Dross generation has always been a costly issue for manufacturers of electronic assemblies. At least half and in many cases more than half of the metal or solder purchased for electronic manufacture is wasted as it becomes tied up in dross. With the advent of lead free solders the moderate economic pain of dross generation becomes acute. A new process recently introduced that includes a solder surfactant cures virtually all problems caused by dross. This paper will show the true cost of dross, including metal replacement, loss of efficiency, safety and environmental issues and demonstrate a solution for this problem. In addition to dross elimination, the process has been shown to enhance soldering by improving wetting and reducing defects. Collaborating lab test data as well as production data will be presented. In addition to answering the technical questions, why and how the "economics of dross" will be examined and a specific and significant cost savings scenario will be presented including specific case studies.
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