Significant manufacturing cost reductions can be realized with lower-t
emperature surface mount processing by increasing yields and using les
s expensive components and boards. A lower-melting-point solder alloy
(nominal composition Sn-41.75Pb-8Bi-0.5Ag) has been developed that ena
bles significant reductions in peak reflow temperatures during surface
-mount assembly. The solder alloy is compatible with standard Pb-Sn su
rface finishes, melts within the temperature range of similar to 166-1
72 degrees C, and has promising mechanical properties.