Definition
Barrel Crack is a fracture in the plated copper wall of a plated through hole. It often develops after repeated thermal cycling due to differences in expansion between resin and copper.
How It Works
During soldering or rework, the board heats and cools. Copper and resin expand at different rates, which stresses the plating. If the copper is too thin or brittle, cracks can form along the barrel wall. Cross-section analysis is used to identify the issue and confirm root cause.
Practical Example
A field failure investigation reveals intermittent power faults. Microsectioning shows crescent‑shaped cracks in plated through holes near a BGA. Improved plating thickness and refined reflow profiles prevent repeat issues.
Context & Relevance
Barrel cracks are a frequent reliability concern, making plating control and thermal management vital for Class 2 and Class 3 assemblies.
At Rework, we deliver hands-on training and IPC certification that helps teams understand and manage Barrel Crack. Our on-site and virtual courses are designed to improve skills, prevent defects and support reliable electronics assembly.
