5.2 Plated Hole Repair, Double Wall Method

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Outline

This procedure covers the use of an eyelet for the repair of a damaged land on a plated hole that has an inner layer connection.

Caution: This method is used to restore the integrity of a through connection on a multilayer circuit board, having an inner layer connect, but ONLY if the full barrel of the plated through hole remains intact. If there is barrel damage, see the appropriate procedure.

Caution: This method will reduce the inside diameter of the hole. The minimum hole size requirement must be checked for acceptance.

Minimum Skill Level - Advanced

Recommended for technicians with soldering and component rework skills and exposure to most repair/rework procedures, but lacking extensive experience.

Conformance Level - Medium

This procedure may have some variance with the physical character of the original and most likely varies with some of the functional, environmental and serviceability factors.

Procedure References
1-0	1.0 Foreword
2-1	2.1 Handling Electronic Assemblies
2-2	2.2 Cleaning Procedures

Tools and Materials

Ball Mills, Abrasives, Cutting Tools
Ball mills, abrasives and cutting tools for working on circuit boards.

Cleaner
General purpose cleaner for removing contamination.

Eyelet Press
Heavy duty eyelet press designed to set and form eyelets in circuit boards.

Eyelets
Copper and brass eyelets electroplated with tin designed for repair of plated through holes.

Flex-Rack PCB Holder
Sturdy rack for PCBs used for rework and positioning.

Knife with #16 Blades
A must-have tool for precise cutting, scraping and trimming.

Micro Drill System
Versatile power tool for milling, drilling, grinding, cutting and sanding.

Microscope
Precision microscope with stand and lighting for work and inspection.

Pin Gauges
Use to provide accurate measurements for thickness and hole diameters.

Precision Tool Set
Nine precision-crafted tools for detailed circuit board work.

Setting Tool, Small
Used to properly form eyelets used to repair plated holes in circuit boards.

Soldering Iron
Properly maintained soldering iron and properly sized soldering iron tips.

Tool Base
Support base for Setting Tool when forming eyelets for plated hole repair.

Tool Grip, Small
Handy tool has vise jaws to grip small items.

Wipes
Nonabrasive, low-linting wipes for cleanup.

Procedure

Eyelet Selection Criteria

ID - Inside Diameter
The eyelet inside diameter should be .075 - .500 mm (.003"-.020") greater than the component lead diameter.

OD - Outside Diameter
The clearance hole drilled through the circuit board should allow the eyelet to be inserted without force, but should not exceed .125 mm (.005") greater than the eyelet's outside diameter.

LUF - Length Under Flange
The length of the eyelet barrel under the flange should be .630 - .890 mm (.025" - 035"), greater than the thickness of the circuit board. This added length allows for proper protrusion when setting the eyelet.

FD - Flange Diameter
The eyelet flange diameter should be small enough to prevent interference with adjacent lands or circuits.

Note: Be sure to select an eyelet meeting the proper criteria. An eyelet with an oversized flange may interfere with adjacent circuits. An eyelet that is too short will not protrude through the circuit board for proper setting.

Procedure

Clean the area.
Examine the hole to ensure that there is no damage to the wall of the hole. Check continuity to establish the integrity of the connection.
Select an eyelet using the Eyelet Selection Criteria. Use a pin gauge and caliper to measure the existing plated hole dimensions. The eyelet must have an inside diameter sufficient to receive the component lead and an outside diameter that will allow the eyelet to be inserted into the hole without force.
Remove oxides from the surface lands where the eyelet will be installed using a buffer and clean.
Apply a small amount of liquid flux to the land or circuit on the circuit board surface, if any, and tin with solder using a soldering Iron and solder. Clean the area.
Insert the eyelet into the hole. If a new circuit is required, it may extend into the hole, and the eyelet flange will secure it in place. (See Figure 1)
Select the proper setting tools and insert them into the Eyelet Press or Tool Grip. (See Figure 2)
Turn the circuit board over and rest the eyelet flange on the lower setting tool.
Apply firm, even pressure to flare the eyelet barrel.
Change the upper setting tool from a flare tool to a flat-end tool. Apply firm, even pressure to flatten the eyelet barrel.
Note: Inspect the eyelet for evidence of damage. Refer to IPC-A-610 Acceptability of Electronic Assemblies.
Apply a small amount of liquid flux and solder the eyelet flanges to the lands on the circuit board surface if necessary. Clean the area. Inspect for good solder flow and wetting around the eyelet flanges and lands.
Clean the area.
Install the component lead and solder, if required.

Evaluation

Visual examination, the dimensional requirement of land diameter and inside diameter.
Electrical continuity measurement.

Images

Plated Hole Repair, Double Wall Method

Insert the eyelet into the hole.

Completed repair.