Our customers use OSP, HASL, immersion tin and immersion gold as board finishes. If I recommend a finish to the customer, it is one of the immersion finishes or OSP. Those finishes have the advantage of a flat surface to deposit paste. HASL has variation between pads and on pads, resulting in problems, especially if you micro-reduce your fine pitch apertures. The HASL process usually has a low Cp/Cpk as a process at board houses. Using an OSP, you want to follow good handling procures; ie, do not touch solderable surfaces with your bare hands. Wear gloves or finger cots. You have 3-5 heat cycles, depending on the OSP. I have not had a problem with shelf life, but we have a high inventory turn. Some folks I know store boards for several months and have hadd no problem with OSP. My experience has also been that OSP is usually cheaper than HASL. With the immersion finises, you may have to adjust your profiles slightly.
I much prefer immersion finises or OSP when doing fine pitch. I get a more consistent paste volume, and less problem with lead coplanarity. I have solder defects back to the HASL plating (causing coplanarity issues, poor paste deposistion, etc).
Hope this helps, Brian
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