Services & supportSurface Insulation Resistance (SIR) Testing & Reliability Analysis
Surface Insulation Resistance (SIR) testing is a critical reliability assessment method that measures the electrical resistance across insulated surfaces on printed circuit boards (PCBs) to quantify the effects of process residues, ionic contamination, and moisture on long‑term insulation performance. Conducted under controlled temperature, humidity, and electrical bias conditions in accordance with industry standards such as IPC‑TM‑650, Method 2.6.3.7, SIR testing helps electronics manufacturers identify potential failure mechanisms early, support process qualification, and ensure higher product reliability and compliance. ZESTRON’s expert analytical services provide detailed reporting and actionable insights to optimize board cleaning and assembly processes for robust performance.
SIR Testing
ZESTRON’s SIR testing capability is offered to clients whose goal is to understand the impact of flux residues on the electrical reliability of a device, and who require an effective predictor of long-term failure mechanisms and service life reliability.
IPC-TM-650 Test Method 2.6.3.7All testing is conducted in accordance with the latest IPC test method.
The Benefits
SIR Services
- Improved reliability and performance of electronic devices
- Reduce field failures and warranty costs
- Predict the long-term reliability of electronic products.
Analytical Services & SupportYour benefits...
- RAPID SERVICE TURNAROUND TIMES
- COMPREHENSIVE TROUBLESHOOTING
- DETAILED TECHNICAL REPORT
- PROCESS RECOMMENDATIONS
Frequently Asked Questions (FAQ) – Surface Insulation Resistance (SIR) Testing
Surface Insulation Resistance (SIR) testing is a quantitative reliability analysis method that measures the electrical resistance across insulated surfaces of a printed circuit board (PCB) to assess the effect of flux residues and contaminants on long‑term electrical performance and reliability. It helps predict potential failure risks due to leakage current or electrochemical migration.
SIR testing identifies how process residues influence electrical insulation on assemblies, making it a critical tool for process qualification, verification, new process development, and achieving reliable product performance. It can reduce field failures, warranty costs, and unexpected electrical issues in the field.
SIR testing services are conducted in accordance with IPC‑TM‑650, Method 2.6.3.7, a widely recognized industry standard for evaluating surface insulation resistance of assemblies.
SIR analysis can help uncover issues caused by flux residues, ionic contamination, moisture effects, or process variability that may lead to electrical failure mechanisms such as leakage current, short circuits, or corrosion under operating conditions.
ZESTRON’s SIR testing provides detailed reporting, troubleshooting insights, and process improvement recommendations tailored to specific assembly requirements to enhance reliability and inform process decisions.
Yes, SIR testing is frequently integrated into failure analysis and reliability evaluations to determine whether residues or process conditions contributed to electrical degradation or performance issues.