IPC-9797A

Press-Fit Standard for

Automotive Requirements
and Other High-Reliability
Applications

Developed by the Cold Joining Press-Fit Task Group (5-21m) of

the Assembly and Joining Committee (5-20) of IPC

Users of this publication are encouraged to participate in the

development of future revisions.

Contact:

IPC
3000 Lakeside Drive, Suite 105N
Bannockburn, Illinois
60015-1249
Supersedes: Tel 847 615.7100
IPC-9797 — May 2020 Fax 847 615.7105
May 2023 IPC-9797A

Table of Contents
1 SCOPE.................................................................... 1 1.9.16 Pin Shoulder..........................................................5
1.1 Purpose .................................................................1 1.9.17 Pull-Out Force.......................................................5
1.2 Classification.........................................................1 1.9.18 Push-In Force........................................................5
1.3 Measurement Units ..............................................1 1.9.19 Push-Out Force......................................................5
1.3.1 Verification of Dimensions ...................................1 1.9.20 Push-Through Force..............................................5
1.4 Definition of Requirements ..................................1 1.9.21 Strip and Strip Thickness......................................5
1.4.1 Acceptance Criteria ..............................................2 1.9.22 Supplier.................................................................5
1.4.1.1 Target Condition....................................................2 1.9.23 User.......................................................................5
1.4.1.2 Acceptable Condition............................................2 1.9.24 Whitening..............................................................5
1.4.1.3 Defect Condition...................................................2 1.10 Additional Requirements.......................................6
1.4.1.4 Process Indicator Condition..................................2 1.10.1 Requirements Flowdown.......................................6
1.4.1.5 Combined Conditions ...........................................2 1.10.2 Personnel Proficiency............................................6
1.4.1.6 Conditions Not Specified .....................................2 1.11 Inspection Methodology........................................6
1.4.1.7 Specialized Designs ..............................................2 1.11.1 Lighting.................................................................6
1.5 Process Control Requirements .............................3 1.11.2 Magnification Aids................................................6
1.6 Order of Precedence..............................................3 2 APPLICABLE DOCUMENTS.................................. 6
1.6.1 Conflict .................................................................3
2.1 IPC.........................................................................6
1.6.2 Appendices ...........................................................3
2.2 JEDEC...................................................................7
1.7 Use of “Lead”........................................................3
2.3 International Electrotechnical Commission
1.8 Abbreviations and Acronyms................................3 Documents.............................................................7
1.9 Terms and Definitions ..........................................3 2.4 ASTM International..............................................7
1.9.1 Compliant Press-Fit Pin .......................................3 2.5 International Organization for Standardization
1.9.2 Compliant Press-Fit Pin Connection.....................3 (ISO)......................................................................7
1.9.3 Compliant Press-Fit Tip .......................................4
3 REQUIREMENTS.................................................... 7
1.9.4 Compliant Press-Fit Zone .....................................4
3.1 Compliant Press-Fit Pin Requirements.................7
1.9.5 Contact Area..........................................................4
3.1.1 Cleanliness Requirements.....................................7
1.9.6 Deposition of Surface Finishes..............................4
3.1.2 Design Requirements............................................7
1.9.6.1 Deposition.............................................................4
3.1.2.1 Design Requirements for Compliant Press-Fit
1.9.6.2 Co-deposition.......................................................... 4
Pins .......................................................................8
1.9.7 Electrical Clearance...............................................4
3.1.3 Compliant Press-Fit Pin Contact Finish
1.9.8 Intimate Metal-to-Metal Connection.....................5 Requirements........................................................8
1.9.9 Jet effect Deformation j.........................................5 3.2 Requirements for Printed Boards for Press-Fit
1.9.10 Laminate Buckling................................................5 Technology............................................................8
1.9.11 Manufacturer (Assembler)....................................5 3.2.1 Printed Board Design and Specification
1.9.12 Pad Bulging...........................................................5 Requirements ........................................................8
1.9.13 Pad Lifting.............................................................5 3.2.1.1 Board Thickness....................................................9
1.9.14 Pin Neck ...............................................................5 3.2.1.2 Hole Roughness.....................................................9
1.9.15 Pin Shaft................................................................5 3.2.1.3 Minimum Annular Ring........................................9

Copyright 2023 by IPC International, Inc. All rights reserved. v

IPC-9797A May 2023

3.2.1.4 Press-fit Plated Through Hole Copper Thickness .9 5.2 Test Groups B-E..................................................25
3.2.1.5  Distance from Drilled Holes to the Printed Board 5.2.1 Push-In Force......................................................25
Edge / Cut Outs ....................................................9 5.2.2 Optical Inspection...............................................25
3.2.1.6 Drill Hole Size.......................................................9 5.2.2.1 Integrity of Annular Ring on Insertion and
3.2.2 Printed Board Material Requirements...................9 Protrusion Side....................................................25
3.2.3 Printed Board Surface Finish................................9 5.2.2.2 Integrity of Solder Resist.....................................27
3.2.4 Printed Board Requirements for Qualification and 5.2.2.3 Integrity of Laminate...........................................28
Test of Compliant Press-Fit Zones........................9 5.2.2.4 Formation of Metallic Particles (Shavings,
4 TESTS....................................................................10
Burrs)...................................................................29
5.2.3 Contact Resistance..............................................31
4.1 General................................................................10
5.2.4 Push-Out Force....................................................32
4.2 Unassembled Tests - Test Group A......................18
5.2.5 Cross-Sectional Criteria......................................33
4.2.1 Optical Inspection of Surface Condition - A1.....18
5.2.5.1 Jet Effect..............................................................33
4.2.2 Examination of Pin and Test Printed Board
Dimensions - A2..................................................18 5.2.5.2 Cu Thickness in Longitudinal and Transverse
Cross-Sections.....................................................34
4.2.3 Adhesion Test - A3 .............................................18
5.2.5.3 Deformation of Press-fit Plated Through Hole
4.2.4 Spring Force Measurement - A4.........................18
in Transverse Cross-Sections...............................36
4.2.5 Cross-Sections of Pins and Printed Board - A5...19
5.2.5.4 Cracks in Cu of Press-fit Plated Through Hole and
4.3 Assembled Tests - Test Group B to F..................19
Traces in Longitudinal Cross-Sections................37
4.3.1 Push-In and Measurement of Push-In Force -
5.2.5.5 Cracks in Laminate in Longitudinal
B1, C1, D1, E1, F1..............................................19
Cross-Section......................................................37
4.3.2 Storage - B2, C2, D2, E2.....................................20
5.2.5.6 Cracks in Compliant Press-Fit Tail of the Pin.....39
4.3.3 Optical Inspection on Protrusion and Insertion
5.3 Test Group F........................................................41
Side - B3, C3 + C6, D3 + D10, E3 + E7.............20
5.3.1 Whiskers..............................................................41
4.3.4 Contact Resistance - B4, C4 + C7, D4 + D11,
APPENDIX A Abbreviations And Acronyms............44
E4 + E8 ...............................................................20
4.3.5 Push-Out and Measurement of Push-Out Force - APPENDIX B Requirements for Aerospace
Applications.........................................45
B5, C8, D12, E9..................................................20
4.3.6 Transverse and Longitudinal Cross-Sections -
B6, C9, D13, E10................................................20
4.4 Environmental Tests - Test Groups C, D, E.........22
4.4.1 Temperature Cycle - C5, D5, E5.........................22
4.4.2 Climatic Sequence - D6.......................................23
4.4.3 Dry Heat - D7......................................................23
4.4.4 Flowing Mixed Gas Corrosion Test - D8............23
4.4.5 Vibration Test - E6..............................................23
4.5 Whisker Test........................................................23
4.5.1 2,000 Hour Storage - F2......................................23
4.5.2 Whisker Detection - D9, F3................................23

5 ACCEPTANCE CRITERIA...................................... 24

5.1 Test Group A.......................................................24

5.1.1 Adhesion..............................................................24
vi Copyright 2023 by IPC International, Inc. All rights reserved.
May 2023 IPC-9797A

Figures Figure 5-11 Cracking of Solder Resist............................27

Figure 1-1 Examples of Interface Contacts, Compliant Figure 5-12 ......................................................................28
Press-Fit Pin and PPTH .................................4 Figure 5-13 ......................................................................28
Figure 1-2 Schematic of Longitudinal Schematic of Figure 5-14 Indications of Delamination (Whitening)....28
Longitudinal (a) and Transverse (b) Figure 5-15 ......................................................................29
Cross-Section of a Compliant Press-Fit
Figure 5-16 ......................................................................29
Connection.....................................................4
Figure 5-17 ......................................................................30
Figure 4-1 Spring Force Measurement Tool with
Figure 5-18 ......................................................................30
Compliant Press-Fit Pin on the Left and
Closed Tool on the Right..............................18 Figure 5-19 ......................................................................31

Figure 4-2 Typical Spring Force Diagrams and a Figure 5-20 ......................................................................31
Corrective Curve..........................................19 Figure 5-21 ......................................................................33
Figure 4-3 Regions of Interest for Visual Inspection Figure 5-22 ......................................................................33
of a Press-Fit Joint are Marked with Blue Figure 5-23 ......................................................................33
Ovals............................................................19 Figure 5-24 ......................................................................34
Figure 4-4 Test Setup for the 4-Point Resistance Figure 5-25 ......................................................................34
Measurement................................................20 Figure 5-26 ......................................................................34
Figure 4-5 Test Setup for the Push-Out Test..................20 Figure 5-27 ......................................................................35
Figure 4-6 Schematic Force Versus Distance/ Figure 5-28 ......................................................................36
Displacement Graph Obtained in a
Figure 5-29 ......................................................................36
Push-Out Test...............................................21
Figure 5-30 ......................................................................36
Figure 4-7 Indication of Plane for Transverse
Figure 5-31 ......................................................................37
Cross-Section...............................................21
Figure 5-32 ......................................................................37
Figure 4-8 Exemplary Schematics for Indication
of Planes (blue lines) for Longitudinal Figure 5-33 ......................................................................38
Cross-Sections..............................................21 Figure 5-34 ......................................................................38
Figure 4-9 Lateral PPTH Deformation (a) and Figure 5-35 ......................................................................39
Remaining Cu Thickness (b)........................22 Figure 5-36 ......................................................................39
Figure 4-10 Remaining Cu Thickness (b), Deformation Figure 5-37 ......................................................................39
of Cu Layer (Jet Effect - j) and Whitening of Figure 5-38 ......................................................................40
Printed Board (w).........................................22
Figure 5-39 ......................................................................40
Figure 4-11 Cracks in Circles..........................................22
Figure 5-40 ......................................................................42
Figure 5-1 ......................................................................24
Figure 5-41 ......................................................................42
Figure 5-2 ......................................................................24
Figure 5-42 ......................................................................42
Figure 5-3 ......................................................................24
Figure 5-43 ......................................................................43
Figure 5-4 ......................................................................25
Tables
Figure 5-5 ......................................................................25
Figure 5-6 ......................................................................26 Table 3-1 Examples of Common Press-Fit
Applications...................................................7
Figure 5-7 ......................................................................26
Table 4-1 Test Sequence...............................................12
Figure 5-8 ......................................................................26
Table 4-2 Qualification Tests Required for Initial
Figure 5-9 ......................................................................27
Qualification and Changes in Production....16
Figure 5-10 ......................................................................27
Table 4-3 Test Conditions for Temperature Cycle.......22

Copyright 2023 by IPC International, Inc. All rights reserved. vii

May 2023 IPC-9797A

IPC-9797A
Press-Fit Standard for Automotive Requirements
and Other High-Reliability Applications

1 SCOPE
This standard prescribes practices for the characterization, qualification and acceptance requirements of compliant
press-fit technology for printed boards that cover the manufacturability and reliability needs for high-reliability
applications intended for use in harsh environments such as automotive and aerospace.

Additional requirements for aerospace applications in Appendix B may apply.

For a more complete understanding of this document’s practices and requirements, one may use this document in
conjunction with IPC-HDBK-9798.

1.1 Purpose This standard prescribes practices for the characterization, qualification and acceptance requirements of
compliant press-fit technology for printed boards.
Standards may be updated at any time, including with the use of amendments. The use of an amendment or newer
revision is not automatically required. The revision in effect shall be as specified by the user.

1.2 Classification

CLASS 1 General Electronic Products

Includes products suitable for applications where the major requirement is function of the completed assembly.

CLASS 2 Dedicated Service Electronic Products

Includes products where continued performance and extended life is required, and for which uninterrupted service is
desired but not critical. Typically, the end-use environment would not cause failures.

CLASS 3 High Performance/Harsh Environment Electronic Products

Includes products where continued high performance or performance-on-demand is critical, equipment downtime
cannot be tolerated, end-use environment may be uncommonly harsh, and the equipment must function when required,
such as life support or other critical systems.

All requirements in this standard pertain to IPC Class 3. When this standard is contractually required, IPC class 3
requirements shall be adopted for all other contractually required standards.

1.3 Measurement Units This standard uses International System of Units (SI units) per IEEE/ASTM SI 10, Section 3
[Imperial English equivalent units are in brackets for convenience]. The SI units used in this standard are millimeters
(mm) [in] for dimensions and dimensional tolerances, Celsius (°C) [°F] for temperature and temperature tolerances,
grams (g) [oz] for weight, and lux (lx) [footcandles] for illuminance.
Note: This standard uses other SI prefixes (ASTM SI10, Section 3.2) to eliminate leading zeroes (for example, 0.0012 mm
becomes 1.2 μm) or as an alternative to powers-of-ten (3.6 x 103 mm becomes 3.6 m).

1.3.1 Verification of Dimensions When an inspection is done on an assembly, measuring dimensions and determining
percentages listed in the standard are not required unless there is a doubt or a question is raised about the acceptance
of the product. When there is a doubt or a question is raised, then a referee determination should be implemented, at
which time measurements should be made or percentages calculated using the referee magnifications defined in the
standard. For determining conformance to the specifications in this standard, round all observed or calculated values
“to the nearest unit” in the last right-hand digit used in expressing the specification limit, in accordance with the rounding
method of ASTM E29. For example, specifications of 2.5 mm max, 2.50 mm max or 2.500 mm max, round the measured
value to the nearest 0.1 mm, 0.01 mm or 0.001 mm, respectively, and then compare to the specification number cited.

1.4 Definition of Requirements The words “shall” or “shall not” are used in the text of this document wherever there is
a requirement for materials, preparation, process control or acceptance.

Copyright 2023 by IPC International, Inc. All rights reserved. 1