When I consider circuit board failures in the field, and they are due to the conformal coating, then I immediately think of two reasons for it occurring.
The first reason is that the wrong conformal coating material was selected.That is during the material specification the wrong material was chosen and it cannot protect the circuit regardless of how it is applied.
The second reason is that the conformal coating was applied incorrectly. That is the right material is being used but the application process is failing.
This problem in the production line leads to conformal coating failures of the confomal coating that need to examined.
Both issues lead to the circuit failing but they are very different.
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Dr Lee Hitchens is the author of the Nexus conformal coating website and eBook.
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