We expect to see a copper shadow along the edge of pads when soldering boards with organic solderability protection [OSP]. IPC-A-610 has defined this as acceptable for years. During early reflow stages, the flux in paste dissolves the OSP where there is contact. Generally, the flux does not spread to allow solder to cover the entire pad. Of course you will not see this copper shadow if your paste deposit is 1:1 with pad.
The thickness of OSP should be whatever the OSP supplier says it should be. There isn't any one acceptable thickness, it really depends on the type of OSP being used and your assembly process and chemistries. If possible work with the board fabricator and their OSP supplier. They should be able to give you a guideline for determining thickness. We see thickness ranges from 1500 to 3500 Angstroms for one supplier and 3000 to 5500 for another supplier. Actually, thickness is not the issue. Too little creates more problems than too much. OSP is self-limiting.
More importantly, your board fabrictor should be capable of measuring OSP thickness in order to maintain proper control.
Predominant OSP compounds are: * Benzotriazole [ http://en.wikipedia.org/wiki/Benzotriazole ]: Initially used in metal finishing and restoration industries. Adopted for limited heat cycle solder applications for electronics. * Substituted Benzimidazole [http://www.enthone.com/resources_detail.aspx?Page=subenz.ascx ]: Developed to withstand multiple heat cycles and extend storage life. * Substituted imidazole
Shikoku Glicoat SMD process is the market share leader for OSP in Japan and the Asian Rim.
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