This ESA-authorized training develops an understanding and ability to interpret specifications covering high-reliability and high-quality electronic assemblies and ensures sufficient knowledge to make confident decisions within the specification parameters, understanding the use of materials in the space environment.
These requirements have been developed to ensure process consistency and acceptable workmanship standards, resulting in the production of reliable hand-soldered connections. ECSS-Q-ST-70-08 “Manual Soldering of High Reliability Electrical Connections” and ECSS-Q-ST-70-38 “High Reliability Soldering for Surface Mount and Mixed Technology” form the basis of this training.
This training is intended for Production Inspectors and Operators wishing to upgrade their certification to Inspector level. Engineers and Quality Assurance Engineers, Designers, and Production staff can also benefit from this training.
The training provides hands-on experience. All necessary tools and equipment are provided, although participants may bring their own hand tools if they wish.
Training Objectives
- Learn and understand the requirements of the ECSS-Q-ST-70-08 standard.
- Learn and understand the requirements of the ECSS-Q-ST-70-38 standard.
- Identify factors that affect the quality, reliability, and performance of soldered connections.
- Perform a range of soldered connections and understand manual assembly methods necessary to produce reliable assemblies according to ECSS-Q-ST-70-08 and ECSS-Q-ST-70-38 standards.
- Develop skills in inspecting and analyzing errors related to soldered connections according to ECSS-Q-ST-70-08 and ECSS-Q-ST-70-38 standards.
- Develop skills in controlling and evaluating electronic assembly according to ECSS-Q-ST-70-08 and ECSS-Q-ST-70-38 standards.
Experience and Prerequisites
- Knowledge of electronic components and assembly processes.
- Good practical and observational skills.
- Positive attitude towards high-quality workmanship.
- Holding an ESA Cat 3 certificate is required.
- Visual acuity certificate in accordance with ESA STR 258 document.
Training Program
Day 1
- Complete the student registration form.
- Provide the visual acuity test certificate.
- Introduction and orientation, including safety, equipment, procedures, and break times.
- Training presentation: what we will learn, how, why, and when.
- Overview of specification structure: relevant ECSS standards; release status and how to access them.
Studying the ECSS-Q-70-08 standard:
- Chapter 1 Scope
- Chapter 2 Terms and Definitions
- Chapter 3 Principles and Prerequisites
- Chapter 4 Preparatory Conditions
- Chapter 5 Material Selection
- Chapter 6 Soldering Preparation
- Practical exercises: this is a good time to demonstrate the use of cutters, wire strippers, solder wicking tools, and solder pots for preparing wire bundles; the class can then prepare their own wires for later terminal soldering exercises.
Day 2
Studying the ECSS-Q-70-08 standards (continued):
- Chapter 7 Soldering Preparation
- Chapter 8 Connecting Conductors to Terminals, Solder Cups, and Cables
- Practical exercises: this is a good time to demonstrate soldering previously prepared wires to terminals; tinning silver-plated terminals, with excess solder wicking before connecting the wire; the class can then start soldering exercises to terminals: side turret connection, side split connection, through-hole, hook, and solder cup.
- Practical exercises: this is a good time to demonstrate soldering shielded connectors to the cable shield; the class can then repeat the exercise.
- Chapter 9 Soldering to Terminals and PCBs
- Chapter 10 PCB Cleaning
- Chapter 11 Final Inspection
- Chapter 12 Verification
- Chapter 13 Quality Assurance
- Appendix A: Typical Satisfactory and Unsatisfactory Soldered Connections
- Multiple-choice operator test: All students must achieve a minimum of 80% on 50 questions, with the 70-08 open book and multiple-choice questions test
Days 3 and 4
- ECSS-Q-70-38: studying the requirements of the ECSS-Q-ST-70-38 standard * Passive and Active SMC * Substrates * Stress Relief * Component Placement and Reflow Methods * Inspection * Cleaning
- Multiple-choice test: All students must achieve a minimum of 80% on 50 questions, with the 70-38 open book and multiple-choice questions test.
Practical exercises (Assembly on ESA-approved PCB):
- 3 large axial components
- 3 small axial components (in glass case) using various forms of stress relief and placement
- 3 radial components (mounted horizontally and vertically)
- 3 components in metal case (e.g. TO92) using appropriate lead formation
- 2 DIL components, one mounted on the high thermal capacity side
- Soldering terminals to the board using Sn96 solder, then soldering wire(s) using Sn63 solder with necessary thermal shields to prevent re-melting Sn96
- Solder tails from the above termination to the metallized hole
- Mounting shielded termination to solder pad and PTH on PCB.
- The instructor will monitor each student’s progress to avoid “detection of any shortcomings” at the last minute. Corrective instruction will be provided if necessary. When the instructor confirms that the operator has achieved an acceptable standard, a Control Report sheet will be issued. The student will then clean the board and begin “self-inspection”. Note that Inspector-only candidates do not need to meet aerospace standards for their soldering assembly skills.
Day 5
- Complete self-inspection of the board
- Review of the board with the Instructor
- Complete inspection of the test board
- Review of the test board with the Instructor
Certificate
According to this document, upon successful completion of the training, a Category 2 Certificate approved by ESA will be awarded. Authorization is valid for two years (see note on a 9-month extension under RECERTIFICATION below).
Duration
4½ days (plus ½ day if retake exams are required).
Recertification
To renew the certificate for another two years, attendance at a one-day recertification course is required. The two-year period can be extended by up to 9 months if previous recertification sessions cannot be attended.