Lead-Free (PbFree) Feasibility Program: Assembly and Testing of a Functional IPC Class 3 Avionics Data Unit

ABSTRACT Rockwell Collins Inc. (RCI) has been fully aware of the European Unions Directive driving the electronics industry to Pbfree products. Even though the EU Restriction of Hazardous Substances (RoHS) directive officially went into effect on July 1, 2006, a significant portion of the avionics electronics supply chain began a wide variety of transition actions in the years prior to the implementation deadline in an effort to understand material issues and fabrication concerns. Original Electronic Manufacturers (OEMs) of avionics equipment were either exempt (military products) or excluded (commercial products) from the EU RoHS requirements due to the legislative directive being a single market initiative. However, due to the fact that components used in the avionics industry are largely common with those used in the affected consumer market, Rockwell Collins had no choice but to begin proactively addressing these issues/concerns back in 2003. As a result, RCI has conducted significant internal investigations, participated in industry consortia efforts (e.g. JCAA/JGPP, CALCE, AIA LEAP task groups), and has developed a number of internal protocol/procedures for the use of RoHS compliant materials, components and processes. These procedures/processes have been extensively employed the last two years across all Rockwell Collins when evaluating and resolving Pbfree issues. Figure 1 illustrates the RCI RoHS program timeline. A significant milestone of the RCI RoHS program timeline is the Product Pathfinder Trials. Two of these pathfinder trials, one for a commercial avionics product and one for a government systems avionics product, were to be completed in the 2007/2008 timeframe. This report documents the Commercial Pathfinder Product trial.