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Combating Counterfeits: APEX Hosts Counterfeit Detection Ideas
April 6, 2009 |Estimated reading time: 3 minutes
LAS VEGAS The IPC APEX Expo typically showcases a multitude of new products or applications that focus on a common industry challenge. This year, counterattacks against the increasing influx of counterfeit components, PCBs, and subassemblies were center stage. Inspection systems have evolved into counterfeit detectors; labeling systems have taken on new importance to not only track, but also identify, proper parts; and supply chain and incoming inventory management have emerged as effective prevention systems to keep counterfeits out of the finished PCB assembly.
RMD Instruments has developed X-ray fluorescence (XRF) systems with elemental analysis capability to identify molten solder composition, leaded or lead-free components, and take care of other highly complex tasks. Interestingly, the handheld XRF systems can identify counterfeit components rather easily. It is a matter of simple comparison between a known-good component's elemental graph and the elemental composition of any incoming versions of that product, explained Jack Paster, CEO. Many counterfeit electronic components, also called substandard components, arrive without die, or with entirely different metals than the specified part. While external materials and appearance may pass visual inspection, the components may lack gold, bismuth, tantalum, or other expensive elements that counterfeiters leave out of devices to increase their return. The RMD Instruments solution is to use an XRF system, the LeadTracer, to induce K-Shell characteristic X-rays of elements with higher atomic numbers, like lead and bismuth obtaining qualitative spectrometric data on the part composition. RMD used the example of a tantalum capacitor spectrometrically graphed with the XRF system. A substandard capacitor, reportedly the same product, is also graphed. When overlaid, the graphs are clearly different, proving the counterfeit without destroying the component. Other examples include a counterfeit QFP that contains lead.
David Raby, president and CEO of STI Electronics, a high-reliability EMS provider, training services provider, and distribution company in Madison, AL, pointed out that they are doing a lot of counterfeit testing, a complement to failure analysis (FA) and other in-depth analysis for mission-critical parts. The company, which has ties to space and avionics applications, has a mission to avoid rework and specializes in the "really tough boards," Raby added. A PCBA that is orbiting the Earth is an incredibly undesirable in-field failure, after all.
Labels are often an overlooked piece of the PCBA puzzle. With RoHS/lead-free, labeling became more important for segregation, as seen with the universal green "Pb" strike-out circle. Counterfeit detection/prevention programs are not publicized by the label-making companies, to keep a step ahead of sophisticated counterfeiters, but Jim Williams, Ph.D., chairman and founder of Polyonics, hosted a panel on the topic at APEX, and the company is developing products to fill this niche.
In many cases, dedicated X-ray inspection equipment is too expensive to justify investment in an X-ray system for counterfeit detection, except in life-critical applications like military and medical. However, electronics assemblers with a need for more in-depth defect detection and failure analysis (FA) can add counterfeit detection to their benefits list, improving return on investment (ROI) when eliminating scrap, rework, delays, and field failures that can drain profits and reputation. Companies that already have X-ray on the floor are learning how to use it for counterfeit detection, noted Tony Williams, sales manager, phoenix X-ray, a GE company. This increases the machine's utilization, as it can be part of incoming inspection, sampling from production for quality assurance, and the more conventional use in failure analysis.
No one method will guarantee 100% detection when it comes to counterfeits. Some components are pried off e-waste boards intact and relabeled, making X-ray detection less likely. Some are missing die but labeled with skill and proceses like laser etch, making them virtually undetectable with visual tactics. Counterfeiting is not all involved agree just a back-alley black market business. Entire counterfeiter factories operate "legitimately" as component manufacturers, outputting massive quantities to meet the need for inventory. The industry response witnessed at the 2009 APEX show is encouraging, but the dedication and energy needed to combat counterfeits and the pitfalls of the grey market will continue to task assemblers considerably. As Paster pointed out at RMD Instruments' booth during APEX, the supply chain is completely contaminated with counterfeits.
Meredith Courtemanche, managing editor
To explore the topic of counterfeited electronic parts further, and review solutions, read:Combating Component Obsolescence A Visit to Rochester ElectronicsandCounterfeit Detection by David Bernard, Ph.D., Dage Precision Industries, a Nordson company.