ray inspection PCB comes in handy for this purpose.
It even exceeds different methods like thermal imaging and optical ultrasonic technique. Through X-ray inspection, we can analyze the driven images from the process. So that later we can make changes to our PCBs quite easily.
How PCB X-Ray Inspection Works?
We cannot fully understand the importance of X-ray inspection in the PCB industry without adhering to its work. The better we will indulge in it, the easier it will be for us to see what happens in this inspection method.
- X-ray tube: The X-ray tube is one of the crucial parts of this whole process that serves to produce X-rays by using photons.
- Platform: We also use a platform for the inspection method, which we can use for the thorough checking of our PCBs easily. It works with different angles and positions to ensure complete PCB inspection during the process.
- Detector: The detector acts as a receiver for the X-rays that it uses to convert them into a fine image of the PCBs under observation.
It is important to know that we cannot derive images without using X-ray photons. We let them go through or penetrate a material and reach the other end, where a detector receives these rays to develop an image. Different factors are important to consider here because, without them, some photons cannot cross the material at all.
If we use heavy photons, we can easily develop X-ray images. The different nature of these photons can easily alter the final result of images. Due to this reason, we won’t be able to fully detect the PCBs for faults and defects at all.
Types of X-ray Inspection PCB
Below are the two common types of PCB X-ray inspection methods that most producers rely on:
1. Manual system
We can perform this inspection technique manually. We have to place the PCBs in the setup to begin with the inspection. The system will produce some images based on our PCBs. Besides, we can even get specified images of different sides and angles to see if there is something wrong with the PCBs or not. In this way, we can manually receive insights about a particular PCB to make crucial adjustments.
The best part about this type of inspection is that we can change the dimensions of the PCBs as we want. But for this, highly skilled workers with extensive backgrounds in this type of manual inspection are important. This will reduce the chances of error on all counts.
2. Automated system
Automated PCB X-ray inspection is the second type that we need to discuss here. We can rely on this method when bulk production of PCBs is important. This technique is useful when we have to check multiple PCBs in a safe, accurate, and fast way. We use a computer for visualizing the generated images.
This computer is highly powerful and aids us with accurate inspection on all counts. We can even use it for easy data transmission and critical analysis of PCBs as well. The setup will automatically position the PCB so that we can get accurate images of the PCBs without manual involvement. In this case, too, we need to rely on skilled professionals that can perform this process by using their background knowledge to a great extent.
It is impossible to capture the complete PCB in one image. Therefore, the computer that we use in this process takes multiple photographs of this PCB from different sides so that a full inspection can take place to avoid future complications and technical errors.
Benefits of X-ray inspection PCB
1. Defect Detection
X-ray inspection focuses on enhanced defect detection, and due to this reason, we can ensure complete PCB inspection so that they can be used in high-pressure and sensitive electronics later while meeting industrial quality standards.
2. Non-Destructive Testing
X-ray inspection is the finest example of no destructive testing of PCBs. Unlike destructive methods, where there are chances that our PCBs will be compromised and even damaged, leading to reworking and loss of investment, X-ray inspection is a good way to save money and time and increase the chances of developing flawless PCBs at the same time.
3. High Efficiency & Accuracy
PCBs that undergo X-ray inspection are highly accurate and efficient in terms of performance. Due to this reason, we can use such intensely tested PCBs in technical appliances used in the aerospace, military and automotive industries.
4. Evaluation of Solder Joint
X-ray inspection of PCB is good for solder joint evaluation because, through this, we can go deeper in inspection and find out possible risks for PCBs and technical problems in time before dispatching them.
5. Identification of Pin-hole Fills
If the pin-holes are not adequate, then these can compromise the PCB performance on the whole. Therefore we can use this method to see how we can rectify this problem in time and save our PCBs from complete malfunction as well.
Common Defects through X-ray Inspection PCB
We have been talking about the importance of defect detection through PCB X-ray inspection. But what are these defects? Can we name them for our better understanding? Yes, we can! Below you will find what common problems are easier to find out with the X-ray inspection method:
- Older Joint Problems: All the solder joint problems are possible to detect with this method, including inadequate solder material, excess solder mask, and much more.
- Shorts & Opens: We can detect short circuits and open bridges with the help of this method easily. This ensures the complete safety of the users besides increasing the longevity of the PCBs at the same time.
- Component Misalignment: X-ray inspection finds out poorly arranged PCB components that can hamper its performance and might result in ultimate damage to the PCBs as well.
- Internal Delamination: X-rays can cross the PCB layers and check if they are undergoing delamination or not so that the professionals can work on them in time.
- Component Integrity: X-ray inspection goes deeper to reach out to the cracks and voids where work needs to be done successfully that enhances the component integrity on all counts.
- Wire Bond Quality: X-ray systems have the potential to analyze wire bond systems and check them for their arrangement, performance, and possible defects if they have any.
Conclusion
PCB X-ray inspection is undoubtedly a huge asset for the producers to ensure intense detection of PCBs in an affordable and less invasive manner. We hope that you now have a better understanding of PCB X-ray inspection so that you can rely on it for better results in the future.
