Conformal coatings have traditionally been tested by determining the mean time to failure of conformally coated hardware exposed to corrosive test environments. This test approach has serious shortcomings: The test temperatures are most often too high. At these high temperatures, the conformal coating properties may be quite different from those at the application temperatures. In addition, the times to failure are unacceptably long extending into many months. Overcoming these shortcomings is an iNEMI championed test that involves exposing conformally coated thin films of copper and silver to sulfur vapors at 40-50 oC in flowers of sulfur (FoS) chamber and using the corrosion rates of the coated metal thin films as a measure of the corrosion protection capabilities of the conformal coatings. The test temperatures are similar to the application temperatures, the test durations are no more than a week and can be conducted under various temperature and humidity conditions. The purpose of this paper was to determine if testing in the industry-standard mixed-flowing gas corrosion chamber would give similar results as those using the FoS chamber. Acrylic, fluorinated acrylate, and atomic layer deposition conformal coatings were tested in three environments: (a) flowers of sulfur (FoS), (b) mixed-flowing gas (MFG), and (c) iodine vapor. The performance of the coatings tested in the FoS and the MFG corrosion chambers were quantitatively similar. The iodine vapor test results were in qualitative agreement with the FoS and MFG test results. In addition, we present early results pointing to the utility of terahertz-frequency imaging as a technique for measuring conformal-coating thickness nondestructively.
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