Resistor Failure Analysis

resistor diagram
NumberNameMaterial
1LeadGold plated nickel
2End FilletCopper-silver alloy
3End CapNickel-iron alloy
4CoreCeramic or glass
5Metal or CarbonFilm Nickel-chromium alloy
6EnvelopeCeramic or glass
7End DiskNickel-iron alloy
8SpiralLaser cut exposing core
9Envelope gasDry gas-air mixture
10Varnish CoatingHigh Temp Coating

Success Stories

Stackpole 100-ohm Power Resister Failure Analysis

Stackpole 100-ohm Power Resister Failure Analysis

Gideon Analytical Laboratories received three different vendor 100-ohm resistors, made by Vishay, RCD, and Stackpole, respectively. The two Stackpole resistors were open. A resistoris a passive two-terminal electrical component that implements electrical resistance as a circuit element. In electronic circuits, resistors are used to reduce current flow, adjust signal levels, to divide voltages, bias active elements, and terminate transmission lines, among other uses. Our goal was to test the functionality the Vishay, RCD, and Stackpole resistors, and if any were failing, determine the cause of the failure.
Vishay CRCW2512220RJNEG Thick Film Chip Resistors

Vishay CRCW2512220RJNEG Thick Film Chip Resistors

Gideon Analytical Laboratories received four Vishay CRCW2512220RJNEG thick film chip resistors to be analyzed. Thick film resistors are the most used resistors in electrical and electronic devices. The resistive material is a special paste with a mixture of a binder, a carrier, and the metal oxides to be deposited. These Vishay CRCW2512220RJNEG resistors thick film chip resistors feature stability at different environmental conditions and 2mm pitch packaging option for 0603 sizes.
Susumu RG3216-1000-B-T-T1 Film Resistor Failures

Susumu RG3216-1000-B-T-T1 Film Resistor Failures

Gideon received ultra precision calibration resistors. These resistors have a tolerance of .1%. The ultra precision thin film resistors are designed for high precision circuitry. They have excellent stability and reliability over the operating temperature range and low TCR characteristics. The resistors were running about .3 to .4 ohm too high. Onboard Test 1 Test 2 Test 3 Test 4 Test 5 decapsulated Halogens PCB1 100.
Vishay CRCW1210-HP-e3 SM Resistor Failures

Vishay CRCW1210-HP-e3 SM Resistor Failures

Gideon Analytical Laboratories received two PCB assemblies upon which were several failing Vishay CRCW1210-HP-e3 surface mount (SM) resistors. Surface mount technology (SMT) is a method for producing electronic circuits in which the components are mounted or placed directly onto the surface of printed circuit boards (PCBs). An electronic device so made is called a surface-mount device (SMD). In the industry, it has largely replaced the through-hole technology construction method of fitting components with wire leads into holes in the circuit board.
RNC70H1963FS Resistor Failure

RNC70H1963FS Resistor Failure

Gideon Analytical Laboratories received an RNC70H1963FS resistor for electronic failure analysis. A resistor is a passive two-terminal electrical component that implements electrical resistance as a circuit element. Resistors act to reduce current flow, and, at the same time, act to lower voltage levels within circuits. They are typically constructed of metal wire or carbon and engineered to maintain a stable resistance value over a wide range of environmental conditions. Resistors are rated both in terms of their resistance (ohms) and their ability to dissipate heat energy (watts).
144A9284P4 Resistors

144A9284P4 Resistors

Gideon Analytical Laboratories received several GE Aviation 144A9284P4 carbon film resistors for failure analysis evaluation. A resistor is a passive two-terminal electrical component that implements electrical resistance as a circuit element. Their purpose is for creating a precise quantity of resistance for insertion into a circuit; they are typically constructed of metal wire or carbon and engineered to maintain a stable resistance value over a wide range of environmental conditions. They are frequently integrated within integrated circuits within the silicon; the resistor changes the voltage or the current in the line.
Resistor Films

Resistor Films

Gideon Analytical Laboratories received several amplifier units were supplied to ascertain the difference between a new vintage resistor, which failed, and the older one, which functioned normally. A resistor is a passive electrical component that enacts electrical resistance in a circuit. These resistors were measured at 22 ohms. Failure analysis was performed on the resistors. It was not known if the resistors were from the same vendor or whether the power dissipation of the thick film was the same.
Resistor Contamination on Axial-Lead Resistors

Resistor Contamination on Axial-Lead Resistors

Gideon Analytical Laboratories received three axial-lead resistors for failure analysis (pictured in the first picture directly below). A resistor is a passive two-terminal electrical component that implements electrical resistance as a circuit element. Their purpose is for creating a precise quantity of resistance for insertion into a circuit; they are typically constructed of metal wire or carbon and engineered to maintain a stable resistance value over a wide range of environmental conditions.
Varactor Diode GVD30601-001

Varactor Diode GVD30601-001

Gideon Analytical Laboratories received several GVD30601-001 super hyperabrupt junction tuning varactor diodes with a latent failure mechanism over time. A varactor diode is a P-N junction diode that changes its capacitance and the series resistance as the bias applied to the diode is varied. Hyperabrupt tuning varactor diodes offer a large change in junction capacitance over a small tuning voltage range. Varactors are operated in a reverse-bias state, like a Zener diode.
Resistor Contamination on Failed 510K

Resistor Contamination on Failed 510K

Gideon Analytical Labs received two failed 510K, two used 510K operating for about 3 weeks, and two virgin resistors for failure analysis. A resistor is a component of a circuit that resists the flow of electrical current. It has two terminals across which electricity must pass, and it is designed to drop the voltage of the current as it flows from one terminal to the other. Resistors are primarily used to create and maintain known safe currents within electrical components.